KUHN GMD 801 User manual

ASSEMBLY / OPERATOR'S MANUAL
GMD 801
Multidisc Mower
N° 95000 B.GB - 10.2000
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DEAR OWNER,
In buying a KUHN machine you have chosen wisely. Into it have gone years o thought,
research and improvements. You will ind, as have thousands o owners all over the world, that
you have the best that engineering skill and actual ield testing can produce. You have
purchased a dependable machine, but only by proper care and operation can you expect to
receive the per ormance and long service built into it.
This manual contains all the necessary in ormation or you to receive ull e iciency rom your
machine. The per ormance you get rom this machine is largely dependant upon how well you
read and understand this manual and apply this knowledge. Please DO NOT ASSUME THAT
YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR MACHINE be ore reading this
manual care ully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE.
Your KUHN dealer will instruct you on the general operation o your machine. He is interested
that you get the best per ormance possible and will be glad to answer any special questions
that may arise regarding the operation o the KUHN machine.
Your KUHN dealer can o er a complete line o genuine KUHN service parts.
These parts are manu actured and care ully inspected in the same actory that builds the
machine to assure high quality and accurate itting o any necessary replacements.
When ordering service parts it is important that you indicate the type o machine concerned
and its serial number.
For this reason please complete the model identi ication plate diagram below with the required
in ormation. This will provide you with an easy re erence or uture service parts orders.
ABOUT IMPROVEMENTS
KUHN is continually striving to improve its products and, there ore, reserves the right to make
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
Page
Safety 2
Safety decals 8
Technical specifications 11
Assembly instructions 11
General information 16
Adapting to the tractor 17
P T O shaft 19
Transport 20
Working position 21
Adjustments 23
Safety breakaway 25
Parking the machine 26
Operating the mower 27
Lubrication 28
Maintenance 31
Inspection of knives & securing elements 34
Optional equipment 36
Trouble shooting guide 37
Storing the mower 38
Limited warranty 39
Copyright 2000 KUHN S A
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SAFETY
The above symbol is used throughout this manual every time recommendations are made concerning your safety,
the safety of others, or the good operation of the machine
These recommendations must be made known to all machine operators
DESIGNATED USE OF THE MACHINE
GMD 801 Multidisc Mowers must only be used for the work which they have been designed : mowing on the ground
of hay fields, grass silage fields and improved pastures for the purpose of harvesting fodder for feeding livestock
The manufacturer is not held liable for any damage resulting from machine applications other than those specified
by the manufacturer
Any use other than the designated operation is at the risk and responsibility of the operator
Designated use of the machine also means :
- following operation, maintenance and repair recommendations given by the manufacturer ;
- using only genuine spare parts, equipment and accessories as designated by the manufacturer
GMD 801 Multidisc Mowers must only be operated, maintained and repaired by competent persons who are familiar
with machine specifications and operation and are aware of any danger involved
The operator must imperatively respect current legislation concerning :
- accident prevention,
- work safety,
- public traffic circulation
All safety advice indicated on the machine must be strictly observed
The manufacturer is not held liable for any damage resulting from machine modifications carried out by the operator
himself or by a third party without previous written agreement from the manufacturer
GENERAL SAFETY RECOMMENDATIONS
Before operating the machine, always ensure that tractor and machine are in accordance with work safety and road
traffic regulations
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BASIC PRINCIPLES
1 In addition to the recommendations given in this manual, legislation on work safety and accident prevention must
also be respected
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 Do not wear loose clothing which could become caught up in moving elements
6 The tractor must be equipped with a safety cab Keep windows and roof hatch closed for reduced sound level
while operating the PTO driven implement
7 Before starting up the machine and beginning work, check the surrounding area (beware of children !) Make
sure there is sufficient visibility Keep all people and animals away from the danger zone of the machine (risk
of projection!)
