Kongskilde GXS 2405 P User manual

ORIGINAL INSTRUCTIONS - according to Directive 2006/42/EC, Annex I 1.7.4.1
Part number 81PIGB-182x
1st edition English
February 2018
GXS 2405 P
GXS 2805
GXS 2805 P
GXS 3205
GXS 3205 P
GXS 3605
GXS 4005
Disc Mower
OPERATOR’S MANUAL

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FOREWORD
DEAR CUSTOMER!
We appreciate the confidence you have shown to our company by investing in a
KONGSKILDE product and congratulate you with your new purchase. Of course, it is
our wish that you will experience complete satisfaction with the investment.
This instruction manual is intended for farmers or other persons who have a
corresponding agricultural education. The instruction manual contains information
about correct and safe use of the machine.
When buying the machine you will receive information about use, adjustment and
maintenance.
However, this first introduction cannot replace a more thorough knowledge of the
different tasks, functions and correct technical use of the machine.
Therefore you should read this instruction manual very carefully before using
the machine. Pay special attention to the safety instructions.
This instruction manual is made so that the information is mentioned in the order you
will need it, i.e. from the necessary operation conditions to use and maintenance.
Besides this there are illustrations with text.
"Right" and "Left" are defined from a position behind the machine facing the direction
of travel.
All the information, illustrations and technical specifications in this instruction manual
describe the latest version at the time of publication.
Kongskilde Industries A/S reserves the right to make changes or improvements in the
design or construction of any part without incurring the obligations to install such
changes on any unit previously delivered.

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CONTENTS
FOREWORD.......................................................................................................................3
CONTENTS.........................................................................................................................4
1. INTRODUCTION.............................................................................................................6
INTENDED USE.................................................................................................6
SAFETY..............................................................................................................7
Safety rules............................................................................................7
General safety instructions.....................................................................8
Special safety instructions....................................................................10
Choice of tractor...................................................................................11
Connection and disconnection.............................................................11
PTO drive shaft....................................................................................12
The hydraulic system...........................................................................12
Adjustments.........................................................................................13
Transport..............................................................................................13
Working in the field...............................................................................13
Parking and maintenance ....................................................................14
Machine safety.....................................................................................15
SAFETY DECALS ON PLAIN MOWERS.........................................................17
SAFETY DECALS ON MOWER CONDITIONERS...........................................19
TECHNICAL DATA (PLAIN MOWERS)............................................................21
TECHNICAL DATA (MOWER CONDITIONERS).............................................23
2. CONNECTION AND TEST DRIVING............................................................................24
CONNECTION TO THE TRACTOR.................................................................24
Adjustment of linkage...........................................................................24
Hydraulic connections..........................................................................27
Mounting of PTO drive shaft ................................................................28
TEST DRIVING.................................................................................................30
DRIVING ON PUBLIC ROAD...........................................................................32
Vertical transport position.....................................................................32
Horizontal transport position ................................................................34
DISCONNECTION OF THE MACHINE............................................................36
3. DRIVING AND OPERATION.........................................................................................39
CONSTRUCTION AND FUNCTION.................................................................39
TRANSPORT POSITION .................................................................................40
Vertical, lateral transport position.........................................................40
Horizontal transport position ................................................................42
Vertical rear transport position.............................................................43
WORKING POSITION......................................................................................45
RELIEF OF CUTTER BAR...............................................................................46
Setting of mechanical relief..................................................................46
Setting of hydropneumatic relief...........................................................47
HEADLAND POSITION....................................................................................48
Adjustment of lifting height...................................................................49

