Kellfri 35-FDM240 User manual

Carefully read the operating
instructions before using the product!
Operating instructions translated from Swedish
35-FDM240
ROTARY DISC MOWERS

Table of Contents
Kellfri designs and supplies ecient, aordable machinery and components for forestry, agriculture,
construction and gardening in Sweden, the rest of the Nordic region and Europe.
We recommend that you always read and follow the safety instructions and the instructions in the
machine's operating manual.
Kellfri is not liable for any errors in this document.
TABLE OF CONTENTS
Introduction 3
Product information 3
Safety instructions 4
Instructions for emergency situations 4
Personal protection 4
Surroundings 5
Before use 5
Environment 5
Use 6
After use 6
Maintenance and service 7
Transportation and set-up 7
Recycling 7
When using machine/equipment connected to tractor 8
Machines/equipment connected to hydraulics 9
PTO shaft 9
Risks and hazards associated with the use of grassland machinery 10 - 11
Warning decals 12
Chemicals 13
Parts 14 - 15
Installation 16 - 22
Grease points 23
Connecting the equipment 24
Operation 25
Safety during operation 26
Disconnecting 27
Transport mode 27
Replacement of blades 28
Scythe mower - oil change/oil relling 28 - 29
Gearbox - oil change/reling 30
Belt 30
Troubleshooting and service 32
Exploded diagrams and materials list 34 - 41
Instructions for shortening PTO shaft 42
Rotation pattern 43
Notes 44 - 46
Deviation form 47
Warranty terms and conditions 48

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Table of Contents
INTRODUCTION
Thank you for choosing a product from Kellfri AB. Compliance with the safety instructions, operating
manual and sound common sense will guarantee many years of enjoyment using the product.
Kellfri's equipment and products are aimed at self-employed farmers, horse enthusiasts and other
country-dwellers who have stringent performance demands.
PRODUCT INFORMATION
The FDM240 rotary disc mower is a practical tool for you if you have larger grasslands, and you want
a simple way of mowing grass for feed or hay. The rotary disc mower is designed and adapted to
enable you to mow your elds gently and eectively. The rotary disc mower has a working width
of 2.4 m.
The mower is equipped with six oval rotary discs that cut the grass eectively, with better cutting
performance that gives good growth. There are two raised rotary discs with guide blades in
each outer edge, which raise the throughow speed and ensure that the crop ows freely without
interruption. Individual skids under each disc protect the cutterbar, which lies well balanced and
very lightly against the ground. The cutting height is 0-100 mm.
The rotary disc mower is tted with a protective cover over the whole cutterbar, protecting both
the tractor and the surroundings from stone chippings and grass spray.
The protective frame around the cutterbar is constructed of a single frame which gives stable
support to the entire protective frame and protective cover. The protective frame can also be
folded open during maintenance.
The cutterbar is tted with gliding plates at both ends.
The machine is equipped with a stone ejector as collision protection, which ejects backwards at
an angle in order to reduce stresses in a collision.
Adjustable relief springs relieve the pressure of the rotor cutterbar against the ground to minimise
damage to the ground. The rotary disc mower has a hydraulic raising function with a manual lock
for a secure transport mode. The transport width is no wider than the tractor.
Geometrical and powerful energy transmission from PTO to cutterbar by means of ventilated belt
drive and bevel gear.
TECHNICAL DATA 35FDM240
Machine dimensions 4350 x 1200 x 1320 mm
Working width 2380 mm
Operating height, min-max 60-100 mm
Rotary discs (oval) 6
Blades 12 pcs
Working angle +90 to -35 degrees
PTO shaft Standard
Power requirement, hp 35-50
Weight 557 kg
Three-point linkage Cat.1 and Cat.2
PTO - rpm 540
Cutterbar - transmission oil 80W-140 2.0 lit (NB Exact quantity is important.)
Gearbox - transmission oil 80W-90 0.4 lit (NB Exact quantity is important.)