8 Carrying people or animals on the machine when working or in transport is strictly forbidden
9 Machine must only be attached to tractor using means provided and in accordance with current safety
standards
10 When attaching or removing the machine, place the parking stand into the corresponding position
11 Special care should be taken when attaching or removing the machine from the tractor
12 Before attaching the machine, make sure that the maximum permitted front axle weight and gross weight of
the combination are not exceeded
13 Do not exceed the maximum permitted length and width authorized by road traffic regulations
14 Before transporting the machine on public roads, ensure that all legally required guards and indicators (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 Before travelling on public roads, put the machine into its transport position as instructed in this operators
manual
17 Never leave the tractor seat while the machine is operating
18 Drive speed must be adapted to ground conditions as well as to 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, ballast of front axle, ground or road conditions It is therefore of utmost importance to be cautious in
every given situation
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20 Be particularly cautious when turning corners, paying attention to machine overhang, length, height and weight
21 Before operating the machine, ensure that all safety guards are firmly in place and in good condition If worn
or damaged, replace immediately
22 Before operating the machine, check the tightness of all nuts and bolts, particularly on tool fixing elements
(blades, tines, knives, spades ) Retighten if necessary
23 Keep clear of the machine operating area
24 WARNING ! Danger of crushing and shearing can exist when components are operated by hydraulic or
pneumatic controls
25 Before leaving the tractor or before adjusting, maintaining or repairing the machine, turn off the engine, remove
the ignition key and wait until all moving parts have come to a complete stop
26 Do not stand between the tractor and the machine unless the hand brake is tight and/or stops have been placed
under the wheels
27 Before any adjustments, maintenance or repairs are carried out, ensure that the machine cannot be started
up accidentally
ATTACHMENT
1 When attaching or removing the machine from the tractor, position hydraulic lift control lever in such a way that
it cannot be set off accidentally
2 WARNING ! Danger of crushing and shearing can exist in the lifting zone of the 3-point linkage !
3 Do not stand between the tractor and the machine when operating the outer control lever of the lift mechanism
4 In transport, the machine lift mechanism should be stabilized by tractor tie rods to avoid floatation and side
shifting
5 When transporting the machine in the raised position, lock the lift control lever in place
POWER TAKE-OFF
1 Use only the PTO shaft supplied with the machine or recommended by the manufacturer
2 PTO guards must always be in place and in good condition
3 Check for correct PTO overlap when at work and in transport
4 Before attaching or removing the PTO shaft, disengage PTO shaft, turn off engine and remove ignition key
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5 If a primary PTO shaft is equipped with a slip clutch or a free wheel, these must be fitted on the machine PTO
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 speed (rotational frequency) and direction are in accordance with
manufacturer's recommendations
9 Before engaging PTO, keep all people and animals clear from the machine
10 Never engage PTO shaft when tractor motor is turned off
11 Never surpass the PTO angle recommended by the manufacturer
12 WARNING ! Rotating elements can continue turning momentarily after PTO is disengaged Keep clear until all
rotating elements are at a standstill
13 When removing the machine, place PTO shaft on the supports provided
14 Fit the safety cap on tractor PTO
15 Replace any worn or damaged PTO guards immediately
HYDRAULIC SYSTEM
1 WARNING ! Hydraulic system is under pressure
2 When fitting hydraulic motors or cylinders, ensure that connections have been made correctly, as per
manufacturers instructions
3 Before connecting hoses to the tractor hydraulics, ensure that tractor and machine circuits are not under
pressure
4 It is strongly recommended that the operator marks the hydraulic connections between tractor and machine to
avoid making a wrong connection WARNING ! Functions could be reversed (for example : lift/lower)
5 Check hydraulic hoses regularly ! Worn or damaged hoses must be replaced immediately
Replacement parts must be in accordance with manufacturers recommendations concerning specifications and
quality
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, there could be danger of infection
8 Before any adjustments, maintenance or repairs are carried out, lower the machine, depressurize the circuit,
turn off the engine and remove ignition key
Rotation speed rpm (American Measure) is also expressed in metric measure : Rotational frequency min - 1 Both
units are equivalent, for example : Rotation speed 540 rpm equals Rotational frequency 540 min-1
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MAINTENANCE
1 Before checking for any machine malfunction and before adjusting, maintaining or repairing the machine,
disengage PTO, turn off engine and remove ignition key
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 When replacing a working part, wear protection gloves and only use standardized tools
5 It is forbidden to discard any oil, grease or filters These must be given to waste disposal organisations to protect
the environment
6 Disconnect power source before any work is done to the electric system
7 Check safety guards regularly, particularly those that are subject to wear Replace immediately if damaged
8 Spare parts used must be in accordance with specifications and standards as defined by the manufacturer Use
only genuine KUHN parts !
