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5. MAINTENANCE

PIGB-183X 04 GXS 9005 / P 0218

CUTTERBAR

REPLACEMENT OF HUBS

Fig. 5.16

A cutterbar is used on which each hub

below the discs is easily replaced from

above (Top Service cutter bar).

The hubs with bearing housing are dismounted by loosening the bolts that fix it to the
cutterbar.

Fig. 5.16

Summary of Contents for GXS 9005

Page 1: ...ORIGINAL INSTRUCTIONS according to Directive 2006 42 EC Annex I 1 7 4 1 Part number 81PIGB 183x 1st edition English February 2018 GXS 9005 GXS 9005 P Disc Mower OPERATOR S MANUAL ...

Page 2: ......

Page 3: ...rent 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 illustrati...

Page 4: ...ICAL DATA 19 2 CONNECTION AND TEST DRIVING 20 CONNECTION TO THE TRACTOR 20 Hydraulic connections 22 Mounting of PTO drive shaft 24 TEST DRIVING 27 DRIVING ON PUBLIC ROAD 29 DISCONNECTION OF THE MACHINE 31 3 DRIVING AND OPERATION 32 CONSTRUCTION AND FUNCTION 32 TRANSPORT POSITION 33 Vertical transport position 33 WORKING POSITION 35 RELIEF OF CUTTERBAR 36 Setting of mechanical relief 36 HEADLAND PO...

Page 5: ...Bevel gearbox at the headstock 49 5 MAINTENANCE 50 FRICTION CLUTCH 51 CONTROL OF BALANCE 52 DISCS AND BLADES Q 53 Blades 54 Blade holder 54 Replacement of blades 55 Replacement of discs 59 CUTTERBAR 61 Replacement of hubs 61 WINTER STORAGE 63 6 MISCELLANEOUS 64 DRIVING TIPS AND FAULT FINDING 64 SPARE PARTS ORDER 65 MACHINE DISPOSAL 65 7 WARRANTY 66 ...

Page 6: ...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 cannot be held responsible for any damage resulting from this Intended use of course implies that you observe the instructions in the instructi...

Page 7: ...anual 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 ...

Page 8: ...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 unintentionally 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 ...

Page 9: ... 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 t...

Page 10: ...y 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...

Page 11: ... 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 f...

Page 12: ... 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 sk...

Page 13: ...ectly 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 conditio...

Page 14: ...sk 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 c...

Page 15: ...rs 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 re...

Page 16: ...1 INTRODUCTION PIGB 183X 04 GXS 9005 P 0218 16 ...

Page 17: ...tenance 5 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 6 Children Never let children stand near the machine during operation Especially not small children as they have a tendency to do unfo...

Page 18: ...1 INTRODUCTION PIGB 183X 04 GXS 9005 P 0218 18 PR11 1695 H B X L ...

Page 19: ... friction clutch and free wheel PTO speed rpm 1000 Oil outlets 1 SA or 2 SA Stone release Mechanical Number of discs 16 Number of blades 32 Conditioner width approx 2 48 m Conditioner elements PE fingers Relief of the machine Mechanical Weight approx 1800 kg 2250 kg Dimension B 2 99 m Dimension H 3 99 m Dimension X 0 25 m Dimension L 1 85 m Noise level in the tractor cabin Machine connected Window...

Page 20: ... supervision Make sure that there are no persons in the danger zone Stop the mower immediately if persons are approaching Grease the machine carefully before you start working Fig 2 1 GXS 9005 P is connected to the link arms and top link of the tractor The hitch pins are intended for category III Adjust the link arms to the same height and connect to the machine Adjust and lock sideways so that th...

Page 21: ...9005 P the link arms are lowered in transport position to obtain a transport height of less than 4 m WARNING If the link arms are not locked sideways the machine may influence the tractor with bumps which may change the driving direction of the tractor during transport Fig 2 2 The two front parking stands and the rear parking stand are lifted up and locked with the pin and spring pins C PR12 1696 ...

