Krone BA EasyCollect 600-3, 750-3, 900-3 FP Operating Instructions

EasyCollect 600-3 FP

EasyCollect 750-3 FP

EasyCollect 900-3 FP

(from serial no.: 1056436)

Order no.: 150 000 646 05 us

Maize header

05.07.2021

Table of Contents

1 Table of Contents

1 Table of Contents ................................................................................................................................... 3

2 To this Document ................................................................................................................................... 7

2.1

Validity ................................................................................................................................................ 7

2.2

Re-Ordering ........................................................................................................................................ 7

2.3

Further applicable documents ............................................................................................................ 7

2.4

Target group of this document ........................................................................................................... 7

2.5

How to use this document .................................................................................................................. 8

2.5.1

Directories and References ........................................................................................................ 8

2.5.2

Direction Information ................................................................................................................... 8

2.5.3

Term “Machine” ........................................................................................................................... 8

2.5.4

Figures ........................................................................................................................................ 8

2.5.5

Scope of Document..................................................................................................................... 9

2.5.6

Means of representation ............................................................................................................. 9

2.5.7

Conversion table ....................................................................................................................... 12

3 Safety ..................................................................................................................................................... 14

3.1

Purpose of Use ................................................................................................................................. 14

3.2

Intended use ..................................................................................................................................... 14

3.3

Reasonably foreseeable misuse ...................................................................................................... 15

3.4

Service life of the machine ............................................................................................................... 15

3.5

Basic safety instructions ................................................................................................................... 16

3.5.1

Importance of the operating instructions ................................................................................... 16

3.5.2

Personnel qualification .............................................................................................................. 16

3.5.3

Personnel qualification of the technicians ................................................................................. 17

3.5.4

Children in danger ..................................................................................................................... 17

3.5.5

Coupling the machine safely ..................................................................................................... 17

3.5.6

Structural changes to the machine ........................................................................................... 18

3.5.7

Additional equipment and spare parts ...................................................................................... 18

3.5.8

Workstations on the Machine .................................................................................................... 18

3.5.9

Operational safety: Technically perfect condition ..................................................................... 19

3.5.10

Danger zones ............................................................................................................................ 20

3.5.11

Keeping safety devices functional ............................................................................................. 22

3.5.12

Personal Protective Equipment ................................................................................................. 23

3.5.13

Safety signs on the machine ..................................................................................................... 23

3.5.14

Traffic safety .............................................................................................................................. 24

3.5.15

Parking the machine safely ....................................................................................................... 24

3.5.16

Consumables ............................................................................................................................ 25

3.5.17

Dangers associated with the operational environment ............................................................. 25

3.5.18

Sources of danger on the machine ........................................................................................... 26

3.5.19

Dangers associated with certain activities: Work on the machine ............................................ 27

3.5.20

Behaviour in hazardous situations and when accidents occur ................................................. 28

3.6

Safety routines ................................................................................................................................. 30

3.6.1

Shutting down and safeguarding the machine .......................................................................... 30

3.6.2

Supporting lifted machine and machine parts securely ............................................................ 30

3.6.3

Safely checking the oil level and changing the oil and filter element ........................................ 31

3.7

Position of the Adhesive Safety and Information Labels on the Machine ........................................ 32

3.7.1

Re-Ordering Safety Labels and Information Labels .................................................................. 38

3

Table of Contents

3.7.2

Attaching Safety Labels and Information Labels ...................................................................... 38

3.7.3

Contact for KRONE NORTHAMERICA .................................................................................... 38

3.8

Location and meaning of the information labels on the machine ..................................................... 40

3.9

Safety Equipment ............................................................................................................................. 42

4 Machine Description ............................................................................................................................ 43

4.1

Machine overview ............................................................................................................................. 43

4.2

Overload protection .......................................................................................................................... 45

4.3

Identification Plate ............................................................................................................................ 46

4.3.1

Contact for KRONE NORTHAMERICA .................................................................................... 47

4.4

Approved adaptations ...................................................................................................................... 48

5 Technical data....................................................................................................................................... 49

5.1

Consumables ................................................................................................................................... 50

5.1.1

Oils ............................................................................................................................................ 50

5.1.2

Lubricating grease ..................................................................................................................... 50

5.2

Ballasting of forage harvester .......................................................................................................... 51

6 Commissioning..................................................................................................................................... 52

6.1

Checks before starting up the machine for the first time .................................................................. 52

6.2

Connecting drive type 493, type 494, type 496, type 497, type 498 ................................................ 53

6.2.1

Aligning the coupling disc ......................................................................................................... 55

6.2.2

Connecting operation panel to forage harvester ....................................................................... 59

7 Start-up - CLAAS .................................................................................................................................. 60

7.1

Checking and observing before start-up .......................................................................................... 60

7.2

Attachment to the CLAAS forage harvester ..................................................................................... 61

7.3

Coupling ........................................................................................................................................... 61

7.3.1

Connecting Drive Type 491, Type 492 ..................................................................................... 62

7.3.2

Connecting drive type 493, type 494, type 496, type 497, type 498 ......................................... 63

7.3.3

Connecting hydraulic hoses ...................................................................................................... 64

7.4

Detaching the machine .................................................................................................................... 66

7.4.1

Moving support jacks on right/left into parking position ............................................................ 66

7.4.2

Removing Hydraulic Lines ........................................................................................................ 67

7.4.3

Connecting ................................................................................................................................ 67

7.4.4

Type 491, type 492 ................................................................................................................... 68

7.4.5

Type 493, Type 494, Type 496, Type 497, Type 498 ............................................................... 68

8 Driving and Transport .......................................................................................................................... 69

8.1

Preparing the machine for road travel .............................................................................................. 70

8.2

Switching off the machine ................................................................................................................ 70

8.3

Lifting the machine ........................................................................................................................... 71

9 Operation ............................................................................................................................................... 72

9.1

From transport into working position ................................................................................................ 72

9.1.1

Removing the protective cover ................................................................................................. 72

9.1.2

Support jacks right/left in transport position .............................................................................. 73

9.1.3

Swinging the right-hand / left-hand side parts into working position ......................................... 74

9.1.4

Locking Oscillating Movement of Header ................................................................................. 75

9.1.5

Swinging the plant divider into working position ....................................................................... 76

9.2

Using the Machine for Work ............................................................................................................. 77

9.2.1

Field mode on slopes ................................................................................................................ 77

9.2.2

Insert the maize header ............................................................................................................ 78

9.2.3

Setting the rotational speed of the maize header ..................................................................... 79

4

Table of Contents

9.2.4

Operating Main Gearbox ........................................................................................................... 80

9.2.5

Operating Input Gearbox .......................................................................................................... 81

9.2.6

Operating row detection (for the version with “row detection”) ................................................. 82

9.2.7

Operating active ground contour (for the version with “active ground contour”) ...................... 83

9.3

Switching from working position to transport position ...................................................................... 84

9.3.1

Swinging the plant divider into transport position ..................................................................... 84

9.3.2

Swinging the right hand / left hand side parts upward into transport position .......................... 85

9.3.3

Installing the front guard ........................................................................................................... 86

9.4

Detaching the machine .................................................................................................................... 88

9.4.1

Moving support jacks on right/left into parking position ............................................................ 88

9.4.2

Removing Hydraulic Lines ........................................................................................................ 89

9.4.3

Connecting ................................................................................................................................ 89

9.4.4

Type 491, type 492 ................................................................................................................... 90

9.4.5

Type 493, Type 494, Type 496, Type 497, Type 498 ............................................................... 90

10 Settings ................................................................................................................................................. 91

10.1

Setting Tubular Bars......................................................................................................................... 91

10.1.1

Increased Centre of Gravity of the Plants ................................................................................. 92

10.1.2

Adjusting reflector holder .......................................................................................................... 92

10.2

Adjusting holding-down device roller ................................................................................................ 93

10.2.1

Adjusting the sliding skid ........................................................................................................... 93

10.3

Adjusting the oscillation of the header ............................................................................................. 94

11 Maintenance .......................................................................................................................................... 96

11.1

Special Safety Instructions ............................................................................................................... 96

11.1.1

Test run ..................................................................................................................................... 96

11.2

Spare Parts ...................................................................................................................................... 96

11.3

Maintenance table ............................................................................................................................ 97

11.4

Tightening torques ............................................................................................................................ 98

11.4.1

Metric Thread Screws with Control Thread .............................................................................. 98

11.4.2

Metric Thread Screws with Fine Thread ................................................................................... 99

11.4.3

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................... 99

11.4.4

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes ...................... 100

11.5

Input gearbox ................................................................................................................................. 101

11.6

Main gearbox .................................................................................................................................. 102

11.7

Collector gearbox (upper section) .................................................................................................. 103

11.8

Collector gearbox (lower section on centre section) ...................................................................... 104

11.9

Collector gearbox (lower section on side part) ............................................................................... 105

11.10

Collector pre-tension on the central part (right hand / left hand) ................................................... 106

11.10.1

Checking the collector pre-tension .......................................................................................... 106

11.10.2

Correcting the collector pre-tension ........................................................................................ 106

11.11

Collector pre-tension on the side part (right hand / left hand) ........................................................ 107

11.11.1

Checking the collector pre-tension .......................................................................................... 107

11.11.2

Correcting the collector pre-tension ........................................................................................ 107

11.11.3

Checking the collector pre-tension .......................................................................................... 108

11.11.4

Correcting the collector pre-tension ........................................................................................ 108

11.11.5

Checking the Collector Tensioning Function .......................................................................... 108

11.11.6

Correcting the Collector Tensioning Function ......................................................................... 108

11.12

Gaps on the centre frame .............................................................................................................. 109

11.13

Gaps on the side frame .................................................................................................................. 111

11.14

Scraper (right hand / left hand) ...................................................................................................... 112

5

Table of Contents

11.14.1

Adjusting Scrapers on the Centre Section .............................................................................. 112

11.14.2

Adjusting the scraper on the side part .................................................................................... 113

11.15

Changing the tips ........................................................................................................................... 114

11.16

Adjusting the tips ............................................................................................................................ 115

11.16.1

Adjusting the side tips ............................................................................................................. 116

11.16.2

Adjusting the row tips .............................................................................................................. 116

11.16.3

Adjusting the central tip ........................................................................................................... 117

11.17

Converting Tip Retainer for Special Row Distances ...................................................................... 118

11.18

Aligning the guide brackets ............................................................................................................ 119

11.19

Releasing star ratchet clutch at the universal shaft ....................................................................... 120

11.20

Blade Changing .............................................................................................................................. 121

11.20.1

Replacing the fixed blades (bow and step blades) ................................................................. 121

11.20.2

Replacing the cutting blade on the right hand / left hand side parts ....................................... 123

11.20.3

Changing cutting blades on the central part right/left ............................................................. 126

11.20.4

Changing scraper blades on the side parts right/left and on the central part ......................... 127

11.21

Replacing the wear plates .............................................................................................................. 127

11.22

Hydraulics ....................................................................................................................................... 128

11.22.1

Hydraulic diagram ................................................................................................................... 129

11.22.2

Check hydraulic hoses ............................................................................................................ 130

12 Maintenance – lubrication chart ....................................................................................................... 131

12.1

Special Safety Instructions ............................................................................................................. 131

12.1.1

Lubrication Chart ..................................................................................................................... 132

13 Placing in Storage .............................................................................................................................. 134

14 Before the Start of the New Season ................................................................................................. 135

14.1

Special Safety Instructions ............................................................................................................. 135

14.2

Test run. ......................................................................................................................................... 136

15 Disposal of the machine .................................................................................................................... 137

15.1

Disposal of the machine ................................................................................................................. 137

6

2

2.1

2.2

2.3

2.4

To this Document

To this Document

Validity

These operating instructions are valid for the maize header of the following types:

EasyCollect 600-3 FP, EasyCollect 750-3 FP, EasyCollect 900-3 FP

Re-Ordering

If this document has become unusable in whole or in part, you can order a replacement, quoting the document number on the cover sheet. Contact data can be found in the chapter “Contact persons”.

The document can additionally be downloaded via KRONE MEDIA https://mediathek.krone.de/ .

Further applicable documents

To ensure that the machine is used safely and as intended, observe the following further applicable documents:

– Operating instructions of universal shaft(s)

– Forage harvester operating instructions

Target group of this document

This document aims at the operators of the machine fulfilling the minimum requirements of personnel qualification; refer to chapter entitled Safety “Personnel Qualification”.

7

To this Document

2.5 How to use this document

2.5.1

2.5.2

2.5.3

2.5.4

Directories and References

Table of contents/headers:

The table of contents as well as the headers in this instruction are used for quick navigation in the chapters.

Index directory:

In the index directory, you can find information on the desired subject via catchwords which are in alphabetical order. The index directory can be found on the last page of this instruction.

Cross references:

Cross references to another place in the operating instructions or to another document are in the text and specify the chapter and subchapter or section. The designation of subchapters or sections is presented in quotation marks.

Example:

Check that all screws on the machine are tight, refer to chapter Maintenance, “Tightening

Torques”.

The subchapter or the section can be found via an entry in the table of contents and in the index directory.

Direction Information

Direction information in this document such as front, rear, right and left always applies in the direction of travel.

Term “Machine”

In the rest of this document the maize header is also referred to as the "machine".

Figures

The figures in this document do not always represent the exact machine type. The information which refers to the figure always corresponds to the machine type of this document.

8

2.5.5

2.5.6

To this Document

Scope of Document

In addition to standard equipment, accessories kits and versions of the machine are described in this document. Your machine may deviate from this document.

Means of representation

Icons in the text

In this document, the following means of representation are used:

Action step

A bullet point ( • ) designates an action step you have to perform, as for example:

• Set the left outside mirror.

Sequence of actions

Several bullet points ( • ) located in front of a sequence of action steps identify a sequence of actions to be performed step by step, as for example:

• Loosen counter nut.

• Set the screw.

• Tighten counter nut.

List

Dashes (-) identify lists such as, for example:

– Brakes

– Steering

– Lighting

9

To this Document

Symbols in figures

To visualize parts and actions steps, the following icons are used:

Icon Explanation

1

Reference sign for part

I Position of a part (e.g. move from pos. I to pos. II)

X Dimensions (e.g. B = width, H = height, L = length)

Action step: Tighten screws with torque key with specified tightening torque

Direction of motion

Direction of travel opened closed enlargement of display detail

Framings, dimension line, dimension line limitation, reference line for visible parts or visible mounting material

Framings, dimension line, dimension line limitation, reference line for covered parts or covered mounting material

Laying routes

Left-hand machine side

LH

RH

Right-hand machine side

10

Warning signs

Warning

WARNING! - Type and source of hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention.

Caution

CAUTION! - Type and source of hazard!

Effect: Damage to property.

• Measures for risk prevention.

Notes with information and recommendations

Note

Note

Effect: Economic benefit of the machine.

• Measures to be performed.

To this Document

11

To this Document

2.5.7 Conversion table

By means of the following table, metric units can be converted into US units.

Quantity

Area

Flow

Force

Length

Power

Pressure

Torque

SI Units (Metric)

Unit Name hectare liters per minute

Abbreviation ha

L/min cubic meter per hour newton millimeter meter kilowatt m³/h

N mm m kW kilopascal kPa megapascal MPa bar (non-SI) bar newton meter Nm

Factor

2.47105

0.2642

4.4029

0.2248

0.03937

3.2808

1.3410

0.1450

145.0377

14.5038

0.7376

Inch-Pound Units

Unit Name acre

US gallon per minute pound-force inch foot pound-foot or foot-pound

Abbreviation acres gpm lbf in. ft. horsepower hp pound per square inch psi ft∙lbf

8.8507 pound-inch or inch-pound in∙lbf

Temperature degree

Celsius

Velocity meter per minute

Volume

Weight meter per second kilometer per hour liter milliliter cubic centimeter kilogram

°C m/min m/s km/h

L ml cm³ kg

°Cx1.8+32 degree

Fahrenheit

3.2808 foot per minute

3.2808

0.6215

0.2642

0.0338

0.0610 foot per second miles per hour

US gallon

US ounce cubic inch

2.2046 pound

°F ft/min ft/s mph

US gal.

US oz. in³ lbs

12

This page has been left blank deliberately.

To this Document

13

Safety

3

3.1

Ver

3.2

Safety

Purpose of Use

The KRONE maize header EasyCollect 600-3 FP, EasyCollect 750-3 FP and EasyCollect

900-3 FP is a header with adapter frame designed exclusively to be attached to CLAAS forage harvesters of the Jaguar series 8xx and 9xx.