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 (spring, accumulators etc ) must only be carried out by
competent persons with standardized equipment
SPECIAL SAFETY RECOMMENDATIONS
1 Use a tractor equipped with an enclosed cab with windows made of safety glass and kept closed It is
recommended to fit polycarbonate screens inside the tractor safety cab's side and rear windows or to install mesh
guards on the exterior of 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 Each time before using the mower, inspect condition of cutting elements (knives, discs) Replace any missing,
worn or damaged cutting elements immediately Use only genuine KUHN spare parts
5 To avoid creating dangerous out of balance forces, always replace missing, damaged or worn knives in pairs
6 When replacing knives or discs, systematically inspect their securing elements as per the manufacturers
recommendations
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7 Regularly inspect the disc mowers protection cover Worn or damaged protection covers must be replaced
immediately
8 Protection devices (such as guards, shields etc ) are intended to prevent stones, rocks or other foreign objects
from being projected They also prevent access to the machines danger zones Therefore, it is imperative that
protection devices are put in place and properly secured each time before using the machine
9 Crushing and shearing zones which could cause serious bodily injury when changing the machine from transport
to work position and vice versa may exist To prevent possible injury, be extra careful when maneuvering and
ensure that everyone is at a safe distance away from the machine
10 PTO drive to the mower must never be engaged unless the cutterbar skid shoes are in contact with the ground
and the protective cover is folded down
11 Ground of the pastures to be mown must be free of foreign objects
12 Even when the machine is used in accordance with it purpose, objects may be projected It is therefore imperative
that everyone be kept away from the danger zone, that extra care is taken and that extra precaution (such as
safety indicators) be taken when mowing pastures alongside roads or near public areas (parks, schools etc )
13 Never mow in reverse
14 When disengaging the PTO drive, moving parts continue to rotate for some time Wait for all moving parts to come
to a complete stop before approaching the machine
15 If an obstruction is hit, stop the tractor immediately, disengage PTO drive, turn off engine, remove ignition key
and wait for all moving parts to come to a complete stop
Check the entire machine for any damage before resuming work
16 It is strongly recommended to have your machine checked by your dealer after each season, especially blades
and discs and their fixing devices (nuts, bolts etc )
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SAFETY DECALS
THE FOLLOWING SAFETY PICTORIALS HAVE BEEN PLACED ON YOUR MACHINE IN THE AREAS
INDICATED THEY ARE INTENDED FOR YOUR PERSONAL SAFETY AND FOR THE SAFETY OF THE
PEOPLE WORKING WITH YOU THE TEXT SHOWN ON THEM GIVES THEIR PRECISE MEANING
ENSURE THAT THESE PICTORIALS ARE ALWAYS LEGIBLE IF THEY ARE NOT, REPLACE THEM
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Number of discs 8
Width of cut 3 11 m / 10' 2"
Width in transport position (1) 350 mm (14") wider than tractor width
Disc speed (rotational frequency) 2991 rpm (min-1)
P T O power requirement (as from) 41 kW (56 hp)
P T O speed (rotational frequency) 1000 rpm (min-1)
Lift system hydraulic
Tractor attachment cat 2
Weight (approx ) 710 kg / 1565 lbs
Bevel gearbox oil capacity 1 litre / 2 US pint / 1 75 Imp pint
Oil quality : SAE 80 W EP (GL4)
Cutterbar oil capacity 2 25 litres / 4 5 US pint / 4 Imp pint
Oil quality : SAE 80 W EP (GL4)
(1) Applicable if machine is attached in such a way that a 5 cm / 2" distance "A" is respected (see page 17)
TYPE GMD 801
TECHNICAL SPECIFICATIONS
ASSEMBLY INSTRUCTIONS
To facilitate shipping of the GMD 801 certain parts or complete sub-assemblies have been disassembled in order
to reduce bulk
1. Mount ng chass s to cutterbar
Make sure that the bore of nylon bushings is clean and
well greased Remove protective paint from the front
cover of bevel gearbox where bushings make contact
Chock chassis Lock the stand (C) in its lowered
position with pin (D) (photo A) Attach chassis to
cutterbar with 2 self-locking screws (B) (M 16 x 50)
and 2 washers (A) (dia 17 x 61 x 8) as shown in photo
A Torque : 30 daNm/220 ft lbs
FOR YOUR SAFETY BE SURE TO CHOCK CHASSIS CORRECTLY.