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STONE RELEASE............................................................................................50
Mechanical stone release ....................................................................50
Hydraulic stone release........................................................................51
WORKING IN THE FIELD................................................................................52
Turning.................................................................................................52
Stubble height......................................................................................52
Securing against overload....................................................................53
CONDITIONER.................................................................................................54
EQUIPMENT FOR WIDE SPREADING (TOP DRY)........................................55
4. GREASING ...................................................................................................................56
GREASE...........................................................................................................57
OIL CHANGE: ..................................................................................................58
Cutter bars...........................................................................................58
Oil level................................................................................................58
Oil change:...........................................................................................59
Bevel gearbox above the cutter bar .....................................................61
Bevel gearbox at the headstock...........................................................62
5. MAINTENANCE............................................................................................................63
FRICTION CLUTCH.........................................................................................64
CONTROL OF BALANCE ................................................................................65
DISCS AND BLADES - QS...............................................................................66
Blades..................................................................................................67
Blade holder.........................................................................................67
Replacement of blades ........................................................................68
DISCS AND BLADES –Q+..............................................................................72
Blades..................................................................................................73
Blade holder.........................................................................................73
Replacement of blades ........................................................................74
Replacement of discs...........................................................................78
DISCS AND CUTTERBAR ...............................................................................80
Replacement of discs...........................................................................80
Replacement of hubs...........................................................................80
WINTER STORAGE.........................................................................................82
6. MISCELLANEOUS .......................................................................................................83
DRIVING TIPS AND FAULT-FINDING.............................................................83
SPARE PARTS ORDER...................................................................................84
MACHINE DISPOSAL......................................................................................84
7. WARRANTY..................................................................................................................85

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1. INTRODUCTION
INTENDED USE
KONGSKILDE disc mowers are developed for agricultural work. They should only be
connected to tractors and driven by the PTO of the tractor.
The disc mowers are solely intended for:
Cutting on the ground of natural or planted grass and stem crops for animal feeding
purposes. The mowers are solely constructed for usual work in agriculture.
It is assumed that the work is performed under reasonable conditions, i.e. that the
fields are cultivated normally and to a reasonable extent kept clear of foreign matter
and the like.
Any other use is regarded as not intended. Kongskilde Industries A/S is not
responsible for any damage resulting from such use, the user bears that risk.
If changes are made on the machine and its construction without permission from
Kongskilde Industries A/S, Kongskilde Industries A/S cannot be held responsible for
any damage resulting from this.
Intended use, of course, implies that you observe the instructions in the instruction
manual and the spare parts book, use original spare parts and contact an authorised
workshop, in so far as it is necessary.
The following safety instructions as well as common rules concerning technical
safety, working practices and road safety must be observed altogether.
The disc mowers should only be used and maintained by persons who, through
relevant instructions and after reading the instruction manual, are familiar with the
machine in question and, in particular, are informed of possible dangers.

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SAFETY
The safety of persons and machines is an integral part of KONGSKILDE’s
development work. However, damage can occur as a consequence of misuse and
insufficient instruction. We wish to ensure the safety of you and your family in the
best possible way, but this also requires an effort on your part.
A disc mower cannot be constructed in such a way that it guarantees the full safety of
persons and at the same time performs an efficient piece of work. This means that it
is very important that you as user of the machine pay attention and use the machine
correctly and thereby avoid exposing yourself and others to unnecessary danger.
The machine demands skilled operation, which means that you should have a
relevant agricultural background and experience and you should read the
instruction manual before you connect the machine to the tractor. Even though
you have been driving a similar machine before, you should read the manual - this is
a matter of your own safety!
You should never leave the machine to others before you have made sure that they
have the necessary knowledge to operate the machine safely.
SAFETY RULES
The safety decals and the instruction manual of the machine contain a line of safety
notes. The safety notes mention certain measures, which we recommend you and
your colleagues to follow as to increase the personal safety as much as possible.
We recommend that you take the necessary time to read the safety instructions and
inform your staff to do the same.
In this instruction manual this symbol is used with reference to
personal safety directly or indirectly through maintenance of the
machine.
CAUTION: The word CAUTION is used to ensure that the operator follows the
general safety instructions or the measures mentioned in the
instruction manual to protect the operator and others against injuries.
WARNING: The word WARNING is used to warn against visible or hidden risks,
which might lead to serious personal injuries.
DANGER: The word DANGER is used to indicate measures which, according to
legislation, must be followed to protect the driver and others against
serious injuries.