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SAFETY INSTRUCTIONS
Before using the equipment or product, and for the safety of yourself and others, you must read the
safety instructions and instruction manual and understand their contents. Always keep the safety
instructions and operating manual handy for users of the equipment or product. For the safety of both
yourself and others, it may be a good idea to read through the safety instructions every now and then.
If the safety instructions or the operating manual are damaged, or become unusable for any other
reason, new copies may be ordered from: Kellfri AB, Munkatorpsgatan 6, SE-532 40 SKARA, Sweden.
Tel.: [phone]
The safety instructions can also be downloaded from Kellfri's website: www.kellfri.co.uk
Do not use the equipment or product if you feel ill, tired or are under the inuence of alcohol. Do not
use the equipment or product if you are taking prescribed medication or drugs, or suering from
severe depression or mental illness. Always comply with general rules of the road and applicable
rules stipulated by animal welfare legislation. People under the age of 15 are not allowed to use
the equipment.
INSTRUCTIONS FOR EMERGENCY SITUATIONS
In case of emergency, call 112.
Always have a mobile phone or emergency phone available when working alone. A rst-aid kit
and re extinguisher must be kept in an easily accessible location when carrying out any work,
maintenance or service.
Warning!
The original design of the machine must not, under any circumstances, be modied
without the approval of the manufacturer. Unauthorised modications and/or accessories
may cause life-threatening injuries or death to users and others.
PERSONAL PROTECTION
Always use suitable protection equipment. Do not wear loose clothing or jewellery while working
with the equipment. Long hair should be tied up when working with equipment that has
moving parts. Use protective gloves to avoid the risk of burns if hot surfaces such as exhaust pipes
are touched, and to avoid oil and petrol getting in contact with the skin. Ear defenders must be
worn whilst the engine is running.
Kellfri is not liable for any modications, changes or rebuilds carried out by customers.
Where the machine is used professionally, employers are responsible for ensuring that users of the
machine have theoretical and practical knowledge of the machine and that work is performed in
a safe manner. Stay informed by complying with work environment legislation; contact your local work
environment authority.

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Table of Contents
SURROUNDINGS
Check that the work area is free from bystanders and objects before hitching or using the
equipment. Otherwise, there is a risk of serious injury. Be extra careful if there are children in
the vicinity of the area where the equipment or product is used or stored. Check that there are
no low-hanging electrical cables within the work area. Exercise caution when working on slopes
and close to ditches.
Always work alone with equipment or products that are made for working alone. Never leave
rubbish in the work area, and keep work surfaces clean. Always respect the equipment's risk zone.
BEFORE USE
Carefully read the safety instructions and the operating manual. Make sure that you understand
the safety instructions, the operating manual and warning decals. Use common sense and
suitable personal protective equipment when using the product. Always check the performance
of the machine combination to be used. It is important that these are compatible and work
satisfactorily together. This is to ensure that the equipment or product works as expected, and
to guarantee the safety of yourself and others. Carry out a visual inspection of the equipment
or product before use. Repair or replace damaged or worn parts to reduce the risk of injury. Grease
moving parts and check that all nuts and bolts are tightened. Repair if necessary. Learn and
remember the correct working method. Beginners must work slowly until they have learned how
the machine or product works.
Users/customers are responsible for ensuring users can handle the situation. If a user feels that the
machine is dangerous to use, they should not use it until they have received thorough training.
WARNING!
Never use equipment or products with defective safety components.
Children must not be left unsupervised in the area!
Warning!
ENVIRONMENT
• Disposal of oil and other waste
• Improper disposal of oil or other waste may be hazardous to the
environment.
• When oil is emptied from the machine, it must be poured into
a leak-proof container suitable for oil. It is not permissible to store oil
in a container used for food or drink, in order to avoid the oil being
consumed by mistake and causing serious injury.
• It is prohibited to spill oil on the ground, or pour it into a drain or
anywhere leading to a water source.
• Discarded oil, fuel, coolant, brake uid, lters and batteries must not
be thrown away or emptied in just any manner. Contact your local
authority for further information.