The KRONE maize header EasyCollect 600-3 FP, EasyCollect 750-3 FP, EasyCollect 900-3 FP is used for harvesting maize and other thick-stalked forage plants independently of rows.

When, e.g. harvesting Sudan grass, modifications to the maize header are required. Details on the modification options are available from your local specialised dealer.

Intended use

This machine is a maize header and is used to cut crops and to feed them to the forage harvester.

The crops designated for the intended use of this machine are stem-type crops such as maize plants.

The machine is designed exclusively for use in agriculture and may only be used when

– all safety devices are available according to the operating instructions and are in the protective position.

– all safety instructions of the operating instructions have been observed and complied with, both in chapter “Basic safety instructions” and directly in the chapters of the operating instructions.

The machine may be used only by people who satisfy the personnel qualification requirements designated by the machine manufacturer.

These operating instructions are part of the machine and must therefore be at hand when the machine is in use. The machine may be operated only when the operator has received training and in compliance with these operating instructions.

If the machine is used for applications which are not described in these operating instructions, this may result in serious injuries or death and damage to the machine and other property.

Unauthorised modifications to the machine may affect the properties of the machine or disrupt the proper operation. For this reason, unauthorised modifications shall exclude any liability of the manufacturer for consequential damage.

The intended use shall also include the adherence to the operating, maintenance and repair conditions set by the manufacturer.

14

3.3

3.4

Safety

Reasonably foreseeable misuse

Any use beyond the intended use, see chapter Safety, “Intended use”, is regarded as improper use and is therefore misuse according to the Machinery Directive. The manufacturer is not liable for damage resulting from this, the user alone bears the risk.

Such misuse is for example:

– Processing of crops which are outside the intended use of the machine, see chapter Safety,

“Intended use”

– Transportation of people

– Transportation of goods

– Exceedance of the permitted technical total weight of the carrier vehicle

– Non-compliance with the safety labels on the machine and safety notes in the operating instructions

– Performing troubleshooting, setting, cleaning, repair and maintenance work contrary to the information in the operating instructions

– Unauthorised modifications to the machine

– Attachment of unauthorised or unapproved additional equipment

– Use of spare parts which are not KRONE original spare parts

– Stationary operation of the machine

Unauthorised modifications to the machine may affect the properties of the machine or disrupt proper operation. For this reason, unauthorised modifications will exclude any liability of the manufacturer for consequential damage.

Service life of the machine

– The service life of this machine strongly depends on proper use and maintenance as well as the operating conditions.

– Permanent operational readiness as well as long service life of the machine can be achieved by observing the instructions and notes of these operating instructions.

– After each season of use, the machine must be checked thoroughly for wear and other damage.

– Damaged and worn parts must be replaced before placing the machine into service again.

– After the machine has been used for five years, carry out full technical inspection of the machine. According to the results of this inspection, a decision concerning the possibility of reuse of the machine should be taken.

15

Safety

3.5

3.5.1

3.5.2

Basic safety instructions

Non-compliance with the safety instructions and warnings

Non-compliance with the safety instructions and warnings may result in injuries and damage to the environment and property.

Importance of the operating instructions

The operating instructions are an important document and a part of the machine. They are aimed at the user and contain safety-relevant information.

Only the procedures indicated in the operating instructions are reliable. If the operating instructions are not observed, people may be seriously injured or killed.

• Before using the machine for the first time, read and follow all the “Basic Safety Instructions” in the Safety chapter.

• Before working, also read and observe the respective sections in the operating instructions.

• Keep the operating instructions ready to hand for the user of the machine.

• Hand over the operating instructions to subsequent users.

Personnel qualification

If the machine is not used properly, people may be seriously injured or killed. To avoid accidents, each person who works with the machine must satisfy the following minimum requirements:

– He is physically capable of controlling the machine.

– He can work safely with the machine in accordance with these operating instructions.

– He understands the method of operation of the machine within the scope of his work and can identify and avoid the dangers associated with the work.

– He has read the operating instructions and can implement the information in the operating instructions accordingly.

– He is familiar with driving vehicles safely.

– For road travel he has adequate knowledge of the highway code and has the stipulated driving licence.

16

3.5.3

3.5.4

3.5.5

Safety

Personnel qualification of the technicians

If the work (assembly, conversion, modification, extension, repairs, retrofitting) is performed improperly on the machine, people may be seriously or fatally injured. To avoid accidents, everyone who performs work according to these instructions must meet the following minimum requirements:

• Qualified professional, with relevant training.

• Capable of assembling the (partially) disassembled machine according to the assembly instructions provided by the manufacturer.

• Capable of extending, modifying or repairing the function of the machine according to the relevant instructions provided by the manufacturer.

• Ability to perform the work safely according to these instructions.

• Understands the mode of operation of the work to be performed and the machine and is able to identify and avoid the hazards associated with the work.

• Has read these instructions and is able to apply the information in these instructions accordingly.

Children in danger

Children cannot assess danger and behave unpredictably.

As a result, children are especially at risk.

• Keep children away from the machine.

• Keep children away from consumables.

• Especially before starting up and moving the machine, ensure that there are no children in the danger zone.

Coupling the machine safely

When the machine is connected incorrectly to a forage harvester, dangers are caused which could lead to severe accidents.

• Observe all operating instructions when connecting:

– The operating instructions of the machine

– The operating instructions of the forage harvester

– The operating instructions of universal shaft

• Follow the coupling instructions, see chapter Initial Operation, “Adjusting the Machine to

Forage Harvester” and chapter Initial Operation “Attaching to the Forage Harvester”.

• Observe the changed driving behaviour of the combination.

17

Safety

3.5.6

3.5.7

3.5.8

Structural changes to the machine

Structural changes and enhancements may impair the functionality and operational safety of the machine. Thus there is a risk of serious injuries or death.

Structural changes and enhancements are not permitted.

Additional equipment and spare parts

Additional equipment and spare parts which do not comply with the requirements of the manufacturer may impair the operational safety of the machine and cause accidents.

• To ensure operational safety, use original parts or standard parts which correspond to the requirements of the manufacturer.

Workstations on the Machine

Passengers

Passengers may be seriously injured by the machine or fall off the machine and get run over.

Ejected objects may strike and injure passengers.

• Never let people ride on the machine.

18

3.5.9

Safety

Operational safety: Technically perfect condition

Operation only when the machine has been started up correctly

If the machine is not started up correctly according to these operating instructions, the operational safety of the machine is not ensured. As a result, accidents may occur and people may be seriously injured or killed.

• Do not use the machine unless it has been started up correctly, see chapter Start-up.

Technically perfect condition of the machine

Improper maintenance and adjustment may affect the operational safety of the machine and cause accidents. As a result, people may be seriously injured or killed.

• Perform all maintenance and adjustment work according to the chapters Maintenance and

Adjustment.

• Before performing any maintenance or adjustment work, shut down and safeguard the machine, see chapter Safety "Shutting down and safeguarding the machine".

Danger resulting from damage to the machine

Damage to the machine may impair the operational safety of the machine and cause accidents.

As a result, people may be seriously injured or killed. The following parts of the machine are particularly important for safety:

– Safety devices

– Connecting devices

– Hydraulic system

– Universal shafts

If there are doubts about the operational safety of the machine, for example due to leaking fuel, visible damage or an unexpected change to the operational behaviour:

• Shut down and safeguard the machine, see chapter Safety, "Shutting down and safeguarding the machine".

• Immediately eliminate potential causes of damage, for example heavy soiling, or tighten slack screws.

• If possible, repair the damage according to these operating instructions.

• In the case of damage which may affect operational safety and cannot be repaired according to these operating instructions: Have damage repaired by a qualified service centre.

Technical limit values

If the technical limit values of the machine are not observed, the machine may be damaged. As a result, accidents may occur and people may be seriously injured or killed. Observance of the following technical limit values is particularly important for safety:

– Maximum permitted operating pressure of hydraulics

– Maximum permitted drive speed

– Maximum permitted axle loads of forage harvester

• Observe limit values, refer to chapter “Technical Data”.

19

Safety

3.5.10 Danger zones

When the machine is switched on, a danger zone may be created around this machine.

To avoid getting into the danger zone of the machine, maintain at least the safety distance.

If the safety distance is not followed, people may be seriously injured or killed.

• Do not switch on the drives and the engine until you are sure that no one has ignored the safety distance.

• If people ignore the safety distance, switch off the drives.

• Stop the machine in the shunting operation and field mode.

The safety clearance is:

For machine in shunting operation and field mode

In front of the machine

Behind the machine

Laterally to the machine

30 m

5 m

3 m

For machine switched on without driving motion

In front of the machine 3 m

Behind the machine

Laterally to the machine

5 m

3 m

The safety distances named here are minimum distances according to the intended use. These safety distances must be increased depending on operating conditions and environmental conditions, when required.

• Before performing any work in the danger zone of the machine: Shut down and safeguard the machine, see chapter Safety, "Shutting down and safeguarding the machine". This also applies to brief inspection work.

• Consider the information in all relevant operating instructions:

– The operating instructions of the machine

– The operating instructions of the universal shaft

– The operating instructions of the forage harvester

– The operating instructions of the transport wagon

20

Safety

Danger zone universal shaft

People may be caught, pulled in and seriously injured by the universal shaft.

• Observe operating instructions for the universal shaft.

• Ensure sufficient overlap of section tube and universal shaft guards.

• Allow the universal shaft locks to engage. There must be no areas of the locking device on the PTO shaft fork which could cause catching or entrapment (e.g. by annular design, protective collar around the locking pin).

• Attach chains to prevent the universal shaft guards from rotating with the shaft.

• Make sure that there is no one in the danger zone of PTO shaft and universal shaft.

• Make sure that the universal shaft guards are mounted and that they are fully functional.

• Switch off the PTO shaft when the angles between the universal shaft and the PTO shaft are too large. The machine may be damaged. Parts may be hurled up and cause injury to people.

Danger zone PTO shaft

People may be caught, pulled in and seriously injured by the PTO shaft and the driven components.

Before switching on the PTO shaft:

• Make sure that all safety devices are fitted and in the protection position.

• Ensure that there is nobody in the danger zone of PTO shaft and universal shaft.

• Switch off the drives if they are not necessary.

Danger zone between precision forage harvester and header

People staying between precision forage harvester and header could be seriously hurt or killed caused by precision forage harvester rolling away, carelessness or machine movements.

• Before working between precision forage harvester and header: Shut down and safeguard the machine, see chapter Safety, “Shutting Down and Safeguarding the Machine”. This also applies to brief inspection work.

• If the lifting unit has to be actuated, keep all people away from the range of movement of the header.

Danger zone because objects may shoot out

Crops and foreign bodies may shoot out and injure or kill people.

• Before starting the machine, instruct all persons to leave the danger zone of the machine.

• If people are in the danger zone of the machine, switch off drives and diesel engine immediately.

21

Safety

3.5.11

Danger zone when drive is switched on

When the drive is switched on, there is a danger to life caused by rotating machine parts. There must be nobody in the danger zone of the machine.

• Before starting the machine, direct all people out of the danger zone of the machine.

• If hazardous situations arise, switch off drives immediately and instruct people to leave the danger zone.

Danger zone due to coasting machine parts

When machine parts are coasting, people may be seriously injured or killed.

When the drives have been switched off, the following machine parts will coast:

– Universal shafts or quick coupler

– Collector

– Rotating towers

• Do not approach the machine until all machine parts have come to a complete stop.

Keeping safety devices functional

If safety devices are missing or damaged, people may be seriously injured or killed by moving machine parts.

• Replace damaged safety devices.

• Remount dismounted safety devices and all other parts before start-up and move them to protective position.

• If it is doubtful whether all safety devices have been correctly installed and are functional, have a service centre check them.

22

3.5.12

3.5.13

Safety

Personal Protective Equipment

The wearing of personal protective equipment is an important safety measure. Missing or unsuitable personal protective equipment increases health risks and injuries.

Personal protective equipment is for example:

– Suitable protective gloves

– Safety boots

– Tight-fitting protective clothing

– Hearing protection

– Protective goggles

• Specify and provide personal protective equipment for the particular job.

• Use only personal protective equipment which is in proper condition and offers effective protection.

• Adjust personal protective equipment to the person, for example the size.

• Remove unsuitable clothing and jewellery (e.g. rings, necklaces) and cover long hair with a hairnet.

Wear suitable clothing

Loose clothing increases the risk of it becoming caught or wrapped around rotating parts and of it becoming caught on protruding parts. As a result, people may be seriously injured or killed.

• Wear tight-fitting clothing.

• Never wear rings, chains or other items of jewellery.

• Cover long hair with a hairnet.

• Wear sturdy shoes or protective work boots.

Safety signs on the machine

Safety labels on the machine warn of hazards at danger points and are an important component of the machine's safety equipment. Missing safety labels increase the risk of severe and fatal injuries.

• Clean soiled safety labels.

• Make sure every time after cleaning the safety labels that they are complete and legible.

• Replace missing, damaged and unrecognisable safety labels immediately.

• Provide spare parts with intended safety labels.

Description, explanations and order numbers of the safety labels, see chapter Safety, "Warning labels on the machine".

23

Safety

3.5.14

3.5.15

Traffic safety

Dangers in road traffic

If the machine exceeds the maximum dimensions and weights specified by national law and if it is not lit properly, other road users could be endangered when driving on public roads.

• Before road travel, ensure that the maximum permitted dimensions, weights and axle loads, supported loads and hitching loads which apply according to national law for driving on public roads are not exceeded.

• Before road travel, switch on lighting and ensure the proper function.

Danger when driving on road and field

The mounted header changes the handling characteristics of the forage harvester. The handling characteristics also depend on the operating state and ground. If the driver of the forage harvester does not consider changed handling characteristics, accidents may be caused.

• Follow procedures for driving on roads and in fields, refer to chapter “Driving and

Transport”.

Dangers if machine is not prepared properly for road travel

If the machine is not prepared properly for road travel, serious accidents may occur with traffic.

• Before driving on roads, prepare the machine for road travel, refer to chapter Driving and

Transport, “Preparations for Road Travel”.

Parking the machine safely

An incorrectly parked and insufficiently safeguarded machine may be hazardous to people, especially children, and may start moving or overturn in an uncontrolled manner. People may be crushed and killed.

• Park the machine on firm, horizontal and level ground.

• Before adjusting, repairing, servicing and cleaning the machine, ensure that it is securely positioned.

• In the chapter "Driving and Transport", observe the section "Parking the Machine".

• Before parking: Shut down and safeguard the machine.

Unattended parking

Adults and especially children are at risk from an inadequately secured and unattended parked machine.

• Before parking the machine: Shut down and safeguard the machine, refer to chapter Safety

“Shutting Down and Safeguarding the Machine“.

24

3.5.16

3.5.17

Safety

Consumables

Unsuitable consumables

Consumables which do not comply with the requirements of the manufacturer may impair the operational safety of the machine and cause accidents.

• Use consumables only which correspond to the requirements of the manufacturer.

For the requirements of fuels, see chapter Description of Machine, “Consumables”.

Environmental protection and disposal

Consumables such as diesel fuel, brake fluid, frost protection agent and lubricants (e. g. gearbox oil, hydraulic oil) may damage the environment and the health of people.

• Do not release consumables into the environment.

• Fill consumables in a liquid-tight labelled container and dispose of according to the official regulations.

• Absorb leaked consumables with an absorbent material, fill them in a liquid-tight labelled container and dispose of them according to the official regulations.

Dangers associated with the operational environment

Danger of fire

Combustible materials can accumulate in the machine due to operation or animals such as rodents or nesting birds or dust resuspension.

In case of dry usage conditions, dust, impurities and crop residues may inflame on hot parts and the resulting fire could seriously hurt people or kill them.

 Check and clean the machine every day before using it for the first time.

 Check and clean the machine regularly during the working day.

25

Safety

3.5.18 Sources of danger on the machine

Noise may damage your health

The noise development of the machine during operation may cause health damage such as hardness of hearing, deafness or tinnitus. When using the machine at high rotational speed, the noise level also increases. The height of the sound pressure level depends mainly on the forage harvester used. The emissions value was measured under conditions according to

DIN EN ISO 4254-7, Appendix C, refer to chapter "Technical data".

• Before starting up the machine, estimate the risk caused by noise.