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GENERAL SAFETY INSTRUCTIONS
Before use, the operator should make sure that the tractor and the machine observe
the general work-related legislation and can comply with the Road Traffic Act.
The following is a brief description of the measures, which should be a matter of
common knowledge to the operator.
1. Always disengage the PTO drive shaft, activate the parking brake and stop the
tractor engine before you
- lubricate the machine,
- clean the machine,
- disassemble any part of the machine,
- adjust the machine.
2. Always lower the machine to the ground and use correct support or transport
safety device when the machine is parked.
3. Always use the transport safety device of the machine during transport.
4. Never work under a raised machine unless the link arms of the tractor are
secured by means of a support chain or other mechanical securing device to
prevent the machine from being lowered unintensionally.
5. Never start the tractor until all persons are safely away from the tractor and the
machine.
6. Make sure that all tools have been removed from the machine before starting
the tractor.
7. Make sure that all guards are intact and have been mounted correctly.
8. The clothes of the operator must be tight-fitting. During work never wear loose
clothes or have your hair hang down as it may be pulled in by the moving parts
of the machine.
9. Do not change the guards or work with the machine when a guard is missing or
defective.
10. Always drive with the statutory lights and safety marking during transport on
public road and at night.

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11. Always adjust the speed to the conditions. If the machine has been marked with
a maximum speed limit, this should never be exceeded.
12. Do not stand near the machine while it is working.
13. When mounting the PTO drive shaft check that the number and direction of
RPM of the tractor matches those of the machine.
14. Always use hearing protectors if the noise from the machine is annoying or if
you are working with the machine for a considerable period in a tractor cabin,
which has not been silenced sufficiently.
15. Before raising or lowering the machine with the link arms of the tractor, check
that no persons are near the machine or touching it.
16. Do not stand near the guards of the cutting unit and do not lift the guards before
all revolving parts have stopped moving.
17. Never use the machine for other purposes than what it has been constructed
for.
18. Do not allow any children to be near when you are working with the machine.
19. Never stand between the tractor and the machine during connection and
disconnection.

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SPECIAL SAFETY INSTRUCTIONS
When working with mowers the following special measures should be observed.
1. Use a tractor with a cabin provided with safety glass. Furthermore it is advisable
to protect the glass of the cabin with polycarbonate plates inside or with a close-
meshed net outside. The cabin should be closed when working in the field.
2. Always keep away from the cutting unit when the parts of the machine rotate.
3. When replacing blades it is important to observe the rules in the instruction
manual to fulfil the safety requirements. Always use original spare parts.
4. Before use, check the revolving parts (blades, blade bolts, discs and flow caps).
If parts are damaged (bent or cracked), worn or missing, they should be
replaced immediately.
5. Damaged, worn or missing blades should be replaced in sets in order not to
create an unbalance in the machine.
6. Check canvases and guards regularly. Replace worn or damaged canvases.
7. Canvases and guards secure against ejection of stones and foreign matter.
Before use canvases and guards must be placed correctly.
8. Lower the cutting unit to working position before starting the power
transmission.
9. The field should be kept clear of stones and foreign matter, if possible.
10. Even if the machine is adjusted and operated correctly, stones and foreign
matter in the field can be ejected from the cutting unit. Therefore no persons
should stand near the cutting unit where the conditions are unknown. Be
particularly careful when working along public roads or facilities (schools, parks
etc.)
11. Though it is possible, you should never reverse with the cutting unit in working
position. The correct movement for the cutting unit only works when driving
forward, as there is a risk of damage if driving backwards with the machine in
working position.
12. Even though the power transmission has stopped, the revolving parts have a
momentum. Therefore, always wait until the revolving parts have come to a
complete stop before getting near the cutting unit.
13. If in doubt, always contact the nearest dealer.