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USE
Only those who understand the safety instructions and the operating manual may use the
equipment or product. Exercise caution and care when working with the equipment or product
and only use it in the way described in the instruction manual.
There is a risk of crushing when working with equipment that has moving parts. Exercise caution
when working with equipment with hydraulic hoses, as oil under pressure can penetrate the skin.
Immediately seek medical attention if this should occur. Always work alone with equipment that
is made for working alone.
Respect the equipment's risk zone.
For further information about your machine, read the machine's operating manual.
DANGER!
CAUTION!
NOTE
Warning symbols identify important safety aspects in this manual in order to help you and others avoid dangers and
accidents. When using the machine: Be extremely careful!
Warning!
This symbol indicates that a serious accident will occur if the directions in the operating manual are
not followed. The accident will lead to serious injury, possibly death, or serious damage.
This symbol indicates that an accident will occur if the directions in the manual are not followed.
The accident will lead to serious injury or damage.
This symbol indicates that an accident may occur if the directions are not followed.
The accident will lead to injury or damage.
NOTE indicates the risk of a breakdown if the directions are not followed.
Where the machine is used professionally, employers are responsible for ensuring that users of the
machine have theoretical and practical knowledge of the machine and that work is performed in
a safe manner. Stay informed by complying with work environment legislation; contact your local work
environment authority.
AFTER USE
• Ensure that the equipment/product is standing on level ground when it is disconnected.
Use stabilisers, if included with the product/tool.
• Wash, rinse with water and dry if necessary.
• Re-lubricate if necessary.

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MAINTENANCE AND SERVICE
• Make sure that the equipment is stable and cannot tip over when carrying out maintenance
and service work.
• Replace damaged or worn parts to reduce the risk of injuries.
• Carry out maintenance, service and checks in line with recommendations.
• Only use spare parts with equal performance to reduce the risk of injuries and breakdowns.
• All electrical repairs and electrical connections must be carried out by a qualied person.
Check that all nuts and bolts are tightened after maintenance and service work.
Always test the machine before starting work.
IMPORTANT! Check the oil level (gearbox/engine oil) and lubricate grease points regularly!
IMPORTANT! Avoid over-lubricating. Dirt collects easily on exposed grease and causes increased
wear. After lubrication, wipe excess grease o from couplings.
DANGER!
WARNING: Pressurised oil and fuel leaks can penetrate skin and cause serious
injuries. Do not use your hands to locate leaks. Use a piece of paper or cardboard
to search for leaks.
Kellfri AB has a policy of continuous product development and therefore reserves the right to make
modications, e.g. to the design and appearance of the product, without prior notice.
TRANSPORTATION AND SETUP
• Check that the work area is free from bystanders, children and objects before driving o.
• Always observe additional caution during transport and moving.
• Ensure that the equipment or product is well anchored and that available transport lashings
are tted.
• Always position the load as low as possible. All protruding loads should be well anchored.
• Respect the risk zones even during transport and moving.
• Do not permit anyone to walk under suspended loads when carrying out lifts.
• Trailers used for transport should have brakes that work.
• An SMV sign must be attached when travelling on public roads.
• Check tyre pressure - see information on sides of tyres. Do not exceed the maximum pressure!
• Always store the equipment or product in a dry place, preferably under a roof, when not in use.
• Ensure that the equipment or product is stable and cannot tip over.
• Never permit children to play at the storage site.
• Be aware of the tipping risk!
RECYCLING
For scrapping, the equipment/product must be dismantled and transported to
a recycling station designated by your local authority. Any liquids should be collected
and transported to a recycling station designated by your local authority. Contact your
local authority for further information.