• Depending on the ambient conditions, working hours and the working and operating conditions of the machine, specify and use suitable hearing protection.

• Specify rules for the use of hearing protection and for the working time.

• During operation keep windows and doors of the cabin closed.

• Remove hearing protection for road travel.

Liquids under high pressure

The following liquids are under high pressure:

– Hydraulic oil

Liquids escaping under high pressure may penetrate the body through the skin and cause severe injuries.

• If there is a suspicion that the hydraulic system is damaged, shut down and safeguard the machine and contact a qualified service centre.

• When searching for leaks, use suitable aids, e.g. a piece of cardboard, to avoid the risk of injury.

• Never search for leaks with bare hands. Even a very pin-sized hole may lead to serious injuries.

• Keep body and face away from leaks. Risk of infection!

• If liquid penetrates the body, immediately consult a doctor. The liquid must be removed from the body as quickly as possible.

Hot liquids

If hot liquids are drained, people may burn and/or scald themselves.

• When draining hot consumables, wear personal protective equipment.

• If required, leave liquids and machine parts to cool down before performing repair, maintenance and cleaning work.

Damaged hydraulic hoses

Damaged hydraulic hoses may tear off, burst or cause oil leaks. As a result, the machine may be damaged and people may be seriously injured.

• Shut down and safeguard the machine, see Safety chapter, "Shutting down and safeguarding the machine".

• If it is suspected that hydraulic hoses are damaged, immediately contact a service centre, see Chapter "Maintenance – Hydraulics, "Checking hydraulic hoses".

26

3.5.19

Safety

Dangers associated with certain activities: Work on the machine

Work on the machine only when it has been shut down

If the machine is not shut down and safeguarded, parts may move unintentionally or the machine may move. Thus there is a risk of serious injuries or death.

• Prior to all repair and maintenance work, setting and cleaning work on the machine, shut down and safeguard it, refer to chapter Safety “Shutting Down and Safeguarding the

Machine”.

Maintenance and repair work

Incorrect maintenance and repair work will endanger operational safety. As a result, accidents may occur and people may be seriously injured or killed.

• Only perform work which is described in these operating instructions. Before performing any work, shut down and safeguard the machine, see chapter Safety, "Shutting down and safeguarding the machine".

• All other maintenance and repair work may be performed by a qualified service centre only.

Raised machines and machine parts

Raised machine and raised machine parts may accidentally drop or overturn. People may be seriously injured or killed as a result.

• Do not stay under the raised machine or raised machine parts which are not supported, refer to chapter “Securely Supporting Raised Machine and Machine Parts”.

• Before performing any work on raised machines or machine parts, lower the machine or machine parts.

• Before performing any work on or under raised machines or machine parts, secure the machine or machine parts from dropping by using rigid safety supports or hydraulic shut-off device or by supporting them.

27

Safety

3.5.20

Danger associated with welding work

Improper welding work will endanger the operational safety of the machine. As a result, accidents may occur and people may be seriously injured or killed.

• Never weld on the following components:

– Gearbox

– Components of the hydraulic system

– Components of the electronics

– Frame or bearing component groups

– Running gear

• Before performing welding work on the machine, obtain the consent of KRONE customer service and, if required, identify alternatives.

• Before performing welding work on the machine, set the machine down safely and disconnect it from the tractor.

• Have welding work performed by experienced technicians only.

• Mount the earthing of the welding device near the welding points.

• Be careful when carrying out welding work near electrical and hydraulic parts, plastic parts and pressure accumulators. The parts may be damaged, endanger people or cause accidents.

Behaviour in hazardous situations and when accidents occur

Neglected or incorrect procedures in hazardous situations may obstruct or prevent the rescue of people in danger. Difficult rescue conditions will impair the chances of helping and healing the injured.

• In principle: Switch off the machine.

• Gain an overview of the hazardous situation and identify the cause of the hazard.

• Safeguard the accident location.

• Rescue people from the danger zone.

• Withdraw from the danger zone and do not enter again.

• Alert rescue teams and, if possible, fetch help.

• Take immediate life-saving measures.

28

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Safety

29

Safety

3.6

3.6.1

3.6.2

Safety routines

Shutting down and safeguarding the machine

WARNING!

Crush hazard due to movement of the machine or machine parts!

If the machine has not been shut down, the machine or machine parts may move unintentionally. As a result, people may be seriously injured or killed.

• Before leaving the machine: Shut down and secure the machine.

To park the machine securely:

• Park the forage harvester with the front attachment on a stable, paved and even surface.

• Switch off the drives and wait until coasting parts have come to a standstill.

• Apply the parking brake.

• Place the front attachment on the ground.

• Switch off the engine, remove the ignition key and take it with you.

• Switch off the main battery switch.

• Secure the forage harvester against rolling away with wheel chocks.

Supporting lifted machine and machine parts securely

WARNING!

Crushing hazard by movement of machine or machine parts!

If the machine is not supported safely, the machine or machine parts may roll, fall or sag.

Thus there is a risk of crushing or death.

• Before working on or under lifted parts: Firmly support machine or machine parts:

In order to firmly support the machine or machine parts:

• Stop and secure the machine, refer to “Stopping and Securing the Machine”.

• Before performing work on or under raised machine parts, lower the machine parts or secure them against lowering either mechanically by means of rigid safety support (e.g. parking block, crane) or by means of hydraulic shut-off device (e.g. stop cock).

• Never use materials that may yield to support the machine.

• Never use hollow blocks or bricks to support the machine or machine parts. Hollow blocks and bricks may break in case of permanent load.

• Never work under the machine or machine parts that are held by a car jack.

30

3.6.3

Safety

Safely checking the oil level and changing the oil and filter element

WARNING!

Perform oil level check, oil change and filter element change safely!

If oil level check, oil change and filter element change are not performed safely, the operational safety of the machine may be affected. This may result in accidents.

• Perform oil level check, oil change and filter element change safely.

In order to perform oil level check, oil change and filter element change safely:

• Lower raised machine parts or secure them against falling, refer to chapter Safety,

“Securely Supporting Raised Machine and Machine Parts”.

• Shut down and safeguard the machine, refer to chapter Safety, “Shutting Down and

Safeguarding the Machine”.

• Observe the intervals for oil level check, oil change and filter element change, refer to chapter Maintenance, “Maintenance Table”.

• Use only oil qualities/quantities mentioned in the consumables table, refer to chapter

Technical Data, “Consumables”.

• Clean the area around the parts (for example gearbox, high-pressure filter) and make sure that foreign bodies do not get into the parts or the hydraulic system.

• Check existing seal rings for damage and replace them, if necessary.

• Collect escaping oil or waste oil in a container provided for that purpose and dispose of it properly, refer to chapter Safety, “Consumables”.

31

Safety

GL

3.7 Position of the Adhesive Safety and Information Labels on the Machine

4 10 4

8

2

5

14

2

8

5

Fig. 1

7

11

3

1

6

9 12

13

11

3

6

7

EC400128

32

L

L

Safety

1) Order No. 27 002 054 0 (1x)

CAUTION

To avoid serious injur y or death

- Read and understand operator´s manual before operating equipment.

leaving operator´s platform.

- K eep all shields and guards in place.

- K eep hands feet and clothing away from moving parts.

- K eep riders off the machine.

tractor engine and starting.

- Do not allow unqualified operator to run equipment.

- Do not operate equipment in transport position.

- Never lubricatem, adjust, unclog or service the equipment with

- Wait for all movement to stop before opening shield or servicing machine.

- Never work underneath equipment without securely supporting.

2 7 0 0 2 0 5 4 0

2) Order No. 942 536 0 (2x)

CAUTION

To avoid serious injury or death.

- Read and understand operator´s manual before operating equipment.

- Lower implement, stop tractor engine and remove key before leaving operator´s platform.

- Keep all shields and guards in place.

- Keep hands, feet and clothing away from moving parts.

- Keep riders off the machine.

- Make certain everyone is clear of the machine before starting tractor engine and starting.

- Do not allow unqualified operator to run equipment.

- Do not operate equipment in transport position.

- Never lubricate, adjust, unclog or service the equipment with tractor engine is running.

- Wait for all movement to stop before opening shield or servicing machine.

- Never work underneath equipment without securely supporting.

WARNING

WARNING

Avoid bodily injuries from rotating knives.

Keep hands out of knife area when cutter head is turning.

L

L

Avoid bodily injuries from rotating knives.

Keep hands out of knife area when cutter head is turning.

942 536 -0

3) Order No. 27 002 057 0 (2x)

Warning

To avoid personal injury.

Never put your hand into the danger area as parts may be moving.

WARNING

To avoid personal injury.

Never put your hand into the danger area as parts may be moving.

27 002 057 0

4) Order No. 27 003 029 0 (4x)

Warning

To avoid Possible injury.

Do not stay in the swivel area of the outrigger arms!

Keep your distance!

WARNING

To avoid possible injury.

Do not stay in the swivel area of the outrigger arms!

Keep your distance!

27 003 029 0

33

GL

Safety

8

5

4

2

14

10 4

8

2 5

Fig. 2

7

11

3

1

6

9 12

13

11

3

6

7

EC400128

34

L

L

L

L

L

Safety

5) Order No. 27 003 030 0 (2x)

Warning y.

Do not climb onto maschine if thePTO shaft is connected and the engine runs.

WARNING

To avoid possible injury.

Do not climb onto machine if the PTO shaft is connected and the engine runs.

27 003 030 0

6) Order No. 27 002 702 0 (1x)

Warning

To avoid Possible injury.

Do not stand between

Self-proppeled Forage Harvester and header or near header while changing from transport position or to transport position.

WARNING

To avoid possible injury.

Do not stand between self-propelled forage harvester and header or near header while changing from transport position or to transport position.

27 002 702 0

7) Order No. 27 002 056 0 (2x)

DANGER

Blade can cause serious injury or death.

- S tay clear of machine while in operation.

- K eep discharge chute and shields in place.

DANGER

Blade can cause serious injury or death.

– Stay clear of machine while in operation.

– Keep discharge chute and shields in place.

8) Order No. 27 003 325 0 (2x)

Warning

To avoid personal injury.

Stay clear of header. Disengage header drive, shut off engine, and remove key before servicing or unclogging header.

WARNING

To avoid possible injury.

Stay clear of header. Disengage header drive, shut of engine and remove key before servicing or unclogging header.

27 003 325 0

9) Order No. 949 228 0 (1x)

DANGER

ROTATING DRIVELINE – CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT-

- All driveline guards, tractor and equipment shields in place.

- Driveline securely attached at both ends.

- Driveline guards that turn freely on driveline.

35

GL

Safety

8

5

4

2

14

10 4

8

2 5

Fig. 3

7

11

3

1

6

9 12

13

11

3

6

7

EC400128

36

L

L

L

L

–

Safety

10) Order No. 942 556 0 (1x)

DANGER

Avoid death or serious injury from entlanglement in the feed rolls.

The harvester takes crop faster than you can release it.

NEVER feed with hands or feet or use as a manually-fed stationary machine.

Disengage drives and shut off engine before manually unplugging.

11) Order No. 27 002 059 0 (2x)

CAUTION

27 002 059 0

CAUTION

– High pressure oil leaks can penetrate skin causing serious injury and gangrene. (See operators manual & consult a physician immediately).

– Do not use finger or skin to check leaks.

– Lower load, release pressure and be sure oil cool before loosening fitting.

12) Order No. 27 002 701 0 (1x)

CAUTION

CAUTION

Max. PTO speed 750 RPM.

Max. PTO speed

750 RPM

27 002 701 0

13) Order No. 27 004 598 0 (1x)

CAUTION

The operating pressure of the hydraulic system must not exceed

200 ba r.

CAUTION

The operating pressure of the hydraulic system must not exceed

200 bar.

27 004 598 0

14) Ord. no. 27 004 017 0 (1x) only for the version with “active ground contour”

WARNING

Hydraulic accumulators store energy.

ToAVOID explosion, depressurize the system on the fluid side before repairing.

Failure to comply could result

WARNING!

Hydraulic accumulators store energy.

To AVOID explosion, depressurize the system on the fluid side before repairing.

Failure to comply could result in death or serious injury.

27 004 017 0

37

Safety

3.7.1

3.7.2

3.7.3

Re-Ordering Safety Labels and Information Labels

Note

Each safety and information label is provided with an order number and can be ordered directly from the manufacturer or from authorised dealer (refer to chapter “Contact Person”).

Attaching Safety Labels and Information Labels

Note - Attaching a label

Effect: Adhesion of label

• The attachment area must be clean, dry and free from dirt, oil and grease.

Contact for KRONE NORTHAMERICA

Mailing address

Krone North America, Inc.

P.O. Box 18880

Memphis, TN 38181-0880

USA

Phone

Fax

E-mail

Internet

Physical address

Krone North America, Inc.

3363 Miac Cove

Memphis, TN 38118

USA

+1 901 842-6011

+1 901 842-6016 [email protected] www.krone-northamerica.com

38

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Safety

39

Safety

3.8 Location and meaning of the information labels on the machine

Each information label has an order number. You can order the labels directly from your

KRONE dealer. Replace missing, damaged and illegible information labels immediately.

Prior to attaching an information label, ensure that the contact surface on the machine is clean and free of dirt, oil and grease so that the label can adhere to properly.

40

Safety

1) Order no. 942 012 2 (4x)

There are lifting points on the machine that are identified with this label. See chapter Driving and transport, "Lifting the machine".

L

L

L

942 012 2

2) Order no. 939 157 1 (2x)

The tightening torque of the screws must be checked after the first

10 hours; see chapters Maintenance "Maintenance table" and

"Tightening torques".

3) Order no. 27 011 917 0 (1x)

Prior to lifting the machine, secure the upper side part with an angle plate and screws at the lower side part; see chapter Driving and transport, "Lifting the machine".

4) Order no. 27 009 685 0 (1x)

Prior to lifting the machine, secure the locking bolt with a linch pin ; see chapter Driving and transport, "Lifting the machine".

2 7 0 0 9 6 8 5 0

• Order no. 27 021 260 0

There are several lubrication points on the machine which must be lubricated at regular intervals; see chapter Maintenance,

"Lubrication".

Lubrication points that are not directly visible are additionally marked with this information label.

41

Safety

3.9 Safety Equipment

Item Designation

1 Support jacks

2 Overload protections

Explanation

– The support jacks ensure the stability of the machine when it is not mounted on the forage harvester; see chapter Driving and transport, "Parking the machine" .

– The overload protections protect forage harvester and machine from load peaks; see chapter Machine description, "Overload protection".

42

4

4.1

Machine Description

Machine overview

Machine Description

Fig. 4 Example: EasyCollect 600-3 with spherical roller adaptation

1) Side part right

4) Crop press roller

2) Central part

5) Scraper sheet

3) Plant divider

6) Side part left

7) Support jack

10) Guide bracket

13) Tubular bar

16) Input gearbox

19) Main gearbox

8) Central tip

11) Row tip

14) Folding cylinder

17) Clutch disc

9) Rotating tower

12) Side tip

15) Pendulum crossbar

18) Locking sheet

20) Document storage tube 21) Sliding skid

43

Machine Description

1 2 3 4 2 5 6

8 7

EC400088_1

Fig. 5: Example: EasyCollect 600-3 FP for CLAAS forage harvesters

1) Centre frame

4) Receiving pocket

7) Lower holder

2) Pendulum tension spring

5) Locking lever

8) Intermediate frame

3) Pendulum locking

6) Connecting rod

44

4.2

Machine Description

Overload protection

Notice

Machine damage due to load peaks

The overload protections protect the machine against load peaks. For this reason, overload protections must not be modified. The warranty for the machine becomes void if other than the factory-specified overload protections are used.

• Use only the overload protections installed in the machine.

• To avoid premature wear of the overload protection, switch off the PTO shaft if the overload protection responds for a longer period of time.

• Shut down and safeguard the machine, see Safety chapter, "Shutting down and safeguarding the machine".

• Eliminate the disturbance; see chapter Maintenance "Releasing star ratchet clutch at the universal shaft".

1

EC400137

Fig. 6

A star ratchet clutch (1) on the double joint protects against overload. This star ratchet clutch (1) need not be disengaged.

If the star ratchet clutch (1) releases when the machine is overloaded, see chapter Maintenance

"Releasing star ratchet clutch at the universal shaft".

45

Machine Description

4.3 Identification Plate

1

EC400012

Fig. 7

This machine data is located on the type plate (1).