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CHOICE OF TRACTOR
Always follow the recommendations specified in the instruction manual of the tractor.
If this is not possible, technical assistance must be sought.
Choose a tractor with a suitable power on the PTO. To obtain full capacity under all
conditions, we recommend you to choose a tractor which has 15 kW more than the
informed minimum.
If the power of the tractor is considerably larger than that, the machine should be
secured against overload with a suitable clutch on the PTO.
If you have chosen a machine which is constructed for 540 rpm, you
should make sure not to use the wrong PTO by mistake. It is highly
dangerous to connect a machine intended for 540 rpm, to a PTO
delivering 1000 rpm.
Long-term overload may damage the machine and at worst result in
ejection of parts.
Choose a tractor with a suitable own weight and track width so that it can drive
steadily on the ground. Also make sure that the link arms and towing hook of the
tractor are intended to carry machines with the own weight in question.
To maintain full control of the tractor under all conditions, minimum 20 % of the own
weight of the tractor should be on the front axle. It may be necessary to use front
weights to fulfil this requirement.
Always choose a tractor with a closed cabin when working with a disc mower.
CONNECTION AND DISCONNECTION
Always make sure that nobody is standing
between the tractor and the machine during
connection and disconnection. An unintentional
manoeuvre with the tractor may cause serious
injury.

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PTO DRIVE SHAFT
Do not use PTO drive shafts with other specifications than the shaft which was
supplied with the machine.
The PTO shaft has its own instruction manual which is supplied with the machine and
should be followed to ensure correct use of the shaft. All instructions should be
followed, particularly the safety and maintenance instructions, in order to prevent
unintentional damage.
Make sure that the PTO drive shaft has been mounted correctly, i.e. that the lock pin
is in mesh and that the support chain has been fastened at both ends.
The guard must be intact. If the guard is defective it must be replaced immediately.
THE HYDRAULIC SYSTEM
Check that all hydraulic couplings are correctly mounted and tight and that all hoses
and fittings are undamaged before activating the hydraulic system.
When the tractor engine has stopped, make sure that there is no pressure in the
hydraulic hoses by activating the tractor hydraulic spool valves.
Hydraulic hoses should only be connected to the tractor outlets if the tractor and the
machine are pressure-free. If the hydraulics of the tractor is activated it may lead to
uncontrolled movements which may cause secondary damage.
Hydraulic oil under pressure can penetrate the skin and cause serious infections.
You should always protect the skin and the eyes against oil splashes. You should
never try to ascertain whether there is a leakage by
using your hands. Oil under pressure may even
penetrate gloves. If, by accident, hydraulic oil under
pressure hits you, consult a doctor immediately.
Make sure that no persons are near the machine when starting as there might be air
in the hydraulic system which might lead to sudden movements.
To ensure all the air has been expelled from the oil in the hydraulic cylinders, test all
the functions after the hydraulic connections are connected to the tractor. Especially
before you enter or drive on public roads.

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ADJUSTMENTS
Never adjust the mower while the PTO drive shaft is engaged. Stop the tractor
engine before you adjust the machine. It is important not to remove the guards until
all revolving parts have stopped.
Before starting check that no blades are missing or are defective and can be turned
freely. Likewise, check that the blade holders are not loose or defective. Replace
damaged blades and blade holders. (see section 5: MAINTENANCE)
Check periodically if blades and blade bolts are worn according to the rules in the
instruction manual. (see section 5: MAINTENANCE)
TRANSPORT
If you wish to transport the machine on the public road, please make sure that the
combination tractor and machine observes the traffic rules in your country. This gives
you and your surroundings the best possible safety.
As an example the following should be checked:
The lighting and warning panels are correctly mounted
The allowable transport dimensions and weights are observed
The tractor and machine combination has sufficient braking capacity
Always adjust the driving speed to the conditions of the road. In case of bad road
conditions and high driving speeds, big forces may occur and cause overload of
tractor and machine. The speed should always be adjusted according to the road and
weather conditions.
Always check that mechanical transport safety devices are activated before
transport.
WORKING IN THE FIELD
The machine should only be put into operation according to instructions from the
dealer or the service engineer of the company.
Before working check blades, blade holders, dicsc and guide shoes for cracks and
other damage. Replace damaged parts.
Check periodically if blades and blade holders are worn according to the rules in the
instruction manual. (See section on maintenance)
Loose stones and foreign matter in the field might get in contact with the revolving
parts and get thrown out again at a very high speed. Therefore, all guards must
always be correctly mounted and intact when you are working with the machine.