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FOR USING MACHINE/EQUIPMENT CONNECTED TO TRACTOR
PAY ATTENTION TO THE FOLLOWING:
• Carefully read the machine's operating manual before using the machine! It is important that
you understand the directions in the manual.
• Keep the work area clear of children and other people. Moving parts increase the risk of
accidents.
• Never put your hands or feet under the machine without rst switching o the equipment and
the tractor's engine.
• Never leave the equipment with the tractor engine running. Turn o the engine and apply the
parking brake when you leave the equipment – even for a short period.
• Always disengage the machine before performing service or maintenance work.
• Never leave the machine in a raised position. There can be a loss of pressure in the hydraulics
and the machine can drop to the ground.
• Ensure that all guards are in place and cannot come loose.
• The entire length of the PTO shaft must be protected. Ensure that the safety chain is well
anchored.
• Only the driver of the tractor may be present in the vicinity of the machine while it is in operation.
• Before operation, ensure that there are no stones protruding from the eld.
• Never exceed the PTO shaft's speed. (Recommended speed for most operation is 540 rpm.)
• Always adjust the rotor speed to the type of work to be carried out.
• Never use the machine if it is unbalanced.
• Do not try to remove jammed objects while the engine is running. Ensure that the engine
and the rotors have stopped before carrying out any measures on the machine.
• Ejection warning! Respect the machine's risk zone of 15 - 25 m.
• Never hand over the machine to someone else until you are sure that they have the necessary
knowledge of the machine.
• It is prohibited to stand between the tractor/loader and the machine during attachment
and detachment.
• Operate a new machine at low speed and without a full load for the rst few hours.
• Exercise caution when working near power lines and telephone lines.
• Do not operate the machine if substantial vibrations develop. Stop the machine immediately
and inspect it.
• Before you connect or disconnect the hydraulic hoses, ensure that there is no longer any
pressure in the system. Pull the hydraulic handle from side to side several times in order
to remove pressure from the hydraulic hoses.
• Carry out a visual inspection of the equipment before use. Lubricate moving parts and check
that nuts and bolts are tightened. Repair or replace damaged or worn parts.
• When you disconnect quick couplings, ensure that you protect them after use, so that they are
not exposed to dirt.
• The tractor/loader should be tted with an ABE2 or ABE3 re extinguisher. Contact your
insurance provider.

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MACHINERY/EQUIPMENT CONNECTED TO HYDRAULICS
Be careful when you connect your machine or equipment to a hydraulic hose.
DANGER!
Pressurised oil and fuel leaks can penetrate skin and cause serious injuries. Do not use your
hands to locate leaks. Use a piece of paper or cardboard to search for leaks.
• Warning of high pressure, risk of penetration injury.
• Before repairs or maintenance are carried out, the system must be relieved of any remaining
pressure.
• Turn o the tractor and move the hydraulic levers back and forth to release any pressure
that may still be in the oil hoses and pipes before starting any work on them or the hydraulic
cylinders.
• Clean the lter in the suction pipe after 10 hours' work.
• Immediately replace hydraulic hoses if cracks or wear are detected.
• Do not adjust the valve settings. Incorrect adjustment can result in damage to the machine
and/or injury.
• The hydraulic system must only be operated using hydraulic oil intended for the purpose.
Check the oil level before you start the machine!
• When commissioning a new machine, it is recommended that the hydraulic oil is changed
after the rst 10 hours of operation, in order to remove any dirt or metal chips which may have
got into the hydraulic system.
POWER TAKEOFF SHAFT
PTO SHAFT
Things to remember when operating equipment with a PTO shaft
The transmission to the gearbox is protected both by the PTO drive shaft and by the shear bolt.
All guards should be correctly assembled and in good condition. If the guards are in poor condition
or worn out, they should be replaced before the equipment is used.
If the PTO shaft is not correctly protected, it can result in death, as it can trap parts
of the body or clothing and cause life-threatening injury.
Ensure that the safety chain is correctly anchored to the PTO drive shaft and that the PTO shaft
is protected along its entire length. Ensure that the PTO shaft spins easily inside the protective
tubular pipe. Keep the spline grooves clean and well lubricated so that the PTO drive shaft can
be connected easily.
For adjustment and use of the PTO shaft, see the PTO shaft operating manual.
Never overload the PTO shaft! Never exceed the PTO shaft's maximum speed.
NOTE The oil becomes hot when it ows through the hydraulic system. Check the oil temperature at regular
intervals in order to avoid overheating. Stop the machine if the oil becomes overheated and allow the oil
to cool down.
Warning! Rotating power take-o
Warning! Risk of crushing!
DANGER!