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4. Frame p pe, l ft bracket and compensat ng spr ng assembly
- Attach frame pipe (G) (photo D) to bevel gearbox with 4 screws (H) (M 16 x 40) Torque : 21 aNm (155 ft.lbs)
At the same time attach plate (K) (photo D)
- Attach lift bracket (L) (photo E) using axle (M) and 2 roll pins (dia 6 x 40) provided
- Connect compensating spring (U) (photo B) to axle (V) of frame pipe (G) and secure with 2 roll pins
(dia 6 x 40) Take care to use the upper mounting hole an to position ro (U) correctly (see
photo E)
2. Assembl ng the frame's p vot ng
cyl nder (photo B)
Connect the pivoting cylinder (Q) to both the oscillating
arm (R) with pin (S) and a self-locking screw (T) and to
the pivoting frame (W) with pin (X) and 2 roll pins (Y)
(diameter 6 x 50) Ensure that the cylinder guard (Z)
and plain washer (J) (diameter 30 5 x 50 x 2) are
inserted between the upper roll pin (Y) and cylinder
mounting yoke
3. Assembl ng the compensat ng
suspens on rod (photo C)
Link the rod (A) to the upper frame casting (B) using pin
(C) and 2 roll pins (D) (diameter 8 x 45)
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5. Assembly of belt sh elds and belt
- Install the inner belt shield (D) (photo F) in place and
secure with the 3 spacer bolts (E) Do not forget to
insert a flat washer (dia 13 x 30 x 5) between each
spacer bolt and the inner belt shield
- Install closing cover (F) equipped with 2 clamp nuts
using 2 underserrated self-locking screws (O) (M 8
x 12) as shown in photo G
- Install belt (G) (photos F and G) on pulleys and
tension it following instructions on page 31
- Attach outer belt shield (N) with 3 self-locking nuts
(I) (M 12) and 3 conical spring washers and install
underserrated self-locking screw (P) (M 8 x 12)
(photo H)
6. Outer swath wheel assembly (photo I)
- Attach swath wheel assembly (U) to outer skid shoe
with 2 cup square bolts (V) (M 12 x 35), 2 conical
washers (dia 13 mm) and 2 self-locking nuts (M 12)
Torque : 8 5 daNm/65 ft lbs
Before tightening the screws (V), check that the
swath wheel does not touch the cone cover or the
blades
Keep to a distance of X = 15 to 25 mm - 3/5" - 1".
I
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- Attach the front safety bar (B) to its 3 hinges (C) with
the 5 cup square bolts (P) (M 10 x 25), 5 self-locking
nuts (O) (M 10) and 5 flat washers (Q) (Ø 11 x 24 x
2) (fig 1)
- Then attach the pre-assembled front safety bar (B)
at (N) with 3 hexagonal screws (M 12 x 75) and self-
locking nuts (M 12) (fig 1 and photo 2) Do not
tighten these 3 screws completely, so that the front
safety bar can still pivot
- Next attach rear safety bar (A) with 6 round head
bolts (P) (M 10 x 25), 6 self locking nuts (O) (M 10)
and 6 flat washers (Q) (Ø 11 x 24 x 2) (fig 1 and photo
2) At the same time attach stop rod (J) as shown in
figure 1 and photo 2, being sure to place 2 flat
washers (Q) (Ø 11 x 24 x 2) 11 x 24 x 2) under the
self- locking nuts (O) Fit 2 end plugs (Z) on rear
safety bars
7° Safety guard assembly
The angular position of the swath wheel
compared to the cutterbar can be adapted
to working conditions enabling a regular
flow of the cut crop towards the rear
Position the swath wheel so that maxi-
mum angle (A') (fig J) is obtained In
difficult working conditions (long, dense,
bent over crops) position it towards mini-
mum angle (A) (fig J)
J
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8° Assembl ng safety curta n and outer safety guard
- Pre-assemble the safety curtain (1) To do this attach clamp collars (2) to curtain (1) and loosely fasten rod (3)
with these clamp collars (photo 3)
- Attach both hinges (6) with cup square bolts (7) (M 10 x 20) (photo 3 and figure 5)
- Install cover (1) as shown in photo 3 Buckle straps around the pipe frame at (8)
- Buckle straps (5) around front and rear safety bar
- All these straps are attached underneath the safety cover (photo 4)
- Punch 3 holes in the safety cover at (10) and attach
cover on the outside arms of the safety bars with
round head screw (R) (M 10 x 30) of stop rod (J), 2
round head screws (U) (M 10 x 35) of outer safety
guard (S), 1 plastic washer (T) (dia 10 5 x 32 x 2 5)
and 3 self-locking nuts (O) (M 10) (fig 1 and photo
4)
- At (9) attach the outer safety guard (S) to the front
