KUHN GMD 400 User manual

ASSEMBLY / OPERATOR'S MANUAL
GMD 400 - 500
GMD 400 HD - 500 HD
MULTIDISC MOWER
N° 95001 C.GB - 03.2003

DEAR OWNER,
In buying a KUHN machine you have chosen wisely. Into it have gone years of thought,
researchandimprovements.Youwillfind,ashavethousandsofownersallovertheworld,that
you have the best that engineering skill and actual field testing can produce. You have
purchased a dependable machine, but only by proper care and operation can you expect to
receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your
machine.Theperformanceyougetfromthismachineislargelydependantuponhowwellyou
readandunderstandthismanualandapplythisknowledge.PleaseDONOTASSUMETHAT
YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR MACHINE before reading this
manual carefully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE.
YourKUHN dealerwillinstruct youonthegeneral operationofyourmachine. He isinterested
that you get the best performance possible and will be glad to answer any special questions
that may arise regarding the operation of the KUHN machine.
Your KUHN dealer can offer a complete line of genuine KUHN service parts.
These parts are manufactured and carefully inspected in the same factory that builds the
machine to assure high quality and accurate fitting of any necessary replacements.
When ordering service parts it is important that you indicate the type of machine concerned
and its serial number.
Forthisreasonpleasecompletethemodelidentificationplatediagrambelowwiththerequired
information. This will provide you with an easy reference for future service parts orders.
ABOUT IMPROVEMENTS
KUHN iscontinuallystriving to improveitsproducts and,therefore,reserves the righttomake
improvements or changes when it becomes practical to do so, without incurring any
obligations to make changes or additions to the equipment sold previously.

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CONTENTS
Safety 2
Safetydecals 9
Assembly instructions 11
Technicalspecifications 12
Generalinformation 17
Fitting to the tractor 18
P.T.O.shaft 20
Workingpositionandadjustments 21
Transportandparkingthemachine 24
Operatingthemower 25
Lubrication 26
Adjustmentsandmaintenance 28
Optionalequipment 33
Troubleshootingguide 35
Storingthemower 36
Limitedwarranty 38
Copyright 2003 KUHN S.A.

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SAFETY
Thesymbolaboveisusedthroughoutthismanualeverytimerecommendationsaremadeconcerningyoursafety,
the safety of others, or the good operation of the machine.
Theserecommendationsmust be made known to all machine operators.
DESIGNATED USE OF THE MACHINE
TheGMD400-500-400HD-500HDDiscMowersmustonlybeusedfortheworkwhichtheyhavebeendesigned:
mowingonthegroundofhayfields,grasssilagefieldsandimprovedpasturesforthepurposeofharvestingfodder
for feeding livestock.
Themanufacturerisnotheldliableforanydamageresultingfrommachineapplicationsotherthanthosespecified
bythemanufacturer.
Any use other than the designated operation is at the risk and responsibility of the operator.
Designated use of the machine also means :
-followingoperation,maintenanceandrepairrecommendationsgivenbythemanufacturer;
-using only genuinespare parts, equipmentand accessories asdesignated by themanufacturer.
TheGMD400-500-400HD-500HDDiscMowersmustonlybeoperated,maintainedandrepairedbycompetent
persons who are familiar with machine specifications and operation and are aware of any danger involved.
Theoperatormustimperativelyrespectcurrentlegislationconcerning:
-accidentprevention,
- work safety,
-public traffic circulation.
All safety advice indicated on the machine must be strictly observed.
Themanufacturerisnotheldliableforanydamageresultingfrommachinemodificationscarriedoutbytheoperator
himselforbyathirdpartywithoutpreviouswrittenagreementfromthemanufacturer.

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GENERALSAFETYRECOMMENDATIONS
Before operating the machine, always ensure that tractor and machine are in accordance with work safety and
road traffic regulations.
BASICPRINCIPLES
1. Inadditiontotherecommendationsgiveninthismanual,legislationonworksafetyandaccidentprevention
mustalsoberespected.
2. Advice is indicated on the machine, specifying safety recommendations in order to prevent accidents.
3. Before travelling on public roads, the operator must ensure that the machine conforms to road traffic
regulations.
4. Before starting work, the operator must be familiar with all machine controls, handling devices and their
functions. Once at work, it is too late to do so !
5. Useatractorequippedwithasafetycab.Keepwindowsandroofhatchclosedforreducedsoundlevelwhile
operatingthePTOdrivenimplement.
6. Beforestartingupthemachineandbeginningwork,checkthesurroundingarea(bewareofchildren!).Make
surethereissufficientvisibility.Keepallpeopleandanimalsawayfromthedangerzoneofthemachine(risk
of projection!).
7. Carrying people or animals on the machine when working or in transport is strictly forbidden.
8. Machine must only be attached to tractor using means provided and in accordance with current safety
standards.
9. When attaching or removing the machine, place the parking stand into the corresponding position.
10. Special care should be taken when attaching or removing the machine from the tractor.
11. Before attaching the machine, ensure that the front tractor axle is sufficiently ballasted.
Ballastis to be placed onthesupportsprovidedinaccordancewithinstructions of the tractormanufacturer.
12. Donotsurpassthemaximumaxleloadortheoveralltransportweightasprescribedbythetractormanufacturer.
13. Do not surpass the maximum transport width authorized by road traffic regulations.
14. Beforetransportingthemachineonpublicroads,ensurethatalllegallyrequiredguardsandindicators(lights,
reflectors ...) are in place and in good operation.
15. All operating controls (cords, cables, rods ...) must be positioned so that they cannot be set off accidently,
risking accident or damage.
16. Beforetransportonpublicroads,locatethemachineintoitstransportpositionasinstructedinthisoperator’s
manual.
17. Neverleave thetractor seat while the machineis operating.