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RISKS AND HAZARDS ASSOCIATED WITH THE USE OF GRASSLAND MACHINERY
Risk of crushing
Observers can be injured when the machine is lowered in the cutting position. Pasture toppers have
crushing points around the hinge areas and between the three-point linkage and the main body.
Respect the risk zone of 15 m!
Rotating blades
WARNING! Any person can risk injury by putting their hands or feet under the machine when it is
lifted from the ground and the blades are still rotating. Nobody is allowed in the vicinity during
operation or when the machine is running.
Risk of crushing
This risk is common in mechanical transmission devices such as belt drives, bevel gears and rollers.
Ensure that all guards are correctly tted.
Rotating blades
Risk when disengaging machine
The heavier a rotating part is, the longer it will continue to rotate after the wheel drive has been
disconnected. This property is called free-wheeling. Rotating blades and other components
such as drive shafts etc. will continue to spin round after the wheel drive has been disconnected.
Injuries occur:
• When the operator disconnects the equipment and attempts to clean or adjust the machine
before the components have stopped rotating.
• When the shear bolt in the protective device in the power outlet disintegrates and the
rotors continue to spin while the power outlet has stopped. The operator's awareness is of
key importance for safety around rotating parts. Never raise the machine while the blades are
still rotating!
Risk of ejected objects
Machines that cut grass eject material during operation. Foreign objects such as stones, sticks and
other debris can nd their way under the machine and be ejected at great speed. Metal guards
at the sides and front prevent these objects being ejected, but this is no guarantee that they will
always capture everything.
Observers or animals standing in the way of an ejected object can suer serious injury.
Never operate the machine when there are observers nearby.
Respect the equipment's risk zone of 15-25 m!
Noise
Note that the machine is intended for outdoor use and that the operator's position is the driver's
seat of the tractor. It is advisable to read the directions given in the tractor manual and maintenance
instructions. The sound pressure level during operation exceeds 70 dB. Hearing protection must
therefore be worn during operation.
Accidents involving slipping and falling are often a result of:
• Slippery surface
• Uneven steps and work platforms.
The risk of slips and falls can be reduced considerably by exercising good judgement.
All unprotected rotating machine parts increase the risk of accidents. Accidents usually occur when
loose-tting clothing or long hair is caught and wrapped around rotating parts, such as PTO shafts
or drive shafts on the machine. Ensure that all guards are correctly tted.

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Drive safely on public roads
• Always follow trac safety rules on public roads, and following the regulations applying
to driving a tractor with towed equipment on a public road.
• Check that reectors, warning signals and/or warning ags indicating protruding equipment
are tted to the machine or tractor. These indicators must be correctly mounted, and must
be visible and easy for drivers of other vehicles to see.
• Observers must not lean against or climb onto the machine during transport or during work.
NEVER allow anyone to travel on the machine!
• The maximum transportation speed must not exceed 20 km/h
• Brake regulations: If the gross weight of the trailer exceeds the gross weight of the towing
vehicle, the trailer must be equipped with a brake. For further information, contact the trac
authorities.
• IMPORTANT! Mark protruding equipment clearly with additional lights or suitable reectors.
It is important that the equipment is visible! If you are driving on a public road, any load or
equipment protruding in front of or behind the tractor must be marked. In darkness, at dusk
or dawn or in weather with poor visibility, the load must be marked with a white reector and
lantern at the front and a red reector and lantern at the rear. In daylight you can mark the
load with a ag or a piece of fabric in colours which are easy to notice, such as red and yellow.
• Think about front-loaded equipment. As well as marking front-loaded equipment clearly, you
can also try to make front-loaded equipment such as a bucket, bale spike or pallet forks less
aggressive if another driver should collide with it.
• Before going out onto public roads, it is also always advisable to look over your vehicle and
check that the brake system on the following vehicle is working, and that your tow bar eyes
are not too worn. A worn-out towing eye can break if subjected to a heavy load, and you can
lose the cart.
• It is also advisable to check that the SMV sign is clearly visible from behind. If it is obscured by
any equipment or load behind, you must hang an additional one at the rear of the vehicle train.