Information Required for Questions and Orders

The type plate shows data to identify the machine.

Maschinenfarbrik Krone Beteiligungs-GmbH

Heinrich-Krone-Str. 10, D-48480 Spelle

2

1

Fig. 8 Type plate

Example image

1) Model 2) Vehicle ID number

For inquiries about the machine and for ordering spare parts, please specify model (1) and the vehicle identification number (2) of the specific machine. To ensure that the data is always available, KRONE recommends that you enter it in the boxes on the front cover of these operating instructions.

Notice

The entire marking is equivalent to a document and must not be modified or made unrecognisable!

Notice

Genuine KRONE spare parts and accessories authorised by the manufacturer ensure safety.

Using spare parts, accessories or additional equipment that was not manufactured, tested or approved by KRONE will make any liability for consequential damage void.

46

4.3.1

Machine Description

Contact for KRONE NORTHAMERICA

Mailing address

Krone North America, Inc.

P.O. Box 18880

Memphis, TN 38181-0880

USA

Phone

Fax

E-mail

Internet

Physical address

Krone North America, Inc.

3363 Miac Cove

Memphis, TN 38118

USA

+1 901 842-6011

+1 901 842-6016 [email protected] www.krone-northamerica.com

47

Machine Description

4.4 Approved adaptations

Carrier vehicles for which the maize header has been approved in connection with a corresponding adaptation.

In order to adapt the forage harvester types Claas 491-498, a basic adaptation and the supplementary kit suitable for the forage harvester must have been mounted.

Manufacturer/type Adaptation

Claas

491-498

Basic adaptation Claas 491-498

Supplementary kit Claas 491-492

Accessories kit

20 298 301 0

20 298 302 0

Supplementary kit Claas 493-498 20 298 303 0

48

5

Technical data

Technical data

All information, illustrations and technical data in these operating instructions correspond to the latest state at the time of publication. We reserve the right to make design changes at any time and without notification of reasons.

Indication

Length

Height in working position

Total width in working position

Working width

Height (folded in)

Width (folded in)

EasyCollect 600-3 FP

2150 mm

1590 mm

6200 mm

6110 mm

2450 mm

3100 mm

EasyCollect 750-3 FP

2150 mm

1590 mm

7530 mm

7500 mm

2450 mm

3100 mm

Weight

Drive speed

Maximum permitted operating pressure

Hydraulic connections

Electrical connection 12V (lighting)

3000 kg

300…750 rpm

200 bar

1x DA 1

7-pole

3300 kg

300…750 rpm

200 bar

1x DA 1

7-pole

Electrical connection 12V (operation panel)

1 double-acting hydraulic connection

Indication

Length

Height in working position

Total width in working position

Working width

Height (folded in)

3-pole

EasyCollect 900-3 FP

2150 mm

1590 mm

9100 mm

9000 mm

2450 mm

3100 mm

3-pole

Width (folded in)

Weight

Drive speed

Maximum permitted operating pressure

Hydraulic connections

Electrical connection 12V (lighting)

3600 kg

300…750 rpm

200 bar

1x DA

7-pole

1

Electrical connection 12V (operation panel)

3-pole

1 double-acting hydraulic connection

Airborne noise emission

Emissions value (sound pressure level)

Measurement device

Accuracy class

73.4 dB(A) ¹

Bruel & Kjaer, Type 2236

2

Measurement uncertainty (according to DIN EN ISO 11201) 4 dB

¹ Value measured with EasyCollect 1050-3 in combination with forage harvester BiG X 1180

Ambient temperature

Temperature range for machine operation -5 to +45°C

49

Technical data

5.1

5.1.1

5.1.2

Consumables

Biodegradable consumables can be used on request.

Oils

Gearbox

Input gearbox

Main gearbox

Collector gearbox (top part)

Collector gearbox

(bottom part on central part)

Filling quantity

[litres]

0.85

1.0

4 x 0.8

2 x 1.1

Refined lubricants

SAE 90 GL 4,

e. g.:

- Esso Spartan EP 150

- Shell Omala Oil 150

- Fuchs- EP 85 W90

- Castrol EPX 90

Bio-degradable lubricants on request

Collector gearbox

(bottom part on side part)

2 x 1.4

The filling quantities of the gearboxes are guide values. The correct values occur by changing the oil/checking the oil level, see chapter Maintenance.

Note - Observe maintenance intervals

Effect: Long expected service life of machine

• With bio-degradable oils always observe the change intervals because of the ageing of the oils.

Lubricating grease

Designation

Manual lubrication points

Filling quantity as required

Specification

Lubricating grease according to DIN 51818 NLGI class 2, lithium soap with EP additives

50

5.2

Technical data

Ballasting of forage harvester

Notice

To ensure safe and reliable operation of the carrier vehicle with the KRONE maize header attached, especially when driving on roads, the ballast of the machine must be distributed evenly. The relevant road traffic regulations must be observed.

The possibly required rear weight for the forage harvester is not included in the scope of delivery.

Notice

If the header con be combined with forage harvesters of other manufacturers, depends on their technical usage regulations.

Since there is no standardised interface for mounting devices between headers and forage harvesters, an adaptation for field operation, road travel etc. is necessary in particular cases. The operating licence of the forage harvester must be adjusted or supplemented.

Notice

Each header, which is mounted to the forage harvester on public roads, must be recorded in the vehicle documents. Usually, this requires an additional approval by an officially recognised expert. Due to different machine weights not all possible technical combinations of forage harvester and headers can be approved in Germany. This must be checked on a case-by-case basis.

For some combinations, there are already sample reports which can be made available on request. If warranty/guarantee is given for the forage harvester, must be clarified with the supplier of the forage harvester.

51

Commissioning

6

6.1

Commissioning

Danger! - Incorrect assembly

Effect: Danger to life, serious injuries or serious damage to the machine.

• Only authorised service centres may assemble the machine.

• The machine must be assembled with special care.

• Always heed the applicable accident prevention regulations.

• Use only safe and sufficiently dimensioned lifting equipment and load-securing equipment.

• The machine may be taken into operation only after all the safety devices have been installed.

• If unauthorised modifications are made to the machine, the manufacturer is released from liability for any resulting damage.

Checks before starting up the machine for the first time

The following points must be checked to ensure that the machine is in a safe condition:

• All cables and plug connections are plugged in and routed properly.

• All hoses are routed properly.

• The tight fit of all screws and nuts was checked. All screws and nuts are tightened to the specified tightening torques; see chapter Maintenance, "Tightening torques".

• The hydraulic system was checked for leaks.

• The oil level of all gearboxes was checked; see chapter Maintenance.

• All defects detected during the visual inspection were eliminated before the initial commissioning.

• The complete machine is lubricated; see chapter Maintenance, "Lubrication chart".

• The universal shafts are lubricated; see chapter Maintenance, "Lubrication chart".

• The safety devices are mounted and checked for completeness and damage.

• The machine is adapted to the forage harvester; see chapter Initial commissioning,

"Adapting machine to the CLAAS forage harvester type 493, type 494, type 496, type 497, type 498".

• The operating instructions provided are in the document storage tube.

52

6.2

Commissioning

Connecting drive type 493, type 494, type 496, type 497, type 498

Note

When mounting the machine on the forage harvester for the first time and whenever changing the forage harvester, the position of the clutch disc must be checked and adapted, if necessary.

Note

Adjust, attach or remove the machine from the forage harvester on level load-bearing ground.

Notice

For Claas forage harvesters type 493, type 494, type 496, type 497, and type 498 without quick coupling, you can operate the header via the universal shaft 27 024 722 0 (to be ordered from KRONE spare parts warehouse).

To do this, the clutch disc must be removed and the universal shaft must be pushed directly onto the drive journal of the input gearbox.

Warning! - Connecting

Effect: Danger to life or serious injuries.

When connecting, ensure that there is nobody between the forage harvester and the machine.

53

Commissioning

Mounting coupling disc

4 3 2 1

EC400109

Fig. 9

To mount the coupling:

• Push the clutch disc (1) on the profile (3) until the clutch disc can be secured with the screw

(2) in the groove (4) on the profile.

• Tighten the screw (2) to 100 Nm.

Cleaning the coupling disc

1 2

EC400093_2

Fig. 10

To prepare the coupling for the attachment of the header:

• Clean the clutch disc (1) on the header.

• Clean the coupling journal (2) on the forage harvester.

54

6.2.1 Aligning the coupling disc

2

1

Commissioning

EC400090

Fig. 11

The clutch disc (2) of the header must be aligned to the coupling journal (1) of the forage harvester so that the coupling journal (1) is positioned centrally in the housing.

The coupling disc must be positioned evenly and flat on the coupling journal.

II

I

EC400094_1

Fig. 12

Correct position of clutch disc

The clutch disc is correctly aligned when:

– it is positioned evenly and flat on the coupling journal.

– the coupling journal is centrically in the coupling housing, i.e. it does not brush against the coupling housing during operation.

The position of the clutch disc is corrected with the setting of the input gearbox (9). The input gearbox can be adjusted laterally (II) by means of shims as well as concerning the inclination

(I).

55

Commissioning

Mounting header on forage harvester

• Dismount the protective cap.

• Mount the header on the forage harvester.

• Prevent the header from dropping, refer to the operating instructions of the forage harvester.

Checking position of the coupling disc and input gearbox y

9

13

EC400095_2 EC400096

Fig. 13

• Check the position of the clutch disc.

If the clutch disc has been correctly aligned:

• The setting is correct, the guard cup must be remounted and the header can be used with forage harvester.

If the clutch disc has not been correctly aligned:

Inclination setting of the input gearbox:

• Loosen the 4 screws M16 (10).

• Adjust the inclination of the input gearbox (9) until the deviation of the axles of the input gearbox (9) and the coupling journal (13) is y = 180 +/- 2°.

• Retighten the 4 screws (10).

If the input gearbox has to be moved laterally:

• Determine the dimension by which the input gearbox should be adjusted laterally so that the clutch disc is correctly aligned.

• Disconnect the header from the forage harvester and readjust the lateral direction of the input gearbox.

56

Setting the input gearbox laterally

Commissioning

EC400095_2

Fig. 14

• Loosen the 4 screws M16 (10).

• Add or remove as many distance sheets (11) as required until the determined dimension is reached.

• Retighten the 4 screws M16 (10).

Checking the position of the coupling disc

• Connect the front attachment to the forage harvester and check the position of the coupling disc.

If the coupling disc has been correctly aligned:

• The setting is correct, the protective cap must be re-attached and the front attachment can be installed with the forage harvester.

If the coupling disc has still not been correctly aligned:

• Repeat the adjustment process of the input gearbox.

Removing header from forage harvester

• Loosen the retainer against lowering of the header, refer to the operating instructions of the forage harvester.

• Remove the header from the forage harvester.

• Reverse the forage harvester.

57

Commissioning

Setting lower holder

In order to set the lower holders, the header must be mounted on the forage harvester.

2 4 3

5 6

7

9 10

11

12

8 13

1 15 14

EC500127_1

Fig. 15

• Dismount the linch pin (5) and swivel the lever (6) outwards.

• Move the forage harvester up to the maize header until the intake housing (1) of the forage harvester is just in front of the adapter frame (2).

• Lower the intake housing until the holding brackets (3) are positioned under the take-up pockets (4) of the maize header.

• Advance the forage harvester until the holding brackets (3) engage in the openings of the take-up pockets (4).

• Using the lifting hydraulics, lift the intake housing until the holding fixtures (8) are in contact with the shaft (7) of the intake housing.

• Shut down the machine.

• Ensure that the shaft (7) sits properly in the holding fixture (8).

If the shaft does not sit properly in the lower holding fixture:

• Remove the header and reverse the forage harvester.

• Loosen the screws M16 (9) (outside) and (10) (inside) on both sides of the machine.

• Mount the header at the harvester. The bottom holding fixtures are centred during installation.

• Tighten the outer screws M16 (9) on both sides of the machine.

• Remove the header and reverse the forage harvester.

• Tighten the inner screws M16 (10) on both sides of the machine.

• Mount the header on the forage harvester.

• Swivel the lever (6) inwards.

The header is mounted properly if the interlocking claw (15) contacts the shaft (7) without a gap, the locking device is pretensioned in the end position via the lever, and the linch pin (5) can be fitted.

The length of the connecting rod (11) must be adjusted if the pin cannot be fitted or if pretension is not built up in the locked end position:

• Dismount the bolt (14).

• Loosen the lock nut (12). Rotate the clevis (13) until the length of the connecting rod is adjusted.

• Tighten the lock nut and mount the bolt.

If the length of the connecting rod is adjusted:

• Swivel the lever (6) inwards and mount the linch pin (5).

58

6.2.2 Connecting operation panel to forage harvester

1

3 2

Commissioning

EC400075

Fig. 16

If the Claas forage harvester (depending on type) only has one double-acting control unit, the function change between “Fold side part” and “Fold plant divider” is controlled via an electrically switchable hydraulic valve on the header.

The electrically switchable hydraulic valve is switched via an operation panel (1) in the cabin.

Mounting the operation panel:

• Fasten the operation panel (1) with the magnetic plate attached on the rear in the cabin.

• Lay the cable (2) to switch the electrically switchable hydraulic valve near the hydraulic connections in the front panel.

• Connect the power supply (3) of the operation panel to the 12V 3-pole built-in socket of the forage harvester.

59

Start-up - CLAAS

7

7.1

Start-up - CLAAS

Warning! - Attaching / detaching and operating the machine

Effect: Danger to life or serious injuries.

• The machine may be attached to the designated forage harvester type only!

• There must be nobody between the forage harvester and the header.

• Switch off the engine, remove the ignition key, and secure the forage harvester from rolling away.

• Wait until all machine parts have come to a complete stop.

• Before working under or on the raised header, support the header securely.

• Ensure that nobody is in the danger zone of the machine during operation.

• The safety devices on the machine, e.g. cloths and hoods, protect against flying stones and similar objects and prevent access to hazardous areas. Therefore, move them into protective position before starting work.

• Do not open or remove the safety devices while the engine is running.

• Keep all persons clear of the swivel range while the machine is being swivelled from transport into working position or vice-versa.

• Before starting up the machine and while working, bring the machine into the working position and lower it onto the ground or to the required cutting height.

• On public streets and highways, the maize header EasyCollect 600-3, FP, 750-3 FP,

900-3 FP must always be in the transport position.

• When lifting to the transport position, make certain the maize header EasyCollect

600-3 FP, 750-3 FP, 900-3 FP does not collide with the tractor cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

• Before starting up the machine, lubricate the front attachment thoroughly.

• Check that the screws are tight.

• Mount and lock all protective devices.

• Before driving the vehicle, check for loose entrained parts. Parts, which may be lost while the vehicle is being driven, must be attached or covered.

• Keep people out of the danger zone. If people approach the danger zone, turn off the machine immediately.

• Never allow the machine to run unsupervised.

60

7.2

7.3

Start-up - CLAAS

Attachment to the CLAAS forage harvester

Coupling

2 4 3

5 6

7

9 10

8

11

12

13

1 15 14

EC500127_1

Fig. 17

• Dismount the linch pin (5) and swivel the lever (6) outwards.

• Move the forage harvester up to the maize header until the intake housing (1) of the forage harvester is just in front of the adapter frame (2).

• Lower the intake housing until the holding brackets (3) are positioned under the take-up pockets (4) of the maize header.

• Advance the forage harvester until the holding brackets (3) engage in the openings of the take-up pockets (4).

• Using the lifting hydraulics, lift the intake housing until the holding fixtures (8) are in contact with the shaft (7) of the intake housing.

• Shut down the machine.

• Ensure that the shaft (7) sits properly in the holding fixture (8).

If the shaft is not positioned properly in the lower holder:

• Set the lower holder, refer to chapter Initial operation, “Adapting machine to CLAAS forage harvester”.

If the cotter pin cannot be mounted:

• Set the lower holder, refer to chapter Initial operation, “Adapting machine to CLAAS forage harvester”.

61

Start-up - CLAAS

7.3.1 Connecting Drive Type 491, Type 492

1 2

4 3

EC400085_1

Fig. 18

• Fold down the guard sheet (3).

• Push the universal joint (2) onto the drive journal of the forage harvester gearbox until the lock engages.

• Push the universal joint (4) onto the maize header gearbox until the lock engages.

• Secure the supporting chain of the universal shaft guard at the support (1) on the forage harvester.

• Close the guard sheet (3).