1. INTRODUCTION
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In stony fields the stubble height should be adjusted to maximum (horizontal cutter
bar) height.
It is important that the cutting unit is correctly relieved to ensure perfect operation in
the field and to reduce the risk of damaging the cutter bar.
If the cutting unit is blocked, stop the tractor engine, activate the parking brake and
wait until the revolving parts have stopped before removing the foreign matter.
Drive in a low tractor gear if working on hillsides.
When working with a mower keep a safe distance from steep slopes and similar
ground conditions, as the ground may be slippery and pull the mower and the tractor
sideways. Also remember to adjust the speed for sharp turns when driving on
hillsides. (See section on driving on hilly ground).
When turning on hillsides always be careful when lifting the machine with the 3-point
linkage since there is a risk of overturning. Adjust the speed to these conditions.
If the vibrations or the noise of the machine increase considerably during the
operation, stop working immediately. Do not continue the work until the fault has
been corrected.
PARKING AND MAINTENANCE
When parking the machine there are some operational risks which may cause
personal injury. Therefore you should:
Make sure that tractor and machine cannot move
Stop the tractor engine and remove the ignition key
Make sure that nobody stands between the tractor and the machine during
disconnection
Make sure that the ground is firm and even during parking
Make sure that the parking stand is secured
Place the PTO shaft in the special holder
The recommended greasing, replacement and inspection intervals should be
observed to prevent secondary damage.
Only use original replacement parts to avoid unintentional risks and damage.
Always make sure that the used spare parts are mounted correctly and that screws
are tightened to the correct torque.
Before you carry out any repair or maintenance work you should:
Park the machine safely and disconnect the tractor.

1. INTRODUCTION
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In case the machine is connected to the tractor during repair and maintenance you
should make sure that:
The PTO is disconnected
The tractor engine is stopped
The ignition key is removed
The tractor cannot move
and
When the machine is raised, the link arms must always be secured by support
chains.
Be careful when using high pressure cleaners, particularly near bearings and seals.
MACHINE SAFETY
All revolving parts are balanced by KONGSKILDE by means of a special machine
with electronic sensors. If it turns out that a part still has an unbalance, small
counterweights should be mounted.
As the discs run at up to 3000 RPM, even the slightest unbalance will cause
vibrations which may lead to fatigue fractures.
If the vibrations and/or the noise of the machine increase considerably during the
operation, stop working immediately. Do not continue the work until the fault has
been corrected.
When replacing blades, both blades on the disc in question must be replaced as not
to create an unbalance.
During the season check daily that no blades, carriers or bolts are missing. If any of
these are missing, mount new parts immediately.
Clean caps of earth and grass regularly.
You should also check and “air” the friction clutch regularly to ensure it does not rust.

1. INTRODUCTION
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56
4
STOP
2 MIN
8
9
2
11
PR80-0841
12
7
1
PR80-0860
10
PR80-0080
3
PR80-0813