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WARNING DECALS
Make sure warning decals are always visible and clean them when necessary. Do not use a high-
pressure washer directly on the warning decal. If a part with a decal is replaced, or the decal
becomes worn or in any other way unusable, order a new set of decals.
SYMBOL EXPLANATION
Read the operating manual! Before carrying out work.
WARNING! Rotating machine parts.
WARNING! The blades continue to rotate for a while after
the product has been switched o.
WARNING Crushing risk! Never use the machine without all
guards correctly mounted. Do not put your hand or any other
part of your body into the machine while it is running.
DANGER! Risk of entrapment in the rotating PTO shaft.
Ejection warning!
Respect the equipment's risk zone!
Risk zone 25 m around the machine.
WARNING! Risk of crushing!
There must be no one standing behind the tractor/towing
vehicle while the machine/equipment is being attached
or detached.
The machine is for individual work only. Nobody is allowed
in the vicinity during operation.
- Lubrication
- Tighten all bolts, nuts and couplings before use.
Warning! Keep o the machine!
Warning! Accident risk for children!
Children are not allowed in the vicinity of the machine.
Always store the product on a dry surface, preferably under
a roof, when not in use.
The product is CE marked
Product name:
Type:
Weight:
Year of manufacture:
Serial no.: 2006/42/EC

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Table of Contents
CHEMICALS
To maximise the service life of a product/equipment, maintenance - and not least preventive
maintenance - is important, and this is largely what greases and oils do. Carefully read the operating
manuals for your new products or equipment to ensure correct maintenance and service life and
that the warranty remains valid!
Lubricating greases
First aid measures.
Inhalation - In the event of unintended inhalation of fumes, move the injured person into fresh air.
Skin contact - Wash with soap and water. Contact a doctor in the event of eczema or skin
complaints.
Eye contact - Remove contact lenses, if any, before rinsing. Rinse thoroughly with large amounts
of water, including under the eyelids. Contact a doctor if discomfort remains.
Ingestion - DO NOT induce vomiting. Drink water in small quantities. In the event of ingestion
or discomfort, contact the poison information service or a doctor.
Hand protection - Wear protective gloves.
Eye protection - Avoid contact with eyes. Wear approved protective goggles.
Body protection - Suitable protective clothing.
Respiratory protection - No protection is necessary during normal handling.
Greases should be stored well-sealed in a cool place in a well-ventilated area. Storage temperature
must not exceed 45°C. Keep away from heat, ames and sparks. The function and strength of
materials such as steel, plastic, oils, grease etc. deteriorates considerably at very low temperatures
(-20 to -30°C).
Degreasing
To ensure the best lubricating eect, you need to clean parts of the product or equipment from time
to time. We recommend degreasing to achieve thorough cleaning and to remove all residues of old
lubricant, which may contain destructive particles.
Keep chemicals out of the reach of children and animals.

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PARTS

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Banjo bolt
Sealing washer
2 pcs 8 pcs 80 x 50 x 8 mm 38 x 25 x 24 mm
2 pcs
63 x 50 x 50 mm
2 pcs
M12
24 pcs
M12 lock washer
24
M16
6 pcs
M18
3 pcs
M24
6 pcs
3 pcs
1 pc 10 pcs
M12x40
4 pcs
M12x45
8 pcs
M16x45
1 pc
M16x50
1 pc
M16x60
1 pc
M12
12 pcs
M16
3 pcs

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ASSEMBLY
Because of the machine's weight, the assistance of a lifting device is required during parts of the
assembly. Tools: ratchet spanner 17 and 18 + socket. Fixed spanner 13, 17, 18 and 24
80 x 50 x 8 mm
M24
M24
63 x 50 x 50 mm
2 pcs
A baton may need to be
used to get the sleeve into
place. Some of the paint at
the very bottom of the pipe
may also need to be scraped
o. Finally, grease the pipe.

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M12 M12x40M12
Note: Use
one washer
above and one
below during
assembly.
Remove the piston.

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M16x45
M16
M16
38 x 25 x 24 mm
M24
M24
M24

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Table of Contents
M16x60 M16x50
M16
M16
Loosen the handle. Assemble the bracket and screw the handle back on.
Repeat this step on the right-hand side of the rotary disc mower.
Loosen the screws and assemble the cover.

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Secure with the chain.
Banjo bolt
Sealing
washer