Page 22: ...cutting units at the same time Fig 2 3 Two outlets Recommended If you want to use two outlets you should close the ball valve in the middle so that the hydraulics works separately for the two sides Both hoses are connected to two different outlets on the tractor and ball valves for both are opened Fig 2 4 One outlet If you only want to use one outlet you should open the ball valve in the middle so...

Page 23: ...that it can be adjusted to use both outlets at the same time when the cutting units are to be lifted or lowered For individual lifting of the cutting units for example in case of short work mowing the outlets can be operated manually instead In that way a simplified operation can be obtained where the cutting units can both be lifted at the same time and separately If the system is also adjusted t...

Page 24: ... with the engine running at low speed Always start the machine with the PTO shaft in a position of maximum 10o from horizontal Last but not least Grease the PTO shaft and especially its profile tubes every 40 working hours minimum In order to ensure the function of the friction clutch it must be aired before the start of a new machine and after a long period of standstill See also the supplied ins...

Page 25: ...aft must fully comply with the overlapping measures shown in Fig 2 5 IN CASE OF SHORTENING Fig 2 5 Adjust the PTO shaft so that it has the biggest possible overlapping in no position has less overlapping than 200 mm is not compressed more than the prescribed 30 mm in order not to bottom the shaft Fig 2 5 ...

Page 26: ...t the same horizontal level and opposite each other The shortest distance from the machine Keep the shaft ends parallel to each other and mark the 30 mm minimum Shorten all 4 tubes equally The ends of the profile tubes must be rounded off and burrs must be removed carefully WARNING Grease the tube carefully before it is reassembled as it will otherwise be exposed to big friction forces Fig 2 6 ...

Page 27: ...ains of the protection tubes have been secured properly and that they do not in any position get too tight or damaged 6 Make sure that the hydraulic hoses have been connected in such a way that they are long enough for the movements of the machine in relation to the tractor 7 Check that the machine has been greased sufficiently and check that the oil level in the gearbox and the cutterbar is corre...

Page 28: ...urnt or scraped paint Then seek authorised assistance REMEMBER Note that because of the smaller centrifugal force at a low number of RPM the blades can touch the guard plates on the cutterbar This sound must disappear at the normal number of RPM during work Also note that the cutter bar under the discs will get very warm The colour of the cutter bar gets darker after some hours of operation CAUTIO...

Page 29: ...lighting system and other traffic marking in accordance with the country s current rules 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 adjust the transport speed to the conditions Fig 2 7 All hydraulic stop cocks must be closed during tra...

Page 30: ...h must be safely engaged when the machine is transported vertically The left picture shows the hook which connects the boom with the suspension The right picture shows the transport safety device which in vertical transport position blocks the pendulum movement between the cutting unit and the boom The mower is placed in vertical transport position by activating the lifting cylinder while pulling ...

Page 31: ...round etc might cause the machine to overturn Fig 2 9 When the machine has been placed in the desired position all hydraulic outlets must be set to floating position Raise the tractor s link arms until the supports can be lowered Secure the front support in the bottom position with spring pin and lower the rear support by pulling the two locking pins Make sure that the two locking pins are reengag...

Page 32: ...e it must be combined with a front mower We recommend that the front mower has a working width of minimum 3 m GXS 9005 is without conditioner and GXS 9005 P is with PE finger conditioner That is the main difference between the two models Fig 3 1 The cutting units of the machine are pendulum suspended in boom arms in order to ensure optimum adaptability to the ground Fig 3 1 ...

Page 33: ...s on the tractor VERTICAL TRANSPORT POSITION Before transport the GXS 9005 P is placed in vertical transport position Fig 3 2 Folding to vertical transport position takes place hydraulically with the lifting cylinder by activating the tractor s hydraulic outlet Between the tractor and the cylinder there is a valve which limits the lifting height to the headland position Easy Lift By pulling the co...

Page 34: ...e guards and clean the machine if necessary 4 Pull the cord for the transport safety device 5 Fold up the machine to approx 45 hydraulically let go of the cord and lift the machine further until the transport safety device is engaged 6 Lower the link arms of the tractor so that the hitch pins are approx 25 cm above the ground 7 Close all hydraulic stop cocks and check that the transport safety dev...