Note

Check to make certain the intake housing is correctly hooked into the receiving pockets and lower holders.

62

7.3.2 Connecting drive type 493, type 494, type 496, type 497, type 498

2

1

Start-up - CLAAS

EC400090

Fig. 19

When raising the header with the forage harvester hydraulics, the clutch disc of the header runs in front of the coupling journal of the forage harvester.

• Check whether the clutch disc (2) of the input gearbox is positioned evenly on the coupling journal (1) of the forage harvester after the coupling process is complete.

Note

Check to make certain the intake housing is correctly hooked into the receiving pockets and lower holders.

Notice

For Claas forage harvesters type 493, type 494, type 496, type 497, and type 498 without quick coupling, you can operate the header via the universal shaft 27 024 722 0 (to be ordered from KRONE spare parts warehouse).

To do this, the clutch disc must be removed and the universal shaft must be pushed directly onto the drive journal of the input gearbox.

63

Start-up - CLAAS

7.3.3 Connecting hydraulic hoses

Warning! - Connecting the hydraulic line

Effect: Serious injuries due to hydraulic oil penetrating the skin.

• When connecting the hydraulic hoses to the forage harvester hydraulics, ensure that the system is depressurised on both sides!

• When searching for leaks, use suitable aids and wear safety googles to prevent the risk of injury.

• Seek medical help immediately should injuries occur! Danger of infection.

• Before uncoupling the hoses and before performing work on the hydraulic system, relieve the pressure!

• Check hydraulic hose lines at regular intervals and replace them in case of damage or if they show signs of ageing! The replacement hoses must comply with the technical requirements set by the equipment manufacturer.

Warning! - Interchanging the hydraulic hoses when connecting them to the forage harvester hydraulics will result in reversed functions.

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

• Always ensure correct connection between the machine and the forage harvester.

• Before coupling the hydraulic hose, ensure that the system is depressurised on both sides!

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

• When connecting the quick couplings, ensure that these are clean and dry.

• Note chafing areas or points of contact.

64

Start-up - CLAAS

4

2 3 1

EC400074_1 EC400076_1

Fig. 20

If the forage harvester is equipped with a double-acting hydraulic connection:

• Connect the hydraulic hoses (1) to the designated hydraulic couplings on the forage harvester.

• Connect the lighting cable (2) to the socket.

• Connect the cable (3) for the electrically switchable hydraulic valve (4) to the cable harness separating point next to the hydraulic connections.

Note

For further information on attachment, refer to the operating instructions of the forage harvester.

65

Start-up - CLAAS

7.4

7.4.1

Detaching the machine

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

• There must be nobody between the forage harvester and the header.

• When swivelling the machine from transport position to working position and vice versa there must be nobody within the swivel range.

• Put the machine down only in working position and with support jacks extended on solid and level ground.

• Switch off the engine, remove the ignition key and secure the forage harvester against the possibility of rolling back.

• Wait until all machine parts have come to a complete stop.

• Before working under or on the raised header, support the header securely.

• Fully swivel up the maize header.

Note

Stop the machine.

Moving support jacks on right/left into parking position

2 2

5

1

1 4

3

2 3

EC400049

Fig. 21

Rear support jacks on the right/left:

• Remove the spring locking pins (2) and pull out the rear support jacks (1).

• Secure the position by means of the spring locking pins (2).

EC400050

Front support jacks on the right/left:

• Remove the front support jacks (3) from the insert pockets (4) and place them in the front holding fixture.

• Secure the position by means of the spring locking pins (2).

• Lower the maize header (5) onto the ground with the forage harvester hydraulics.

Notice

Make sure that the maize header is supported by all four support jacks after it has been lowered. If it is not, raise the maize header via forage harvester hydraulics and look for another place to put it down.

66

7.4.2

Start-up - CLAAS

Removing Hydraulic Lines

Caution! - Danger of accident and damage!

Lay the hydraulic hoses (1) and the electrical connection line (2,3) on the maize header.

Note

Before disconnecting the hydraulic hoses (1), depressurise the system on both sides.

2 3 1

7.4.3

EC400074_1

Fig. 22

• Disconnect the hydraulic lines (1) from the hydraulic couplings and close off with dust caps.

• Detach the lighting cable (2).

• Remove the cable (3) for the electrically switchable hydraulic valve from the cable harness separating point next to the hydraulic connections.

Connecting

2 4 3

5 6

7

1 8

EC400087

Fig. 23

• Remove the linch pin (5) and swivel the lever (6) outwards.

• Lower the intake housing (1) until the holding brackets (3) are positioned under the receiving pockets (4) of the maize header.

67

Start-up - CLAAS

7.4.4 Type 491, type 492

1 2 5 6

7.4.5

4 3

EC400085_1

Fig. 24

• Open the guard sheet (3).

• Disconnect the supporting chain of the universal shaft guard from the support (1).

• Pull the universal joint (4) off the gearbox of the maize header.

• Pull the universal joint (2) off the drive journal of the forage harvester gearbox.

• Put the universal shaft aside for re-assembly.

• Move the forage harvester back.

• Swivel the lever (6) inwards and mount the linch pin (5).

EC400141

Type 493, Type 494, Type 496, Type 497, Type 498

2

1

EC400090

Fig. 25

When lowering the header, the clutch disc (2) of the header and the coupling journal (1) of the forage harvester separate.

• Reverse the forage harvester.

• Swivel the lever (6) inwards and mount the linch pin (5).

68

8

Driving and Transport

Driving and Transport

Danger! - Road travel, carrying passengers, driving conduct

Effect: Danger to life, injuries or damage to the machine.

• It is forbidden to carry passengers on the machine.

• The protective equipment must be attached for transportation on public highways.

• When driving on roads, observe the conditions / requirements of the Road Traffic Type

Approval Law (StVZO) and the Road Traffic Law (StVO).

• The driving speed of the forage harvester must to be adapted to local conditions.

• On public streets and highways, the maize header EasyCollect 600-3, FP, 750-3 FP,

900-3 FP must always be in the transport position.

Note

Operating licence

In case of self-propelled work machines, the headers must be included in the operating licence of the work machine (if necessary extend the operating licence). The conditions of the operating permission must be complied with.

Bedienbox

Notice

There is a fuse in the operation panel. If the operation panel does not function, contact your

KRONE dealer

3

2

A

B

1

EC400098

Fig. 26

If the Claas forage harvester (depending on type) only has one double-acting control unit, the function change between “Fold side part” and “Fold plant divider” is controlled via an electrically switchable hydraulic valve on the header.

The electrically switchable hydraulic valve is switched via an operation panel (1) in the cabin.

• To control the hydraulic cylinders for the side parts, move the switch (2) to the position “B”.

For monitoring purposes the LED (3) goes out.

• To control the hydraulic cylinders for the plant divider, move the switch (2) to the position

“A”. For monitoring purposes the LED (3) goes out.

69

Driving and Transport

8.1 Preparing the machine for road travel

1

8.2

EC400091

Fig. 27

Prerequisite:

• Soiling and crop residue have been removed from the machine, in particular from the lighting and identification elements.

Fold up the maize header for transportation/to drive on the road

• Swing the plant divider upwards into transport position.

• Fold side parts right/left into transport position.

• Switch off the engine and remove the ignition key.

• Push in the support jacks on right/left into transport position (refer to chapter Operation,

"Support jacks right/left in transport position").

• Mount guards right/left and front guards (refer to chapter Operation "Mounting guard right/left" or "Mounting front guard").

• The reflector holder (1) must not protrude beyond the front guard of the machine, adjust the reflector holder if necessary.

• Connect the lighting, (refer to chapter Operation "Connecting direction indicator lamps and front position lamps on right/left").

Switching off the machine

1

2

2

Fig. 28

• Set the maize header (1) in working position down on solid and level ground with the support jacks (2) extended and park it in a dry and clean place, see the chapter on

Operation, "Bringing support jacks right/left into support position".

2

70

8.3

Driving and Transport

Lifting the machine

Warning! - Slings and transportation equipment are inadequately dimensioned.

Effect: Danger to life, serious injuries or serious damage to the machine

Only use sufficiently dimensioned slings and transportation equipment (crane, ropes)!

EasyCollect 750-3 FP, EasyCollect 900-3 FP

Before raising the machine, secure the locking bolt (1) by means of the linch pin (2).

EasyCollect 600-3 FP

Before raising the machine, secure the upper side part with the angle sheet (3) and the screw

(4) on the lower side part.

1

EC600-3 FP

4

2 3

Fig. 29

• For transporting from one place to another onsite, (e.g. loading) brace the lifting tool against the illustrated points.

Note

Check the chain length!

71

Operation

9 Operation

9.1

9.1.1

From transport into working position

Warning! - Lowering the machine into working position

Effect: Danger to life, injuries or damage to the machine.

• Do not lower the machine until you are absolutely sure that there are no persons, animals or objects within the swivel range of the machine.

• Instruct persons to leave the danger zone. If people approach the danger zone, immediately switch off the machine.

• Never allow the machine to run unsupervised.

• Before using the machine, always check the safety devices. Immediately replace damaged safety devices.

• Do not work on the header until the engine has been shut down and the ignition key has been removed. All operating levers should be in neutral position and all hydraulic lines depressurised.

• Before using the machine and after striking an object, always check the header. Worn, damaged or deformed blades must be replaced immediately. The same applies to fastening parts.

• Do not switch on the drive until the header has been folded down into the working position.

Removing the protective cover

6

5

4

EC400092

Fig. 30

• Shutdown and safeguard the machine, refer to operating instructions of forage harvester.

• Remove lighting cable.

• Loosen the tension springs of the side guards (1,2) from the machine.

• Tilt the side guards (1,2) to the front.

• Remove the linch pin (4) and take the side guard (1,2) out of the insert pockets (5).

• Remove the front guard (3).

72

9.1.2 Support jacks right/left in transport position

Note

Stop the machine.

2 2

4

Operation

1

1

3

2

3

EC400046 EC400047

Fig. 31

Support jacks at rear on right/left:

Notice

Make sure that the support jacks (1) are pushed in and secured with the spring cotter pins (2) before switching to working position.

Support jacks at front on right/left:

Notice

Make sure that the support jacks (3) are in the insert pockets (4) on the pendulum frame and secured with the spring cotter pins (2).

73

Operation

9.1.3 Swinging the right-hand / left-hand side parts into working position

6 7 7

5

6

5

1 2

EC400081

Fig. 32

On machines of the EasyCollect series 600-3 FP and 750-3 FP, the left side part is lowered first. Then the left tubular bar swivels upwards and the left securing pin moves out. After that the right side part is lowered. When the right side part has been lowered, the right tubular bar swivels upwards and the right securing pin extends.

Lowering

Do not lower the side parts until the forage harvester is at a standstill.

The plant divider must be in the highest transport position. Then you can be sure that the plant divider does not collide with the cabin.

Lower the side parts via forage harvester hydraulics.

To do this:

• Press and hold down the actuation key for lowering the side parts until the side parts are folded down, the tubular bars are folded up and the securing pins are extended.

After lowering

To ensure that the securing pins are in the guides on right and left:

• Press the actuation key for lowering the side parts for 2 seconds.

Notice

To control and operate the maize header, see the operating instructions for the forage harvester.

74

9.1.4

Operation

Locking Oscillating Movement of Header

WARNING! - If the header oscillates during road travel, people may be injured by the movement.

The header must be locked so that it is unable to oscillate.

• Make sure during road travel that the pendulum locking is positioned between the tension springs and prevents oscillation of the header.

The header is features a pivoting bearing. The oscillating movement is only possible for field mode and is locked for road travel.

1

1

2

3

2

3

4

4

EC400077 EC400078

Fig. 33

To lock the oscillating movement:

• Move the plant divider (1) to the transport position.

The pendulum locking (3) moves between the pendulum springs (4) via a linkage (2) so that the header is locked.

To release the oscillating movement:

• Move the plant divider (1) to the working position.

The linkage (2) moves the pendulum locking (3) to the front and releases the pendulum springs

(4) so that the header is able to oscillate.

75

Operation

9.1.5 Swinging the plant divider into working position

CAUTION! - The plant divider may collide with the cabin

Effect: Property damage

• When raising the plant divider to the transport position, ensure that the plant divider does not collide with the cabin of the forage harvester, even when driving through bumps.

Fig. 34

• Swivel the plant divider (1) via the hydraulic cylinder (2), by controlling the hydraulic valve to lower the plant divider to the working position, refer to chapter Driving and Transport,

“Operation Panel”.

Notice

To control and operate the maize header, see the operating instructions for the forage harvester.

Note

Adjust the plant divider (1) in height to the crop to be harvested so that the upper plant parts are guided by the tubular bars when being drawn into the foraging unit.

76

9.2

9.2.1

Operation

Using the Machine for Work

Warning! - Lowering the machine into working position

Effect: Danger to life, injuries or damage to the machine.

• Do not lower the machine until you are absolutely sure that there are no persons, animals or objects within the swivel range of the machine.

• Instruct persons to leave the danger zone. If people approach the danger zone, immediately switch off the machine.

• Never allow the machine to run unsupervised.

• Before using the machine, always check the safety devices. Immediately replace damaged safety devices.

• Do not work on the header until the engine has been shut down and the ignition key has been removed. All operating levers should be in neutral position and all hydraulic lines depressurised.

• Before using the machine and after striking an object, always check the header. Worn, damaged or deformed blades must be replaced immediately. The same applies to fastening parts.

• Do not switch on the drive until the header has been folded down into the working position.

Field mode on slopes

EC400135

Fig. 35

• Do not change the maize header from transport position to working position or from working position to transport position as long as the machine is used across a slope.

77

Operation

9.2.2 Insert the maize header

Note - clean cut

• The collector speed must be set as high as required to ensure a clean cut of crops.

• The driving speed is based primarily on the throughput of the forage harvester.

• Move maize header into working position and lower it to the ground or to the required cutting height (with active "Lifting unit bearing pressure control" set the bearing pressure to a maximum of 3%; in doing so, set the bearing pressure so that no continuous brush marks of header can be seen on the field)

• Switch on the maize header drive and adjust it to working speed

• Drive into the crop with the forage harvester.

• The driving and collector speed is based on the particular conditions of usage (ground conditions, height and nature of crops)

Note regarding resonance vibrations

It may happen in headland position while in idle that noises are produced on the machine by resonance vibrations. In this case change the set speed slightly.

Note - Reversing

When reversing it is possible that the collector (design specific) rises up slightly from the bottom blades.

During the subsequent run forward the collector is lowered back on to the bottom blade.

78

9.2.3

Operation

Setting the rotational speed of the maize header

The rotational speed of the maize header can be set by switching the input gearbox and main gearbox to different values.

Eight rotational speed values can be set for the types 491 and 492 by using the two-gear gearbox of the forage harvester.

Four rotational speed values can be set for the types 493, 494, 496, 497.

Pos.

II

II

I

Pos.

H

L

H

Speed

120 %

100 %

83 %

I L 70 %

• Refer to the table for information on the actuating lever position of the input gearbox and main gearbox for the desired area.

• Switch the actuating lever of the input gearbox and main gearbox to the indicated position, see chapter Operation, "Operating main gearbox" and "Operating input gearbox".

Notice

For the CLAAS forage harvester types 491 and 492, it is recommended to use the second gear.

For type 498, the rotational speed of the maize header can be variably adjusted, depending on how the forage harvester is equipped.

CAUTION! – Damage to the maize header when exceeding the maximum permitted drive speed

If the maize header is operated at excessively high drive speed, there is a risk of damage to the maize header.

• Ensure that the maximum permitted drive speed of 750 rpm is not exceeded.

79

Operation

9.2.4 Operating Main Gearbox

Different speeds of the header can be selected when switching the main gearbox.

– Position L = low speed

– Position H = high speed

2

1

3

L H

EC400071 EC400070_2

Fig. 36

To switch the main gearbox:

• Put a spanner W/F 24 (1) on the shaft (2) of the input gearbox and move it back and forth during the switching process.

• Swivel the actuating lever (3) of the main gearbox to the other side.

80

9.2.5 Operating Input Gearbox

Different speeds can be selected when switching the input gearbox.

– Position I = lower speed

– Position II = higher speed

2

1

Operation

EC400071

Fig. 37

To switch the input gearbox:

• Put a spanner W/F24 (1) on the shaft (2) of the input gearbox and move it back and forth during the switching process.