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18. Drive speed must be adapted to ground conditions as well as roads and paths.
Always avoid abrupt changes of direction.
19. Precision steering, tractor adherence, road holding and efficient braking are influenced by the type of
implement,weight,ballastoffront axle,groundorroadconditions.Itis thereforeofutmostimportancetobe
cautious in every given situation.
20. Beparticularlycautiouswhenturningcorners,payingattentiontomachineoverhang,length,heightandweight.
21. Keep clear of the machine operating area.
22. WARNING ! Danger of crushing and shearing can exist when components are operated by hydraulic or
pneumaticcontrols.
23. Beforeleavingthetractororbeforeadjusting,maintainingorrepairingthemachine,turnofftheengine,remove
ignition key and wait until all moving parts have come to a complete stop.
24. Donotstandbetweenthetractorandthemachineunlessthehandbrakeistightand/orstopshavebeenplaced
underthewheels.
25. Beforeanyadjustments,maintenanceorrepairsarecarriedout,ensurethatthemachinecannotbestarted
up accidentally.
PRECAUTIONS TO BE TAKEN BEFORE OPERATING THE MACHINE
1. Do not wear loose clothing which could be caught up in moving parts.
2. Wear the individual protection equipment corresponding to the work which is planned (gloves, shoes, eye
protection, helmet, ear protectors...).
3. All operating controls (cords, cables, rods ...) must be positioned so that they cannot be set off accidentally,
causing accident or damage.
4. Beforeoperatingthe machine,checkthetightnessofall nutsandbolts,particularlyon rotatingparts(blades,
tines, knives, spades ...)
5. Before operatingthe machine, ensurethat allsafety guardsare firmlyin placeand ingood condition.If worn
ordamaged,replaceimmediately.

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ATTACHMENT
1. Whenattachingorremovingthemachinefromthetractor,positionhydraulicliftcontrolleverinsuchawaythat
it cannot be set off accidentally.
2. Whenattachingthemachinetotractor3-pointlinkage,ensurethatdiameteroflinkpinscorrespondstodiameter
of ball joints.
3. WARNING ! Danger of crushing and shearing can exist in the lifting zone of the 3-point linkage !
4. Donotstandbetweenthetractorandthemachinewhenoperatingtheoutercontrolleveroftheliftmechanism.
5. In transport, the machine lift mechanism should be stabilized by tractor tie rods to avoid floatation and side
shifting.
6. When transporting the machine in the raised position, lock the lift control lever in place.
7. Donotoperatethemachinewithnarrowwheeltracktractorswhenworkingortransportingonunevenorsloping
terrain.
POWERTAKE-OFF
1. OnlyusePTO shaft supplied withthemachineor recommended by the manufacturer.
2. PTO guards must always be in place and in good condition.
3. Checkfor correctPTOoverlapwhenat workandintransport.
4. BeforeattachingorremovingthePTOshaft,disengagePTOshaft,turnoffengineandremoveignitionkey.
5. IfaprimaryPTOshaftisequippedwithaslipclutchorafreewheel,thesemustbefitted onthemachinePTO.
6. Ensure that PTO shaft is always correctly fitted and locked into place.
7. Make sure guards are correctly in place and secured with the safety chains provided.
8. Before engaging PTO, ensure that PTO frequency and direction are in accordance with manufacturer's
recommendations.
9. Beforeengaging PTO,keepallpeopleandanimals clearfromthemachine.
10. NeverengagePTOshaftwhentractormotoristurnedoff.