Page 35: ...ove the ground 3 Fold up the cutting unit by briefly activating the hydraulic outlet so that there is no load on the hook for the transport safety device 4 Lower the cutting unit by pulling the cord for the transport safety device while activating the hydraulic outlet 5 If the hydraulic oil is cold and or if the cutterbar ground pressure is very light it may happen that the lowering speed decrease...

Page 36: ...may however cause the cutting unit to move up and down which may result in uneven stubbles In that case it may be necessary to increase the ground pressure SETTING OF MECHANICAL RELIEF Fig 3 4 The mechanical relief can be adjusted to 7 different positions by moving the bolt P When the bolt is moved in direction of the springs the relief is increased and the ground pressure reduced In order to move...

Page 37: ...g 3 5 This is secured by a valve Q which is controlled by an arm running on a cam track S When the ball bearing on the arm R meets the notch on the cam track the oil supply between the tractor and the cylinder is interrupted and the cutting unit is not lifted any further If the cutting unit is going to be lifted higher than the headland position the valve can be oversteered by pulling the cord for...

Page 38: ...track is adjusted so that the screw T is at a right angle to the relief rod This will be the optimal adjustment in most cases If you want another lifting height than the standard adjustment do as follows 1 Lift the cutting unit to the wanted headland position by activating the hydraulic outlet Pull the cord for the transport safety device if necessary 2 Loosen the screw T and turn the cam track un...

Page 39: ...lision Fig 3 7 The two springs of the stone release system can be adjusted so that the system releases at a suitable power KONGSKILDE recommends that you tighten the bolt until the springs are tightened and then tighten further 2 mm The stone release only works when driving forwards If the stone release is activated too often it is of course possible to increase the initial tension of the spring N...

Page 40: ...The speed varies from 6 20 km h depending on the crop and the working conditions IMPORTANT When mowing the hydraulic outlet for raising the cutting unit must be in floating position Otherwise the cutting unit is unable to follow the ground TURNING Always drive slowly when turning on the headland and when driving with lifted cutting unit WARNING If you turn at high speed the cutting unit may begin ...

Page 41: ...n against overload When using the machine the following should be considered 1 Always start the machine with the engine running at low speed This especially applies to tractors with electro hydraulic connection of the PTO shaft 2 Only start the machine with the cutting units lowered to working position 3 A sudden increase in the number of RPM of the machine e g when driving into the field or after...

Page 42: ...ing is adjusted with the handle D which can be placed in 3 positions on the bracket E If the handle is placed in pos A the distance between the conditioner plate and the conditioner rotor is short in pos B the distance is medium and in position C the distance is long In general Short distance Strong conditioning Large distance Moderate conditioning The adjustment should be adapted to the forward s...

Page 43: ...hich is mounted behind the conditioner rotor When normal swathing is wanted the plate must be folded up and the handle must be in position A inactive Fig 3 13 For wide spreading the plate is folded down with the handle C in an active position B behind the conditioner rotor During wide spreading the crop is thrown from the conditioner rotor against the plate which leads the crop towards the ground ...

Page 44: ...NG PIGB 183X 04 GXS 9005 P 0218 44 4 GREASING Greasing chart for GXS 9005 P Below grease points must be greased after every 40 hours of operation however at least once a year PR11 1697 40 h 40 h 40 h 40 h 40 h ...

Page 45: ...ons are greased with grease or oil as required WARNING REMEMBER Pay special attention to the sliding PROFILE TUBES of the PTO shafts They must be able to slide back and forth when the torque is heavy If you neglect to grease the profile tubes sufficiently it will result in high axial forces which will damage the profile tubes and in time also connecting shafts and gearboxes Lubricate via external ...

Page 46: ...should be checked by means of a level tube both lengthwise and crosswise On each cutterbar there are 2 plugs for inspection of oil level and filling The oil level must be between 7 and 9 mm as an average of the measurements at the filling holes Even if the cutterbar is inclined or curved up to 20 mm the oil level is read as an average of the two measurements These are placed between 3rd and 4th di...