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SAFETY DECALS ON PLAIN MOWERS
The safety decals shown on the previous page are positioned as shown on the
drawings at the bottom of the page. Before using the machine, check that all decals
are present: if not, require those missing. The decals have the following meaning:
1. Danger through cutting forces
During movement of the kinematics there is a risk of parts making cutting movements. Keep
a safe distance to these parts.
2. Risk of stones being thrown.
Even though all canvases and guards are in the right place, there is still a risk of stones etc.
being thrown out. Therefore, nobody should be allowed to stand near the machine during
operation.
3. Rotating blades.
Do not under any circumstances let anyone get near or stand near the machine during
operation. The rotating blades of the machine can without difficulty cause serious injury to
any part of the body if hit by such a blade.
4. Rotating parts.
After the PTO drive shaft has stopped, the blades will have a momentum where they keep
rotating for up to 2 minutes. Wait until the blades have come to a complete stop before you
remove the canvas and the guards for inspection and maintenance.
5. Children.
Never let children stand near the machine during operation. Especially not small children as
they have a tendency to do unforeseen things.
6. Operation without canvas.
Do not start the machine unless canvases and guards are intact and in their right place. The
machine can throw out stones and other foreign matter during operation. The purpose of the
canvases and the guards is to reduce such danger.
7. Stop the tractor engine and remove the ignition key before touching the machine.
Always remember to stop the tractor engine before lubricating, adjusting, maintaining or
repairing. Also remember to remove the ignition key to ensure that nobody starts the engine.
8. Risk of getting jammed
Never let anyone stand between the machine and the tractor after the connection. An
unintentional manoeuvre may cause serious injury.
9. Risk of injury during the connection
Never let anybody stand between the tractor and the machine during connection to the
tractor. An unintentional manoeuvre may cause serious injury.
10. The number and the direction of rotations.
Check that the PTO drive shaft runs with the right RPM and in the right direction. A wrong
number of rotations and/or direction of rotation can damage the machine with the risk of
personal injury as a result.
11. Read the instruction manual and the safety instructions.
This is to remind you to read the delivered documents to ensure the machine is operated
correctly and to avoid unnecessary accidents and machine damage.
12. Stop PTO
PTO must be stopped before the machine is swivelled into transport position.

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56
4
STOP
2 MIN
8
9
2
11
PR80-0841
12
Min. 10 m
13
7
1
PR80-0860
10
PR80-0080
3
PR80-0813

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SAFETY DECALS ON MOWER CONDITIONERS
The safety decals shown on the previous page are positioned as shown on the
drawings at the bottom of the page. Before using the machine, check that all decals
are present: if not, require those missing. The decals have the following meaning:
1. Danger through cutting forces
During movement of the kinematics there is a risk of parts making cutting movements. Keep a
safe distance to these parts.
2. Risk of stones being thrown.
Even though all canvases and guards are in the right place, there is still a risk of stones etc. being
thrown out. Therefore, nobody should be allowed to stand near the machine during operation.
3. Rotating blades.
Do not under any circumstances let anyone get near or stand near the machine during operation.
The rotating blades of the machine can without difficulty cause serious injury to any part of the
body if hit by such a blade.
4. Rotating parts.
After the PTO drive shaft has stopped, the blades will have a momentum where they keep
rotating for up to 2 minutes. Wait until the blades have come to a complete stop before you
remove the canvas and the guards for inspection and maintenance.
5. Children.
Never let children stand near the machine during operation. Especially not small children as they
have a tendency to do unforeseen things.
6. Operation without canvas.
Do not start the machine unless canvases and guards are intact and in their right place. The
machine can throw out stones and other foreign matter during operation. The purpose of the
canvases and the guards is to reduce such danger.
7. Stop the tractor engine and remove the ignition key before touching the machine.
Always remember to stop the tractor engine before lubricating, adjusting, maintaining or repairing.
Also remember to remove the ignition key to ensure that nobody starts the engine.
8. Risk of getting jammed
Never let anyone stand between the machine and the tractor after the connection. An
unintentional manoeuvre may cause serious injury.
9. Risk of injury during the connection
Never let anybody stand between the tractor and the machine during connection to the tractor. An
unintentional manoeuvre may cause serious injury.
10. The number and the direction of rotations.
Check that the PTO drive shaft runs with the right RPM and in the right direction. A wrong number
of rotations and/or direction of rotation can damage the machine with the risk of personal injury as
a result.
11. Read the instruction manual and the safety instructions.
This is to remind you to read the delivered documents to ensure the machine is operated
correctly and to avoid unnecessary accidents and machine damage.
12. Stop PTO
PTO must be stopped before the machine is swivelled into transport position.
13. Stones being thrown from the conditioner
The conditioner rotor runs with a high number of RPM and stones on the ground can be thrown
up to 10 m backwards at a very high speed. Therefore, always make sure that nobody is standing
near the machine when it is working.

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PR11-1671
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