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11. NeversurpassPTOanglerecommendedbythemanufacturer.
12. WARNING!RotatingelementscancontinueturningmomentarilyafterPTOisdisengaged.Keepclearuntilall
rotating elements are at a standstill.
13. Whenremovingthemachine,locatePTO shaft on thesupportsprovided.
14. Fit safety cap on tractor PTO.
15. Replaceanywornor damagedPTOguardsimmediately.
HYDRAULICSYSTEM
1. WARNING! Hydraulicsystem is underpressure(maximum working pressure: 200 bars/2900psi).
2. When fitting hydraulic motors or cylinders, ensure that connections have been made correctly, as per
manufacturer’sinstructions.
3. Before connecting hoses to the tractor hydraulics, ensure that tractor and machine circuits are not under
pressure.
4. Itisstronglyrecommendedthattheoperatormarksthehydraulicconnectionsbetweentractorandmachineto
avoidmakingawrongconnection.WARNING!Functionscouldbereversed(forexample:lift/lower).
5. Regularlycheckthehydraulichoses!Replacethehydraulichosesevery5years.Damagedorwornhoses must
immediatelybe replaced .
Whenreplacingthehydraulichoses,makesuretousehoseswiththespecificationsandqualityrecommended
bythe manufacturer of themachine.
6. Should a leak be found, take all necessary precautions to avoid accidents.
7. Any liquid under pressure (particularly oil from hydraulics) can penetrate the skin and cause severe injury. If
injured,see a doctor immediately,therecould be dangerofinfection.
8. Beforeany adjustments, maintenanceorrepairs are carried out,lowerthe machine, depressurize thecircuit,
turnofftheengineandremoveignitionkey.

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MAINTENANCE
1. Beforecheckinganymachinemalfunctionandbeforeadjusting,maintainingorrepairingthemachine,disengage
PTO,turnoffengineandremoveignitionkey.
2. Check tightness of nuts and bolts regularly. Retighten if necessary.
3. If the machine is raised, prop it up in a stable position before carrying out any maintenance work.
4. Whenreplacingaworkingpart,wearprotectiongloves and only use standardized tools.
5. Itisforbiddentodiscardanyoil,greaseorfilters.Thesemustbegiventowastedisposalorganisationstoprotect
theenvironment.
6. Disconnect power source before any work is done on the electric system.
7. Check safety guardsregularly, particularly those that aresubject towear. Replace immediately if damaged.
8. Sparepartsusedmustbeinaccordancewithspecificationsandstandardsasdefinedbythemanufacturer.Use
onlygenuineKUHNparts!
9. Before any electric welding is carried out on tractor or attached machine, disconnect generator and battery
terminals.
10.Repairs on elements under pressure or tension (springs, accumulators etc.) must only be carried out by
competentpersonswithstandardizedequipment.
SPECIAL SAFETY RECOMMENDATIONS
1. Use a tractor equipped with an enclosed cab with windows made of safety glass and kept closed. It is
recommendedtofitpolycarbonatescreensinsidethetractorsafetycab'ssideandrearwindowsortoinstallmesh
guardson the exteriorof them.
2. Stay a safe distance away from the mower when discs are rotating.
3. For safe machine operation, it is imperative that cutting tools be fitted in accordance with the manufacturer’s
recommendations. Use only the tool outfit supplied with the machine.
4. Eachtimebeforeusingthemower,inspectconditionofcuttingelements(knives,discs).Replaceanymissing,
wornordamagedcutting elements immediately. Use onlygenuine KUHNspareparts.
5. Toavoidcreatingdangerousoutofbalanceforces,alwaysreplacemissing,damagedorwornknivesinpairs.

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6. When replacing knives or discs, systematically inspect their securing elements as per the manufacturer’s
recommendations.
7. Regularly inspect the disc mower’s protection cover. Worn or damaged protection covers must be replaced
immediately.
8. Protectiondevices(suchasguards,shieldsetc.)areintendedtopreventstones,rocksorotherforeignobjects
frombeingprojected.Theyalsopreventaccesstothemachine’sdangerzones.Therefore,itisimperativethat
protectiondevicesare put in placeandproperly secured each timebeforeusing the machine.
9. Crushingandshearingzoneswhichcouldcauseseriousbodilyinjurywhenchangingthemachinefromtransport
towork positionandviceversamay exist. Topreventpossibleinjury,be extracarefulwhenmaneuveringand
ensure that everyone is at a safe distance away from the machine.
10.PTOdrivetothemowermustneverbeengagedunlessthecutterbarskidshoesareincontactwiththeground
andtheprotectivecoverisfoldeddown.
11.Groundof the pastures to be mown mustbe free offoreign objects.
12.Evenwhenthemachineisusedinaccordancewithitpurpose,objectsmaybeprojected.Itisthereforeimperative
thateveryonebekeptawayfromthedangerzone,thatextracareistakenandthatextra precaution(suchas
safetyindicators)betakenwhenmowingpastures alongsideroadsor nearpublicareas(parks,schoolsetc.).
13.Nevermowinreverse.
14.WhendisengagingthePTOdrive,movingpartscontinuetorotateforsometime.Waitforallmovingpartstocome
toacompletestop before approaching the machine.
15.Ifanobstructionishit,stopthetractorimmediately,disengagePTOdrive,turnoffengine,removeignitionkey
and wait for all moving parts to come to a complete stop.
Checktheentiremachineforanydamagebeforeresumingwork.
16.Itisstronglyrecommendedtohaveyourmachinecheckedbyyourdealeraftereachseason,especiallyblades
and discs and their fixing devices (nuts, bolts etc.).