Page 47: ...be made after 50 working hours and then after every 200 working hours or at least once every season REMEMBER to mount the plug again after draining The drain plug has a magnet to collect metallic impurities Therefore always clean the drain plug before remounting it When changing the oil be sure to use a correct oil type Correct oil type SHELL OMALA S2G 320 Or similar quality of other suppliers WAR...

Page 48: ...E THE CUTTER BAR Fig 4 3 Oil content 0 9 l Oil type API GL4 or GL5 SAE 80W 90 Oil level Check the oil level after every 80 hours of operation Oil change First oil change after 50 working hours and then after every 600 working hours or at least once a year Fig 4 3 ...

Page 49: ...CK Fig 4 4 Oil content 540 rpm 1 1 l 1000 rpm 1 2 l Oil type API GL4 or GL5 SAE 80W 90 Oil level Check the oil level after every 80 hours of operation Oil change First oil change after 50 working hours and then after every 600 working hours or at least once a year Fig 4 4 ...

Page 50: ...anual IMPORTANT Screws and bolts on your new machine must be retightened after some hours of operation This also applies if repairs have been made Ma Ø Class 8 8 MA Nm Class 10 9 MA Nm Class 12 9 MA Nm M 8 25 33 40 M 10 48 65 80 M 12 80 120 135 M 12x1 25 90 125 146 M 14 135 180 215 M 14x1 5 145 190 230 M 16 200 280 325 M 16x1 5 215 295 350 M 18 270 380 440 M 20 400 550 650 M 20x1 5 430 615 720 M 2...

Page 51: ...ion slips The friction clutch must be maintained at regular intervals At the same time the clutch must be checked after any long period of standstill This especially applies after winter storage before the machine is used for the first time in the season Maintaining the friction clutch Fig 5 3 1 The nuts 3 are tightened equally whereby the friction discs are relieved 2 Turn the clutch all the way ...

Page 52: ...00 RPM and one broken blade may cause serious injury to persons or material damage resulting from unbalance If working with a modern closed cabin the symptoms may be difficult to discover and once in a while you have to get out and check if all blades and rotor fingers are intact In the long run unbalance will cause fatigue fractures and serious damage All machines manufactured by Kongskilde Indus...

Page 53: ... high alloyed hardened materials A special heat treatment results in an especially hard and ductile material which can handle extreme stress If a blade or disc is damaged do not attempt to weld the parts together again as the generation of heat will destroy the material properties and expose you and others to increased risk IMPORTANT Damaged blades discs and blade holders must be replaced by origi...

Page 54: ... 6 The blade holder must be replaced if 1 The blade holder does not fix the blade firmly to the disc 2 The blade pin A is badly worn on one side 3 The diameter of the blade pin is less than 15 mm IMPORTANT This must especially be checked after collision with foreign matter after replacement of blades and the first time you use the machine PR12 1730 Min 12 Fig 5 5 PR11 1007b Min 15 A Fig 5 6 ...

Page 55: ...g parts Fig 5 7 Twisted blades can be used on both sides by turning the blade but it must remain on the same disc Please note that twisted blades are available in a left twisted and a right twisted version adapted to the different direction of rotation of the discs The blade is placed correctly if the front edge of the blade is lower than the rear edge when the disc is turned in its direction of r...

Page 56: ...the oblong hole B in the disc When the tool is in the hole it is straightened up and pushed forward in the oblong hole Fig 5 9 When the replacement tool has been pushed forward in the oblong hole B it is situated between the stop C and the blade holder D as shown PR12 1731 A B Fig 5 8 PR12 1732 A B C D Fig 5 9 ...

Page 57: ... back up The replacement tool A must by the force of the blade holder only end up in the same position as before you replaced the blade If the blade holder does not let the replacement tool return fully it indicates that the blade is not placed correctly WARNING Replace the blade with your free hand Do not let go of the handle since the spring power of the blade holder can make the tool spring bac...