3

II

3

4 I

EC400072_3

Fig. 38

• Unscrew the wing screw (3) with detent edged washer.

• Swivel the actuating lever (4) of the input gearbox to the other side.

• Mount the wing screw (3) with the detent edged washer.

EC400073_2

81

Operation

9.2.6 Operating row detection (for the version with “row detection”)

For Claas forage harvesters of type 494 and later

Using row detection permits the forage harvester to be guided automatically between 2 rows of thin-stemmed plants.

1 1

2 2

EC903098

Fig. 39

The "CLAAS AUTO PILOT" takes over automatic guidance of the forage harvester between 2 rows of thin-stemmed plants using the row tracers (2) on the maize header. notice

Incorrect row detection due to contamination of the central tip in the area (1) of the row detection paddles.

The central tip must be clean in the area (1) of the row detection paddles.

1 2

Fig. 40

Prerequisite in order to use the row detection with the forage harvester:

– The forage harvester is fitted with the "CLAAS AUTO PILOT" system for using the row detection.

– The accessories kit B338 "Row detection CL" is mounted.

– The plug connection (1) for the sensor system is connected to the socket (2) on the forage harvester.

• Follow the operating instructions for the forage harvester, in particular the chapter on operation of the "CLAAS AUTO PILOT".

82

9.2.7

Operation

Operating active ground contour (for the version with “active ground contour”)

For Claas forage harvesters from type 494.

By using the active ground contour, the cutting height of the header always remains constant.

2

1

EC500010

Fig. 41

When the ground contour is active, the ground tracers (1) scan the ground under the header.

The unevenness of the ground is compensated by the forage harvester in the direction of travel and at right angles to the direction of travel by the hydraulic cylinder (2) on the intermediate frame of the header.

Notice

The active ground contour constantly controls the stubble height (up to max. approx. 500 mm) relative to the ground as long as the ground tracers have sufficient contact with the ground.

1 2 3 4

6 5

Fig. 42

Prerequisite in order to use the active ground contour with the forage harvester:

– The forage harvester is equipped with the Class AUTO CONTOUR system.

– The accessories kit B338 “Row detection CL” and the accessories kit B341 “Active ground contour CL494-498” are mounted.

– The plug connection (1) for the sensor system is connected to the socket (2) of the forage harvester, refer to chapter Operation “Operating row detection”.

– The hydraulic hose II (6) is connected to the plug-in connector (3), or to the screw coupling of the forage harvester.

– The hydraulic hose I (5) is connected to the plug-in connector (4) or to the screw coupling of the forage harvester.

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of the cutting height control.

83

Operation

9.3 Switching from working position to transport position

Notice

Switch off the drive before folding into the transport position. The maize header may only be folded in when the drive is at a complete standstill.

Note

Side parts must only be swivelled when the forage harvester is at a standstill!

9.3.1 Swinging the plant divider into transport position

2

1

EC400079_1

Fig. 43

To ensure that the plant divider (1) does not collide with the cabin (2) in the transport position:

• Only raise the header as far as necessary so that the space between the plant divider (1) and the cabin (2) is sufficient, even in case of bumps.

Notice

To control and operate the maize header, see the operating instructions for the forage harvester.

84

9.3.2

Operation

Swinging the right hand / left hand side parts upward into transport position

Caution! – Plant divider is not in transport position

Effect: Damage to the machine

• Before swinging up the side parts (1, 2), make sure the plant divider (4) is in transport position.

4

1 2

EC400083_2

Fig. 44

• Swivel up the side parts (1,2) to the transport position by pressing the actuation keys for swivelling the side parts.

Note

The hydraulic procedure of the folding up process of the side parts is predetermined by the hydraulic control. First, the tubular bars on the right and left-hand sides will swivel downward.

Then, the right-hand side part is lifted followed by the left-hand side part.

• Press and hold down the key for swivelling the side parts until the side parts are fully folded in.

• Swing up the maize header with the forage harvester hydraulics to the extent that there is enough ground clearance for road travel.

Notice

To control and operate the maize header, see the operating instructions for the forage harvester.

85

Operation

9.3.3 Installing the front guard

6 6 7

4

5

1

6

2

3

EC400089

Fig. 45

• Immobilize forage harvester and engage parking brake

• Slide the front guard (1,2) onto the tips (3,4,5) and secure it with tension springs (6)

• Route the lighting cable (7) properly and connect it to the socket (8) provided on the forage harvester

8

EC400084_1

Fig. 46

Caution! - Lighting cables not laid properly.

Effect: Lighting system no longer functions.

• Position the lighting cable so that it will not come in contact with the cutter blades.

86

1

3

6

Operation

6

7

5

2

4 6

EC603006

Fig. 47

• Insert the bolts of the side guards (2) into the hole pattern (4) of the insert pockets (3) (the side guards must be held tilted to the front in this process) (right and left machine side)

• Swing up the side guards (2) and secure them with cotter pin (5) (right and left machine side)

• Fasten the guard cloth (7) with tension springs (6) on the parking jack or on the frame (right and left machine side)

87

Operation

9.4

9.4.1

Detaching the machine

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

• There must be nobody between the forage harvester and the header.

• When swivelling the machine from transport position to working position and vice versa there must be nobody within the swivel range.

• Put the machine down only in working position and with support jacks extended on solid and level ground.

• Switch off the engine, remove the ignition key and secure the forage harvester against the possibility of rolling back.

• Wait until all machine parts have come to a complete stop.

• Before working under or on the raised header, support the header securely.

• Fully swivel up the maize header.

Note

Stop the machine.

Moving support jacks on right/left into parking position

2 2

5

1

1 4

3

2 3

EC400049

Fig. 48

Rear support jacks on the right/left:

• Remove the spring locking pins (2) and pull out the rear support jacks (1).

• Secure the position by means of the spring locking pins (2).

EC400050

Front support jacks on the right/left:

• Remove the front support jacks (3) from the insert pockets (4) and place them in the front holding fixture.

• Secure the position by means of the spring locking pins (2).

• Lower the maize header (5) onto the ground with the forage harvester hydraulics.

Notice

Make sure that the maize header is supported by all four support jacks after it has been lowered. If it is not, raise the maize header via forage harvester hydraulics and look for another place to put it down.

88

9.4.2

Operation

Removing Hydraulic Lines

Caution! - Danger of accident and damage!

Lay the hydraulic hoses (1) and the electrical connection line (2,3) on the maize header.

Note

Before disconnecting the hydraulic hoses (1), depressurise the system on both sides.

2 3 1

9.4.3

EC400074_1

Fig. 49

• Disconnect the hydraulic lines (1) from the hydraulic couplings and close off with dust caps.

• Detach the lighting cable (2).

• Remove the cable (3) for the electrically switchable hydraulic valve from the cable harness separating point next to the hydraulic connections.

Connecting

2 4 3

5 6

7

1 8

EC400087

Fig. 50

• Remove the linch pin (5) and swivel the lever (6) outwards.

• Lower the intake housing (1) until the holding brackets (3) are positioned under the receiving pockets (4) of the maize header.

89

Operation

9.4.4 Type 491, type 492

1 2 5 6

9.4.5

4 3

EC400085_1

Fig. 51

• Open the guard sheet (3).

• Disconnect the supporting chain of the universal shaft guard from the support (1).

• Pull the universal joint (4) off the gearbox of the maize header.

• Pull the universal joint (2) off the drive journal of the forage harvester gearbox.

• Put the universal shaft aside for re-assembly.

• Move the forage harvester back.

• Swivel the lever (6) inwards and mount the linch pin (5).

EC400141

Type 493, Type 494, Type 496, Type 497, Type 498

2

1

EC400090

Fig. 52

When lowering the header, the clutch disc (2) of the header and the coupling journal (1) of the forage harvester separate.

• Reverse the forage harvester.

• Swivel the lever (6) inwards and mount the linch pin (5).

90

10

10.1

Settings

Settings

Warning!

– When performing repair, maintenance or cleaning work on the machine, or in the case of technical intervention, drive elements may start moving.

As a result, people may be seriously or fatally injured.

• Switch the drive off and wait until all machine parts have come to a standstill and completely cooled down.

• Switch off the engine of forage harvester, pull off the ignition key and take it with you.

• Secure the forage harvester against unexpected start-up and rolling away.

• Switch off the PTO shaft and disconnect it.

• When working under the machine or on the raised machine, always make sure that it is securely supported. Close the stop cock at the forage harvester!

• Do not perform any work on the hydraulic system unless it is depressurised. Hydraulic liquid escaping under high pressure can penetrate through the skin and cause severe injuries.

• Avoid skin contact with oils, greases, cleaning agents and solvents.

• In the event of injuries or burns caused by oils, cleaning agents or solvents, contact a physician immediately.

• All other safety notices must also be followed to avoid injuries and accidents.

• After the repair, maintenance, cleaning work or technical modifications are completed, mount all protective covers and safety devices properly again.

Setting Tubular Bars

1

2

EC903071_1

Fig. 53

The tubular bars (1) on the right and left are used to guide the maize plants. The tubular bars can be adjusted to the height of the plants.

To do this:

• Swivel the tubular bars (1) into working position

• Loosen the screw connections (2) and mount the tubular bars in the desired position

• Tighten the screw connections (2)

91

Settings

10.1.1 Increased Centre of Gravity of the Plants

1

10.1.2

2

To do this:

• Swivel the tubular bar (1) into transport position

• Mount and tighten additional screw (2) (right and left sides of the machine)

• Swivel the tubular bar (1) into working position

EC903072_1

Fig. 54

In case of an increased centre of gravity of the plants it may be advisable to limit the tubular bar when swivelling into working position, to ensure that the tubular bar is inclined slightly forward to press the plants to be cut slightly into the crop.

Adjusting reflector holder

1

3

II

2

I

EC400066

Fig. 55

The reflector holder (1) on the tubular bar can be adjusted laterally.

To do this:

• Pull the spring-loaded reflector holder forwards (I) and swivel to the side (II).

When the required position has been reached:

• Release the reflector holder, ensuring that the reflector holder is held by the roll pin (3) in one of the notches (2).

92

10.2 Adjusting holding-down device roller

1

2

I II

Settings

10.2.1

I II

EC400023

Fig. 56

The holding-down roller (1) is mounted as standard in position (I). The holding-down roller can be adjusted to match the height of the plants.

To do this:

• Loosen screw connections (2) and shift holding-down device roller to position (II).

Adjusting the sliding skid

Note

The skid height must be adjusted to the tyre sizes of the forage harvester so that the rear area of the skids is still flat on the ground.

The position of the ground skid also affects the cutting height. Adjust all skids equally.

2

2

1

I

EC400053

Fig. 57

• Lift front attachment

• Observe the hazard warnings at the beginning of the chapter.

• Loosen screw connections (2) and mount the ground skid (1) in the required position (I).

• Tighten screw connections

93

Settings

10.3 Adjusting the oscillation of the header

The header is able to adapt to the ground contour of the field due to the oscillating movement.

The height of the header is permanently aligned relative to the ground via the sliding skids.

The pendulum springs (1) counteract the oscillating movement of the header and thus dampen the oscillating movement.

The design of the pendulum spring case with an inner and an outer pipe ensures that during oscillation, the movement takes place in the respective opposite oblong hole (9).

1 Z 2 3 4 5 6

7

9

8

EC400110_2

Fig. 58

Move the pendulum compensation to its initial position:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Remove the screw connection (8).

• Tighten the feed shaft (7) hand-tight.

• Tighten the feed shaft (7) by 4 further rotations and then ensure that the feed shaft (7) can be secured against turning using the screw (8).

• Secure the feed shaft (7) against turning using the screw (8) and mount the screw connection (8).

• Tighten the nut (5) on the bar (6) hand-tight.

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Loosen the counter nut (4).

• Loosen the counter nut (3).

94

1 Z 2 3 4 5

Settings

6

7

9

8

EC400110_2

Fig. 59

If the oscillation movement of the header is too smooth or too hard, the force of the pendulum springs (1) which counteract the oscillation of the header can be adjusted.

To do this, perform the following on both sides of the machine:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Remove the screw connection (8).

To reduce the force for the pendulum compensation:

• Loosen the feed shaft (7). At the same time, ensure that the nut (2) connected with the inner spring casing does not twist.

To increase the force for the pendulum compensation:

• Tighten the feed shaft (7) further. At the same time, ensure that the nut (2) connected with the inner spring casing does not twist.

When the pendulum springs have been adjusted:

• Secure the feed shaft (7) against twisting using the screw (8) and mount the screw connection (8).

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Loosen the counter nut (4).

• Loosen the counter nut (3).

95

Maintenance

11 Maintenance

11.1

11.1.1

11.2

Special Safety Instructions

Danger! - When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving (caution, cutters continue to run).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against accidental start-up and against rolling away.

• When working under or with the machine raised, always secure it with suitable supporting elements.

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

Test run

Danger! - Testing the machine after repair, maintenance or cleaning work and after technical intervention.

Effect: Danger to life or serious injuries

• The machine must be in working position

• Do not switch on the drives until the machine is in cutting height and you are absolutely sure that neither persons, animals nor objects are in the danger zone.

• Start a trial run of the machine from the driver’s seat only.

Spare Parts

Warning! - Using non-approved spare parts.

Effect: Danger to life, serious injuries or loss of warranty claims as well as exclusion of liability

• Use only authentic KRONE spare parts and accessories authorised by the manufacturer.

The use of spare parts, accessories or additional equipment not manufactured, tested or approved by KRONE will exclude any liability for consequential damage.

96

11.3

Maintenance

Maintenance table

Note

To ensure problem-free operation of the machine and to reduce wear and tear, specific maintenance and upkeep intervals must be observed. These include cleaning, greasing, lubricating and oiling parts and components.

Maintenance work Maintenance interval

Blade

Check fixed blades (bow blade, stepped blade, tip blade) and replace damaged or bent blades.

Check cutting blades (collector blades), replace damaged or bent blades.

Collector

Check collector tension.

Check whether the collector rests on the fixed blades. 1

Check insertion fingers, replace damaged or bent insertion fingers.

Tighten screws/nuts

Check if the screws on the swivel-joint of the side parts (left and right) are seated firmly.

Check all other screws. gearbox

X

X X

X

X

X

X

X

X

X

Leakage check

Oil level check

Oil change

Cleaning the machine

X

X

Check the soiling in the collector compartment (inside) and clean it, if necessary.

Coupling

Check coupling for wear.

X

X

X

Hydraulic hoses

Check the hydraulic hoses for leaks and, if necessary, have them replaced by a KRONE service partner.

X

Lubricate machine according to lubrication chart

1 To do this, move the machine to the working position and let it run forwards for approx. 1 minute.

X

97

Maintenance

11.4 Tightening torques

11.4.1 Metric Thread Screws with Control Thread

M4

M5

M6

M8

M10

M12

M14

M16

M20

M22

M24

M27

M30

NOTICE

The table does not apply to countersunk screws with hexagonal socket in case the countersunk screw is tightened via hexagonal socket.

Tightening torque in Nm (unless otherwise stated)

A = thread size

(stability class can be seen on screw head)

A

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

3.0 4.4 5.1

5.9

10

8.7

15

10

18

29

42

25

49

85

36

72

125

43

84

145

135 200 235

210 310 365

425 610 710

571 832 972

730 1050 1220

1100 1550 1800

1450 2100 2450

Note

Regularly check that nuts and bolts are tightly in place (approx. every 50 hours) and tighten them if necessary.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

98

11.4.2

11.4.3

Maintenance

Metric Thread Screws with Fine Thread

Tightening torque in Nm (unless otherwise stated)

A

Stability class

5.6 8.8 10.9 12.9

A = thread size

(stability class can be seen on screw head)

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M24 x 2

M27 x 2

M30 x 1.5

Tightening torque (Nm)

88 130 152

145 213 249

222 327 382

368 525 614

465 662 775

787 1121 1312

1148 1635 1914

800 2100 2650

Metric Thread Screws with Countersunk Head and Hexagonal Socket

M4

M5

M6

M8

M10

M12

M14

M16

M20

NOTICE

The table applies only to countersunk screws with hexagonal socket and metric thread which are tightened via hexagonal socket.

Tightening torque in Nm (unless otherwise stated)

A = thread size

(stability class can be seen on screw head)

A

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

2.5 3.5 4.1

4.7

8

7

12

8

15

23

34

20

39

68

29

58

100

35

67

116

108 160 188

168 248 292

340 488 568

A

BM 400 0234

Note

Regularly check that nuts and bolts are tightly in place (approx. every 50 hours) and tighten them if necessary.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

99

Maintenance

11.4.4 Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes

This table applies only to locking screws with external hex in connection with copper seal ring for bleed valves made of brass with shaped seal ring.