guard flap tube using a round head bolt (C) (M 10 x
50) and a self-locking nut (O) (M 10) (fig 1 and photo
4)
- Attach springs (16 and 17) to their respective
anchorage points with the small chains (photos 3, 6
and fig 5) an close the eyelets
9° Attach ng break-away latch
Connect the break-away latch (34) to the yoke of
3-point frame (30) with axle (31), 2 roll pins (32) (dia
6 x 36) and a plain washer (33) (dia 23 x 40 x 7) as shown
in photo 6
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Note : 825 mm dimension is correct when the distance (X) is the same for the two lower hitch pins (T)
1 Minimum tractor PTO power should be 41
kW / 56 hp for the GMD 801 If tractor power
is insufficient, quality of work will be
unsatisfactory
2 GMD 801 mowers can be adapted to all tractors
having a PTO spee (rotational frequency) o f
1000 rpm (min-1) and equipped with a normalized
Cat 2 three-point hitch
3 GMD 801 mowers are equipped with adjustable
lower hitch pins allowing the machine to be
offset +/- 50 mm (2") to the left and to the right
4 To adjust lower hitch pins (T) (photo 9), loosen
the 4 hexagonal screws (U) of collar flanges (V)
on each side
Reposition lower hitch pins respecting :
825 mm (28") dimension (page 17) and retighten
screws (U)
Torque : 12 aNm / 88 ft.lbs
Check tightness of screws (U) after the first
ten hours of use.
GENERAL INFORMATION
The lower hitch pins shoul stay parallel to the groun when the machine is parke . If this
is not the case the lift cylin er shoul be ble in exten e position.
The parking stan on the GMD 801 machines has been esigne to support the weight of the
3-point frame only an the following points must be respecte :
1) If at any time it becomes necessary to move the machine with a fork lift or loa er type
vehicle it is very important that the 3-point frame is :
a) lifte from the groun first, when lifting the machine
b) lowere onto the groun last when lowering the machine.
Failure to comply with the above points will result in amage being cause to the parking
stan .
2) If at any time it becomes necessary to transport the machine on a lorry or trailer then some
form of support must be use i.e. a piece of woo , to take the weight of the 3-point frame,
so relieving the weight on the parking stan . This action will prevent amage being
cause to the parking stan when the machine is secure by loa straps.
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ADAPTING TO TRACTOR
A) Attachment of lower l nks and
pos t on ng of h tch p ns :
Follow fig. 10 for category 2 tractors with narrow
wheel tracks
Follow fig. 11 for category 2 tractors with standard
wheel tracks
Follow fig. 12 for category 2 tractors with wide wheel
tracks
NOTE : Always attach machine in such a way that
distance (A) is approximately 50 mm (2")
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B) Attach ng the mach ne
- Attach the lower links (A) to the hitch pins and
secure with linchpins (photo 13)
- Attach top link (P) using hitch pin (D) on the 3-point
frame so that it is relatively parallel to the lower links
(A) (photo 13)
- Connect hydraulic hose (H) to the tractors single
acting valve (photo 13) First make sure that the
hydraulic connection is clean ; if not, cylinders may
not function correctly
C) Adjust ng cutterbar hor zontal pos t on
- Activate the tractors hydraulic lift mechanism and
check that the 3-point frame is lifted parallel to the
ground (photo 13A) If necessary, adjust levelling
rods (F) (photo 13)
If, once this adjustment has been made, the cutterbar
is still not parallel to the 3-point frame, level it by
adjusting threaded cylinder rod (V) (photo 13A)
D) Ra s ng cutterbar and park ng stand
NOTE : ONLY OPERATE THE PARKING STAND
(E) WHEN THE CUTTERBAR IS IN THE
VERTICAL TRANSPORT POSITION
(COMPENSATING SPRING IS
RELEASED).
- Activate the machines hydraulic cylinders to bring
the cutterbar into its vertical position
- With the machine in the transport position (cutter-
bar vertical), raise the stand (E) and connect it to the
suspension rod (F) using pin (L) (photo 14)
Note : The PTO shaft must be a apte
at a later stage. Correct length can-
not be checke as long as the
cutterbar is in horizontal position.
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