Page 58: ... replacement of blades check the blade pins B on the discs regularly with the gauge A in the spare parts package IMPORTANT When the gauge A can get over the blade pin B it MUST be replaced immediately When mounting blades this is done in reverse order PR12 1089 B A Fig 5 12 ...

Page 59: ...blade holder should be replaced IMPORTANT All discs must have the correct number of blades CAUTION When mounting is finished the discs must be turned a minimum one complete revolution by hand in order to check that no parts are colliding CAUTION Worn blades and the replacement tool must be removed from the machine and the guards must be placed correctly REMEMBER The blades can be used on both side...

Page 60: ...blades and blade bolts it must be checked that the blades are mounted correctly and that all discs have the correct number of blades CAUTION When mounting is finished the discs must be turned a minimum one complete revolution by hand in order to check that no parts are colliding WARNING After replacement of blades blade bolts discs and the like check that no tools have been left on the machine and...

Page 61: ...TERBAR REPLACEMENT OF HUBS Fig 5 16 A cutterbar is used on which each hub C below the discs is easily replaced from above Top Service cutter bar The hubs with bearing housing are dismounted by loosening the bolts that fix it to the cutterbar Fig 5 16 ...

Page 62: ...ed to 92 Nm 9 2 Kpm Fig 5 19 Make sure that the discs are mounted 90 degrees staggered in relation to each other CAUTION When mounting is finished the discs must be turned a minimum one complete revolution by hand in order to check that no parts are colliding WARNING After replacement of blades blade bolts discs and the like check that no tools have been left on the machine and that the guards hav...

Page 63: ...er cleaning so that possible water is pressed out of the bearings The following points are instructions how to prepare for winter storage Check the machine for wear and other defects Note down the wearing parts needed before the next season and order the spare parts Dismount the PTO drive shafts lubricate the profile tubes and keep them in a dry place Spray the machine with a coat of rust preventi...

Page 64: ...s Increase the driving speed if possible Irregular flow through the machine Conditioner fingers may be worn or missing The distance between the conditioner plate and the conditioner rotor is too long Replace worn fingers and mount new ones where these are missing Adjust the conditioner plate to shorter distance to the rotor Increase the driving speed The machine vibrates uneven operation Blades ma...

Page 65: ...roper way Observe the following The machine must not be placed somewhere outside it must be emptied of oil gearboxes and hydraulic system These oils must be handed over to a destruction company Disassemble the machine and separate the individual parts e g tyres hydraulic hoses hydraulic valves etc Hand over the usable parts to an authorised recycling centre The large scrapping parts are handed ove...

Page 66: ...ontractual agreement with the selling dealer No warranty shall however apply if the machine has not been used adjusted and maintained according to the instructions given in this operator s manual It is prohibited to carry out any modifications to the machine unless specifically authorized in writing by a NEW HOLLAND representative ...

Page 67: ...ълномощение също да състави Техническото досие akiket képvisel Antoon Vermeulen Leon Claeysstraat 3A B8210 Zedelgem Belgium aki szintén jogosult a műszaki dokumentumok összeállítására v zastoupení Antoon Vermeulen Leon Claeysstraat 3A B8210 Zedelgem Belgium s autorizací k tvorbě technického souboru atstovaujami Antoon Vermeulen Leon Claeysstraat 3A B8210 Zedelgem Belgija taip pat turintis teisę su...

Page 68: ...vyžaduje i s podmínkami Směrnice 2014 30 EU týkající se elektromagnetické kompatibility atitinka Mašinų direktyvos Nr 2006 42 EB ir jeigu taikoma Elektromagnetinio suderinamumo direktyvos Nr 2014 30 ES reikalavimus je v súlade s podmienkami Smernice 2006 42 ES o strojných zariadeniach a pokiaľ si to jeho uplatnenie vyžaduje aj s podmienkami Smernice 2014 30 EÚ o elektromagnetickej kompatibilite în...

Page 69: ......

Page 70: ...property of those respective companies CNH Industrial Belgium N V reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold Specifications descriptions and illustrative material herein are as accurate as known at time of publication but are subject to change without notice...

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