Thread Locking screw and viewing glass with copper ring*)

Ventilation/breather filter made of steel

Bleed valve made of brass

Ventilation and breather filter made of brass

Aluminium

M10x1

M12 x 1.5

Steel and cast Aluminium Steel and cast

Maximum tightening torque (Nm) (±10%)

8

14

G1/4“

M14 x 1.5

M16 x 1.5 45

M18 x 1.5 50

M20 x 1.5

G1/2“

M22X1.5

M24x1.5

40

45

14

16

24

30

32

32

35

60

G3/4“

M33x2

G1“

M42x1.5

G1 1/4“

*) Always replace copper rings

60

80

80

100

100

24

30

NOTE

The tightening torques only apply to assembly of locking screws, viewing glasses, ventilation and breather filters and bleed valves in gearboxes with cast housings or aluminium or steel housings. The term “locking screw” includes the drain plug, the inspection screw as well as the ventilation and breather filters.

100

11.5

Maintenance

Input gearbox

Note

Check the oil level, top up oil and drain oil when the gearbox is in the horizontal position.

1

3

4

2

EC400099_1

Fig. 60

1) Filler plug / filling hole

3) Inspection screw / inspection hole

2) Drain plug

4) Guard sheet

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw with the specified tightening torque, refer to chapter

Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes".

If the oil does not reach the inspection hole:

• Unscrew the filler plug.

• Top up oil via the filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug with the specified tightening torque, refer to chapter Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheet.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheet.

101

Maintenance

11.6 Main gearbox

Notice

For oil level check and oil change, the header (collector) must be in horizontal position!

1

2

EC400014

Fig. 61

1) Inspection screw / inspection bore 2) Drain screw

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

102

11.7

Maintenance

Collector gearbox (upper section)

Note

Check the oil level and change the oil while the gearbox is horizontal in the working position of the attachment!

1

2

EC400044

Fig. 62

1) Inspection screw / inspection bore 2) Drain screw

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

103

Maintenance

11.8 Collector gearbox (lower section on centre section)

Note

Check the oil level and change the oil while the gearbox is horizontal in the working position of the attachment!

1

EC400048

Fig. 63

1) Inspection screw / inspection bore

2

2) Drain screw

EC400035

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

104

11.9

Maintenance

Collector gearbox (lower section on side part)

Note

Check the oil level and change the oil while the gearbox is horizontal in the working position of the attachment!

1

2

EC400045

Fig. 64

1) Inspection screw / inspection bore 2) Drain screw

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

105

Maintenance

11.10 Collector pre-tension on the central part (right hand / left hand)

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

5

3

1

2

4

EC903030_3

11.10.1

Fig. 65

Checking the collector pre-tension

11.10.2

Note

Check the collector pretension after the first 10 operating hours, then every 50 operating hours.

• Remove the guard (1)

• The compression spring (2) is correctly pre-tensioned if the washer (4) flushes with the plate

(5).

Correcting the collector pre-tension

• Loosen the counter nut (3).

• Correct the pre-tension (2) of the compression spring until the washer (4) flushes with the plate (5).

• Tighten the counter nut (3).

• Install the guard (1)

106

Maintenance

11.11 Collector pre-tension on the side part (right hand / left hand)

EasyCollect 750-3

3 2

1

6 a

5 4

3 2 5 4

EC400067

11.11.1

Fig. 66

Checking the collector pre-tension

11.11.2

Note

Check the collector pretension after the first 10 operating hours, then every 50 operating hours.

• Remove the plastic cover (1).

• The pressure disc (2) must be set with a= 2 ± 1 mm from the spring housing (3).

• If necessary, correct the collector pre-tension.

Correcting the collector pre-tension

• Disassemble the cover (6).

• Loosen the counter nut (4) and adjust the compression spring by turning the hexagonal nut

(5) until the pressure disc (2) has a distance of 2 ± 1 mm to the spring housing (3).

• Tighten the counter nut (4).

• Install the cover (6).

• Plug the plastic cover (1)

107

Maintenance

EasyCollect 600-3

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

7 9

10

2

1

8

5

6 3 4

EC400068_1

11.11.3

Fig. 67

Checking the collector pre-tension

11.11.4

11.11.5

11.11.6

Note

Check the collector pretension after the first 10 operating hours, then every 50 operating hours.

• Remove the cover (1)

• The disc (8) must rest on the stop plate (9)

• If this is not the case, correct the collector pre-tension

Correcting the collector pre-tension

• Loosen the counter nut (10).

• Tighten the nut (7) until the disc (8) is positioned the stop sheet (9).

• Tighten the counter nut (10).

• Check the collector tensioning function.

Checking the Collector Tensioning Function

• The edge (2) of the spring guide must be between the marks (3) and (4)

• If this is not the case, correct the collector tensioning function

Correcting the Collector Tensioning Function

• Loosen the counter nut (5) and set the spring guide by turning the hexagon nut (6) until the edge (2) of the spring guide has a distance of 8 ±1 mm to the marking (3).

• Tighten the counter nut (5).

• Check collector pre-tension, refer to “Checking collector tension”.

• Mount the cover (1).

108

11.12

Maintenance

Gaps on the centre frame

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

3

I

2 a I

III

1

2 a

II

II 2 b III

4

1

EC903069_1

Fig. 68

Following repair work or cleaning work on the centre frame, the gaps in the areas (I,II and III) must be checked and, if required, re-adjusted.

Gap in area (I) = 0 to 2 mm

Gap in area (II) = 0 to 2 mm

Gap in area (III) = 0 to 3 mm

When adjusting the scrapers/cover sheets, set the gaps as low as possible (almost 0 mm) to ensure that the machine functions as optimally as possible.

Procedure for adjusting the gaps:

Area (I)

The gap "a" between the collector finger (1) and the cover sheet (2) must be a=0–2 mm (on right and left).

• Start by checking gap "a" in area (I) and, if required, adjust dimension a = 0 to 2 mm by loosening the screw connection (3).

• Tighten the screw connection (3)

109

Maintenance

Area (II and III)

The clearance "a" between the collector finger (1) and the cover sheet (2) in area (II) must be a= 0 - 2 mm (on right and left).

The clearance "b" between the collector covers (4) and the cover sheet (2) in area (III) must be b= 0 - 3 mm (on right and left).

5

2 a

I / II

2

1 b III

4

6 7

EC903080_1

Fig. 69

If this is not the case:

• Unscrew cover (5).

• Loosen screws (6). The clearances (a, b) for area (II and III) are adjusted via the bearing rail

(7) by laterally shifting the screws in the oblong hole.

• Tighten screws (6) and re-attach cover (5).

110

11.13

Maintenance

Gaps on the side frame

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

I

2 a

I

II

1

3 2 II b

3

5

4

EC903081

Fig. 70

Following repair work or cleaning work on the side frame, the gaps in the areas (I and II) must be checked and, if required, re-adjusted.

Gap in area (I) = 0 to 3 mm

Gap in area (II) = 0 to 1.5 mm

When adjusting the scrapers/cover sheets, set the gaps as low as possible (almost 0 mm) to ensure that the machine functions as optimally as possible.

Procedure for adjusting the gaps:

Area (I)

The gap "a" between collector covers (1) and cover sheet (2) must be a= 0 - 3 mm in area (I)

(on right and left).

• Start by checking gap "a" in area (I) and, if required, adjust dimension a = 0 to 3 mm by loosening the screw connection (3).

• Tighten the screw connection (3).

Area (II)

The gap "b" between collector finger (4) and cover sheet (2) must be b= 0 - 1.5 mm in area (II)

(on right and left).

• Start by checking gap "b" in area (II) and, if required, adjust dimension b = 0 to 1.5 mm by turning the setting screw (5).

• Secure the setting screw (5) by locking it.

111

Maintenance

11.14

11.14.1

Scraper (right hand / left hand)

Note

The distance between back of the collector (2) and scraper (1) must not exceed dimension

“a = 3 mm”.

Adjusting Scrapers on the Centre Section

Fig. 71

• Slightly loosen the screw connections (3) and adjust the scraper (1) so that the distance is

“ a = 1...3 mm ” between the back of the collector (2) (in the area of the collector bolt (4)) and the scraper (1).

Gap dimensions (b): a+4 7 a 1

112 b

EC903033_1

Fig. 72

The scrapers (1) must be aligned centrally to the collector fingers (5) in area “X”. In area “Y” the gap between the scrapers must be widened conically to the rear (a+4).

Note

If necessary, also align the cover (7) by loosening the screws (6).

• Tighten the screw connections (3) and (6).

11.14.2 Adjusting the scraper on the side part

Maintenance

Fig. 73

• Slightly loosen the screw connections (3) and set the scraper (1) in a way, that the distance between the back of the collector (2) (in the area of the collector bolt) and the scraper (1) is

“a = 1-3 mm”.

Gap dimensions (b):

1

4

EC903035

Fig. 74

Within the range “X” the scrapers (1) must be centrally aligned with the collector fingers (4).

• Tighten the screw joints (3).

Note

The scrapers can exert light contact pressure on the collector fingers (< 1 kg)

113

Maintenance

11.15 Changing the tips

How to change the side tips is described below; the central tip and the row tips are changed similarly.

2 1

3

1

EC903067

Fig. 75

• Detach row registration sensor (on central tip only) from the cable harness

• Remove cheese-head screws (2) and remove tip (1)

• Remove the bearing rings (3) from the tip (1) and insert them into the new tip. If required, renew worn bearing rings (3)

• Mount new tip (1) with cheese-head screw (2) and secure with lock nut

Note

Self-locking nuts must always be replaced.

114

11.16 Adjusting the tips

Maintenance

Fig. 76 a = freely selected ground distance (we recommend a = approx. 20 to 40 cm).

Set the lower edges of the row tips (2) to the same height.

Set the lower edges of the side tips (1) approx. y = 0 to 30 mm higher than the lower edges of the row tips (2).

Set the lower edge of the central tip (3) approx. x = 30 to 50 mm below the lower edges of the row tips (2).

115

Maintenance b

11.16.1

11.16.2 a

2

1

EC903037_6

Fig. 77

Adjusting the side tips

The height of the side tips (a) can be adjusted with the screw (1).

To do this:

• Unscrew the counter nut (2)

• Adjust the height of the tips with the screw (1)

• Tighten the counter nut (2)

Adjusting the row tips

The height of the row tips (b) can be adjusted by moving the sliding piece (3)

To do this:

• Loosen the screw (4).

• Adjust the height of the row tip by moving the sliding piece (3).

• Tighten the screw (4).

4

3

116

11.16.3 Adjusting the central tip

1

2

Maintenance

EC500107

Fig. 78

• Loosen the screw connections (2) slightly.

• Adjust the central tip (1) so that the lower edge of the central tip is approximately x = 30...50 mm below the lower edges of the other tips.

• Tighten the screw connections (2).

117

Maintenance

11.17 Converting Tip Retainer for Special Row Distances

EasyCollect 750-3

To ensure that the maize header can achieve an optimal crop collection result for special row spacings, the outer row tips of EasyCollect 750-3, EasyCollect 900-3 and EasyCollect 1050-3 must be mounted 250 mm to the middle of the machine. The altered position of the row tip means that the cutter blades in this area must also be adjusted.

2 1

EC400100

3 4

EC400101

5

6 7

EC400103 EC400102

Fig. 79

To convert the row tip from the original position (1) to the position for special row spacings (2):

• Remove the cover sheet (3).

• Dismount the outer row tip (4).

• Remove the tip extension (5) from the row tip and keep in a safe place for re-attachment when the row tip is put back in the original position.

• Replace the stepped blade (6) and the V-blade (7).

• Mount the outer row tip (4) in the position for special row spacing.

• Mount the cover sheet (3) on the screwing points vacated at the original position.

118

11.18 Aligning the guide brackets

1

2

Maintenance

3

2

1

EC903048_2

Fig. 80

Notice

Periodically check the guide brackets (1) for proper position and align them as required.

• The guide brackets (1) must be aligned parallel to the collector fingers (2).

• In the front area “X”, the guide brackets (1) must be at a distance of approx. 70 mm and in the rear area “Y” range at a distance of approx. 60 mm from the back of the collector (3).

119

Maintenance

11.19 Releasing star ratchet clutch at the universal shaft

Use the following procedure if a star ratchet clutch on the double joint is actuated at overload during the work process:

• Immediately switch off the header drive of the forage harvester; see operating instructions of the forage harvester.

• Shut down and safeguard the machine, see Safety chapter, "Shutting down and safeguarding the machine".

• Remove the crop blockage.

• When you switch on the header drive of the forage harvester, ensure that the star ratchet clutch is not actuated again.

120

Maintenance

11.20

11.20.1

Blade Changing

DANGER! – Danger from sharp blades!

Serious injuries, in particular to the hands, may occur.

• Wear protective gloves when performing any work on the collector to avoid being cut by the blades.

Note

Always check the blades before use and after driving into an obstacle. Worn, damaged or deformed blades must be replaced immediately.

Note

Before making any adjustments on the blades let the collector run (not reverse) for a short time.

Afterwards, switch drive off and wait until all drive elements have come to a complete stop.

Remove the ignition key, secure the machine against accidental start-up and against rolling.

Note

Clean maintenance area of any dirt and contamination.

Replacing the fixed blades (bow and step blades)

Note

When replacing observe the right / left cutting direction!

1

Fig. 81

• Unscrew the hexagonal head screws (2) and pull out blade (1) to the front.

• Insert the new blade (1) and fasten it with the hexagonal head screws (2).

Note

Use a “high-strength” screw locking agent (for example Loctite).

2

EC903041_2

121

Maintenance

3

EC903042_2

Fig. 82

Note

After replacing the blades, ensure that there are no abutting edges.

If required, adapt the height compensation by removing a compensation plate (3).

3

3

WHBEC0082_2

Fig. 83

122

11.20.2 Replacing the cutting blade on the right hand / left hand side parts

EasyCollect 750-3 FP/ EasyCollect 900-3 FP

Note

When replacing observe the cutting direction right/left, blade short/long!

6

2

Maintenance

1

5

1

4

1

3

EC500133

Fig. 84

• Unscrew the screws (5) and remove the cover (6).

• To dismount the cutting blades (1), unscrew the internal hexagon head screw (2) in the straight area.

• Push up the collector on the stepped blade (4) with mounting lever (3) and first pull the cutting blade (1) downwards off the cam and then remove it to the back.

Installation is in reverse order to removal.

Notice

Tightening torque of hexagon head screws M12 (2) with a strength of 10.9 = 110 Nm.

Tightening torque of hexagon head screws M8 (5) = 45 Nm.

123

Maintenance

EasyCollect 600-3 FP

Note

When replacing observe the cutting direction right/left, blade short/long!

WARNING!

Position the blade to be changed by reversing the machine.

Ensure that no persons are in front of the machine.

1 2

EC400104_1

Fig. 85

• Dismount the cob stopper (1).

• Remove the screws (2) and take off the cover (3).

3

EC400134

124

Maintenance

4

EC400105_1

5

EC400106_1

5

EC400107_1

Fig. 86

• Move the blade (5) to be changed into a position at the front on the machine by reversing the machine.

• Unscrew the hexagon head screw (4) of the blade to be changed.

• Drive the blade (5) downwards out of the collar bushing and remove it towards the rear.

• Insert the new blade from behind and drive it from below into the collar bushing.

• Mount the hexagon head screw (4) and tighten it to 110 Nm.

2 1

3

EC400134 EC400104_1

Fig. 87

• Mount the cover (2).

• Mount the cob stopper (1).

Notice

Tightening torque of hexagon head screws M12 (4) with a strength of 10.9 = 110 Nm.

Tightening torque of hexagon head screws M8 (2) = 45 Nm.

125

Maintenance

11.20.3 Changing cutting blades on the central part right/left

Note

When replacing observe the cutting direction right/left, blade short/long!

WARNING!

Position the blade to be changed by reversing the machine.

Ensure that no persons are in front of the machine.

1 9

7

EC500157_1

2 4

8

3

EC400130

126

6 5

2

EC400129 EC400112

Fig. 88

• Remove the screws (9) and take off the cover (1).

• Dismount the sliding skid (8).

• Move the blade (2) to be changed into a position at the front on the machine by reversing the machine.

• Unscrew the hexagon head screw (7) of the blade to be changed.

• Drive the blade (2) downwards out of the collar bushing and remove it towards the rear.

• Insert the new blade from behind and drive it from below into the collar bushing.

• Mount the hexagon head screw (7) and tighten it to 110 Nm.

• Mount the sliding skid (8).

• Mount the cover (1).

Replacing the roll

• Fit the provided open-end wrench (3) onto the base of the roll (4).

• Insert the extension of a ratchet (5) into the square head hole of the open-end wrench, counter the countersunk screw (6) and tighten the roll with 110 Nm.

Notice

Tightening torque of hexagon head screws M12 (7) with a strength of 10.9 = 110 Nm.

Tightening torque of hexagon head screws M8 (9) = 45 Nm.

11.20.4

Maintenance

Changing scraper blades on the side parts right/left and on the central part

11.21

Fig. 89

• Loosen the hexagon head screw (2)

• Replace the blade (1) and secure it with the hexagon head screw (2) notice

After the screws have been tightened, the scraper blade must be in full (a) contact with the collector blade, without lifting the collector. Check and correct if necessary.

Replacing the wear plates

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

1

1

1

1

EC903057

Fig. 90

Notice

Check wear plates (1) on the right / left side sections and on the middle section 1x weekly for correct fit and wear and, if required, correct or replace.

• Loosen the corresponding screw connection.

• Replace the wear plate.

• Tighten the screws.

127

Maintenance

11.22 Hydraulics

WARNING!

Risk of injury from incorrect handling of liquids under high pressure. Escaping highpressure liquids may penetrate the skin and cause serious injury.

• Repair work on the hydraulic system may only be performed by authorised KRONE professional workshops.

• Depressurise the system before disconnecting lines.

• When working on the hydraulic system, wear personal protective equipment (protective goggles and protective gloves).

• High-pressure liquid that is escaping from a small opening is virtually invisible. Therefore, use suitable aids when searching for leaks (for example a piece of cardboard).

• If liquid penetrates the skin, consult a doctor immediately. The liquid must be removed from the body as quickly as possible. Danger of infection! Physicians who are not familiar with this area must consult appropriate information from a competent medical source.

• Check the hydraulic hoses at regular intervals and replace them if damaged or worn! Only original KRONE spare parts are permitted to be used as replacement lines as they correspond to the technical requirements of the manufacturer.

• Before the pressure in the system builds up again, ensure that all line connections are tight.

128

11.22.1

–

Hydraulic diagram

3) Verriegelung links 4) Verriegelung rechts

1) Pflanzenteiler 2) Rohrbügel links 5) Rohrbügel rechts

Maintenance

7) Seitenteil rechts klappen

6) Seitenteil links klappen

11) 27-017-407-0

6/2-Wegeventil

13)

14)

14)

13)

Einklappen

Ausklappen

Ausklappen

Einklappen

10) Die 2/2Wegeventile sind im Zylinderboden eingeschraubt. DasVentil wird mechanich vom

Kolben betätigt, der Schaltpunkt liegt ca. 15 mm vor der hinteren Endlage des Kolbens.

8) 27-010-333-1

Steuerblock Ein-/Ausklappen

9) 27-011-730-0

Druckzuschaltventil DZ5E

15) bei Ausführung „Aktive Bodenkopierung“

12) Druckstromversorgung vom Feldhäcksler

Fig. 91: The working position is shown.

1) Plant divider 2) Tubular bar left

4) Locking right 5) Tubular bar right

7) Fold side part right 8) Control block

Fold in/out

9) Pressure supply valve

DZ5E

10) The 2/2 directional valves are screwed in the cylinder base. The valve is operated mechanically by the piston, the switching point is approximately 15 mm in front of the rear end position of the piston.

11) 6/2 directional valve 12) Pressure flow supply

from forage harvester

13) Fold in

14) Fold out 15) for the version with

“active ground contour”

3) Locking left

6) Fold side part left

129

Maintenance

11.22.2 Check hydraulic hoses

250 BAR 43/2010

250 BAR 43/2010

EFL000026

Fig. 92

Hydraulic hoses are subject to natural ageing. This limits their service life. The recommended service life is 6 years, including a maximum storage time of 2 years. The date of manufacture is printed on the hydraulic hoses. When checking hydraulic hoses, the state-specific conditions

(e.g., BGVU) must be observed.

Perform a visual inspection

• Visually inspect all hydraulic hoses for damage and leaks and have them replaced by an authorised specialist if necessary.

130

12

12.1

Maintenance – lubrication chart

Maintenance – lubrication chart

Special Safety Instructions

Warning!

– When performing repair, maintenance or cleaning work on the machine, or in the case of technical intervention, drive elements may start moving.

As a result, people may be seriously or fatally injured.

• Switch the drive off and wait until all machine parts have come to a standstill and completely cooled down.

• Switch off the engine of forage harvester, pull off the ignition key and take it with you.

• Secure the forage harvester against unexpected start-up and rolling away.

• Switch off the PTO shaft and disconnect it.

• When working under the machine or on the raised machine, always make sure that it is securely supported. Close the stop cock at the forage harvester!

• Do not perform any work on the hydraulic system unless it is depressurised. Hydraulic liquid escaping under high pressure can penetrate through the skin and cause severe injuries.

• Avoid skin contact with oils, greases, cleaning agents and solvents.

• In the event of injuries or burns caused by oils, cleaning agents or solvents, contact a physician immediately.

• All other safety notices must also be followed to avoid injuries and accidents.

• After the repair, maintenance, cleaning work or technical modifications are completed, mount all protective covers and safety devices properly again.

The information on maintenance intervals is based on average load of the machine. In case of an increased load and under extreme working conditions, the time periods must be reduced.

The types of lubrication are marked by means of icons in the lubrication chart, refer to table.

Type of lubrication

Lubricant Note

Greasing Multi-purpose grease

Lubrication

Oiling

Multi-purpose grease

– Apply two strokes of lubricating grease from the grease gun per grease nipple.

– Remove excess lubricating grease at the grease nipple.

– Remove old lubricating grease.

– Apply a thin layer of new lubricating grease by means of a brush or spray can.

– Remove excess lubricating grease.

– Distribute the oil evenly. Unless otherwise prescribed, use oils based on vegetable matter.

131

Maintenance – lubrication chart

12.1.1 Lubrication Chart

• The lubrication points mentioned below must be lubricated according to the operating hours indicated.

50 h

50 h

50 h 50 h

25 h

25 h

250 h

250 h

25 h

250 h

250 h

25 h

250 h

50 h EC400025_2

Fig. 93:

50 h

132

250 h 250 h

Maintenance – lubrication chart

50 h

Fig. 94:

Only for EasyCollect 600-3 and EasyCollect 600-3 FP

EC400111_1

Fig. 95

250 h

EC603009_1

133

Placing in Storage

13 Placing in Storage

• Park the machine in a dry location, but not in the vicinity of artificial fertilisers or livestock buildings.

• Before placing the machine in winter storage, clean inside and outside thoroughly. If you use a high-pressure cleaner to do this. do not keep a stream of water directed at bearing points. After cleaning is completed, lubricate all lubrication points. Do not wipe off any grease that comes out of bearing points. The hardened grease will provide additional protection against moisture.

• Disassemble the PTO shaft. Lubricate the inner tubes and the guard tube with grease.

Grease the lubrication points on the cross joint and on the bearing rings of the guard tubes.

• Oil all joint points!

• Touch up damaged paint and preserve all uncoated areas thoroughly with rust protection agent.

• Check all movable components such as deflector rollers, joints, tension rollers, etc. to make certain they move easily. If necessary remove, clean, grease and remount. If necessary, replace with new parts.

• Use only original KRONE replacement parts.

Perform the necessary repair tasks during the time immediately after the harvest season. Draw up a list of all replacement parts you will need. This will make it easier for your KRONE dealer to process your orders and you will be certain that your machine will be ready for use at the beginning of the next season.

134

14

14.1

Before the Start of the New Season

Before the Start of the New Season

Special Safety Instructions

DANGER! - When performing repair, maintenance or cleaning work on the machine, or in the case of technical intervention, drive elements may start moving.

Effect: Danger to life, injuries or damage to the machine.

• Switch off forage harvester engine and remove the ignition key.

• Secure forage harvester against accidental start-up and rolling away.

• Switch off PTO shaft and disconnect it.

• Before working under or on the raised machine: Secure machine or machine parts with hydraulic shut-off device (e.g. stop cock) on machine side against lowering, refer to operating instructions of forage harvester!

• After the repair, maintenance, cleaning work or technical modifications are completed, mount all protective covers and safety devices properly again.

• Do not perform any work on the hydraulic system unless it is depressurised. Liquid escaping under high pressure can penetrate through the skin and cause severe injuries.

• Avoid skin contact with oils, greases, cleaning agents and solvents.

• In the event of injuries or burns caused by oils, cleaning agents or solvents, contact a physician immediately.

• All other safety instructions must also be followed to avoid injuries and accidents.

Danger! - When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving (caution, cutters continue to run).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against accidental start-up and against rolling away.

• When working under or with the machine raised, always secure it with suitable supporting elements.

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

135

Before the Start of the New Season

14.2 Test run.

Danger! - Testing the machine after repair, maintenance or cleaning work or after technical intervention.

Effect: Danger to life or serious injuries

• Machine must be in the working position

• Do not switch on the drives until the machine is at cutting height and you are sure that there are no people, animals or objects in the danger zone.

• Start a test run of the machine from the driver’s seat only.

• Lubricate the machine completely. This will remove any condensation water which may have collected in the bearings.

• Check the oil level in the gearboxes; top up if necessary.

• Check all screws for tight seat; retighten if necessary.

• Check all electrical connection cables and the lighting; repair or replace if necessary.

• Check the entire setting of the machine and correct if required.

• Re-read the operating instructions thoroughly.

136

15

15.1

Disposal of the machine

Disposal of the machine

Disposal of the machine

After the service life of the machine has expired, the individual components of the machine must be disposed of properly. The applicable country-specific, current waste disposal guidelines and the legal laws must be observed.

Metal parts

All metal parts must be brought to a metal recycling centre.

The components must be freed from operating fluids and lubricants (gear oil, oil from hydraulic system, ...) before being scrapped.

The operating fluids and lubricants must be brought separately to an environmentally friendly disposal point or recycling centre.

Operating fluids and lubricants

Operating fluids and lubricants (diesel fuel, coolant, gear oil, oil from hydraulic system, ...) must be brought to a disposal point for waste oil.

Synthetic materials

All synthetic materials must be brought to a recycling centre for synthetic materials.

Rubber

Rubber parts (hoses, tyres, …) must be brought to a rubber recycling centre.

Electronic scrap

Electronic parts must be brought to a disposal point for electronic scrap.

137

16 Index

A

Additional equipment and spare parts ................ 18

Adjusting holding-down device roller .................. 95

Adjusting Scrapers on the Centre Section ....... 115

Adjusting the central tip .................................... 120 adjusting the oscillation of the header ................ 96

Adjusting the sliding skid .................................... 95

Adjusting the tips .............................................. 118

Aligning the coupling disc ................................... 56

Approved adaptations ......................................... 48

Attaching Safety Labels and Information Labels 38

B

Ballasting of forage harvester ............................. 52

Basic safety instructions ..................................... 16

Before the Start of the New Season ................. 139

Behaviour in hazardous situations and when accidents occur ............................................... 28

Blade Changing ................................................ 124

C

Changing scraper blades on the side parts right/left and on the central part .................... 131

Changing the tips .............................................. 117

Checks before starting up the machine for the first time ................................................................. 53

Children in danger .............................................. 17

Collector gearbox (lower section on centre section) ......................................................... 107

Collector gearbox (lower section on side part) . 108

Collector gearbox (upper section) .................... 106

Commissioning ................................................... 53

Connecting .................................................... 68, 91

Connecting Drive Type 491, Type 492 ............... 63

Connecting drive type 493, type 494, type 496, type 497, type 498 .................................... 54, 64

Connecting hydraulic hoses ............................... 65

Connecting operation panel to forage harvester 60

Consumables ................................................ 25, 51

Contact for KRONE NORTHAMERICA ........ 38, 47

Conversion table ................................................. 12

Converting Tip Retainer for Special Row

Distances ...................................................... 121

Coupling the machine safely .............................. 17

D

Danger zones ..................................................... 20

Dangers associated with certain activities

Work on the machine ...................................... 27

138

Dangers associated with the operational environment ................................................... 25

Detaching the machine ................................ 67, 90

Direction Information ............................................ 8

Directories and References ................................. 8

Disposal of the machine .................................. 141

Driving and Transport ........................................ 70

F

Field mode on slopes ......................................... 78

From transport into working position .................. 73

Further applicable documents ............................. 7

G

Gaps on the centre frame ................................ 112

Gaps on the side frame ................................... 114

H

How to use this document ................................... 8

Hydraulic diagram ............................................ 133

Hydraulics ........................................................ 132

I

Identification Plate .............................................. 46

Importance of the operating instructions............ 16

Information Required for Questions and Orders 46

Input gearbox ................................................... 104

Intended use ...................................................... 14

K

Keeping safety devices functional ..................... 22

L

Lifting the machine ............................................. 72 location and meaning of the information labels on the machine ................................................... 40

Locking Oscillating Movement of Header .......... 76

Lubricating grease ............................................. 51

Lubrication Chart .............................................. 136

M

Machine overview .............................................. 43

Main gearbox ................................................... 105

Maintenance ...................................................... 98

Maintenance – lubrication chart ....................... 135

Maintenance table .............................................. 99

Means of representation ...................................... 9

Notes with information and recommendations 11

Warning signs ................................................. 11

Means of Representation

Figures ............................................................. 8

Metric Thread Screws with Control Thread ...... 100

Metric Thread Screws with Countersunk Head and Hexagonal Socket .................................. 101

Metric Thread Screws with Fine Thread ........... 101

O

Oils ...................................................................... 51

Operating active ground contour ........................ 84

Operating Input Gearbox .................................... 82

Operating Main Gearbox .................................... 81

Operating row detection...................................... 83

Operation ............................................................ 73

Operational safety: Technically perfect condition

........................................................................ 19

Overload protection ............................................ 45

P

Parking the machine safely ................................ 24

Personal protective equipment ........................... 23

Personnel qualification........................................ 16

Placing in Storage ............................................. 138

Position of the Adhesive Safety and Information

Labels on the Machine .................................... 32

Preparing the machine for road travel ................ 71

Purpose of Use ................................................... 14

R

Reasonably foreseeable misuse ........................ 15

Releasing star ratchet clutch at the universal shaft

...................................................................... 123

Removing Hydraulic Lines ............................ 68, 91

Re-Ordering Safety Labels and Information Labels

........................................................................ 38

Re-Ordering this Document .................................. 7

Replacing the wear plates ................................ 131

Road travel

Preparing machine .......................................... 71

S

Safely checking the oil level and changing the oil and filter element ............................................ 31

Safety ................................................................. 14

Safety Equipment ............................................... 42

Safety routines ................................................... 30

Safety signs on the machine .............................. 23

Scope of Document ............................................. 9

Service life of the machine ................................. 15

Setting the rotational speed of the maize header

....................................................................... 80

Setting Tubular Bars .......................................... 93

Settings .............................................................. 93

Shutting down and safeguarding the machine .. 30

Sources of danger on the machine .................... 26

Spare Parts ........................................................ 98

Start-up - CLAAS ............................................... 61

Structural changes to the machine .................... 18

Supporting lifted machine and machine parts securely .......................................................... 30

Switching from working position to transport position ........................................................... 86

Switching off the machine .................................. 71

T

Target group of this document ............................. 7

Technical data .................................................... 49

Term ..................................................................... 8

Test run ............................................................ 140

Test run .............................................................. 98

Tightening torques ........................................... 100

Tightening Torques for Locking Screws and Bleed

Valves on the Gearboxes ............................ 103

Traffic safety ...................................................... 24

U

Using the Machine for Work .............................. 78

W

Workstations on the Machine ............................ 18

139

Maschinenfabrik

Bernard Krone GmbH & Co. KG

Heinrich-Krone-Straße 10, D-48480 Spelle

Postfach 11 63, D-48478 Spelle

Phone +49 (0) 59 77/935-0

Fax +49 (0) 59 77/935-339

Internet: http://www.krone.de

eMail: [email protected]