Krone BA X-Disc 620 Operating Instructions


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Krone BA X-Disc 620 Operating Instructions | Manualzz

Direct cutting system

XDisc 620

(from serial no.: 1040747)

Order no.: 150 000 687 05 us

13.11.2020

Table of Contents

2

Table of Contents

1 Table of Contents

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

2 To this Document ................................................................................................................................... 8

2.1

Validity ................................................................................................................................................ 8

2.2

Re-Ordering ........................................................................................................................................ 8

2.3

Further applicable documents ............................................................................................................ 8

2.4

Target group of this document ........................................................................................................... 8

2.5

How to use this document .................................................................................................................. 9

2.5.1

Directories and References ........................................................................................................ 9

2.5.2

Direction Information ................................................................................................................... 9

2.5.3

Term “Machine” ........................................................................................................................... 9

2.5.4

Figures ........................................................................................................................................ 9

2.5.5

Scope of Document................................................................................................................... 10

2.5.6

Means of representation ........................................................................................................... 10

2.5.7

Conversion table ....................................................................................................................... 13

3 Safety ..................................................................................................................................................... 15

3.1

Purpose of Use ................................................................................................................................. 15

3.2

Intended use ..................................................................................................................................... 15

3.3

Reasonably foreseeable misuse ...................................................................................................... 16

3.4

Service life of the machine ............................................................................................................... 16

3.5

Basic safety instructions ................................................................................................................... 17

3.5.1

Importance of the operating instructions ................................................................................... 17

3.5.2

Personnel qualification .............................................................................................................. 17

3.5.3

Personnel qualification of the technicians ................................................................................. 18

3.5.4

Children in danger ..................................................................................................................... 18

3.5.5

Connecting front attachments or trailers ................................................................................... 18

3.5.6

Structural changes to the machine ........................................................................................... 19

3.5.7

Additional equipment and spare parts ...................................................................................... 19

3.5.8

Workstations on the Machine .................................................................................................... 19

3.5.9

Operational safety: Technically perfect condition ..................................................................... 20

3.5.10

Danger zones ............................................................................................................................ 21

3.5.11

Keeping safety devices functional ............................................................................................. 24

3.5.12

Personal Protective Equipment ................................................................................................. 24

3.5.13

Safety signs on the machine ..................................................................................................... 25

3.5.14

Traffic safety .............................................................................................................................. 25

3.5.15

Parking the machine safely ....................................................................................................... 26

3.5.16

Consumables ............................................................................................................................ 27

3.5.17

Dangers associated with the operational environment ............................................................. 27

3.5.18

Sources of danger on the machine ........................................................................................... 27

3.5.19

Dangers associated with certain activities: Work on the machine ............................................ 29

3.5.20

Behaviour in hazardous situations and when accidents occur ................................................. 30

3.6

Safety routines ................................................................................................................................. 32

3.6.1

Shutting down and safeguarding the machine .......................................................................... 32

3.6.2

Supporting lifted machine and machine parts securely ............................................................ 32

3.6.3

Safely checking the oil level and changing the oil and filter element ........................................ 33

3.7

Position of the Adhesive Safety Stickers on the Machine ................................................................ 34

3.7.1

Re-Ordering Safety Labels and Information Labels .................................................................. 41

3

Table of Contents

3.7.2

Attaching Safety Labels and Information Labels ...................................................................... 41

3.7.3

Contact for KRONE NORTHAMERICA .................................................................................... 41

3.8

Location and meaning of the information labels on the machine ..................................................... 42

4 Machine Description ............................................................................................................................ 46

4.1

Machine overview ............................................................................................................................. 46

4.2

Overview of the different adaptation types ....................................................................................... 48

4.3

Identification Plate ............................................................................................................................ 49

4.3.1

Contact ...................................................................................................................................... 50

4.4

Overload protection .......................................................................................................................... 51

5 Technical data....................................................................................................................................... 53

5.1

Consumables ................................................................................................................................... 54

5.1.1

Oils ............................................................................................................................................ 54

5.1.2

Lubricating grease ..................................................................................................................... 54

6 Commissioning..................................................................................................................................... 55

6.1

Checklist for Initial Operation ........................................................................................................... 55

6.2

Attachment to the forage harvester .................................................................................................. 55

6.3

Adjusting the machine to the forage harvester BiG X 480/530/580/630 and BiG X

680/780/880/1180 ......................................................................................................................................... 56

6.3.1

Adjusting the locking plates ...................................................................................................... 57

6.3.2

Setting input gearbox ................................................................................................................ 60

6.4

Adapt the machine to the forage harvesters BiG X 600/700/770/850/1100 .................................... 63

6.4.1

Adjusting the adapter frame ...................................................................................................... 63

6.5

Preparing the pendulum frame for installation of the front attachment ............................................ 64

6.6

Mounting the front attachment ......................................................................................................... 64

6.6.1

Aligning cutting unit ................................................................................................................... 66

6.7

Detaching the machine .................................................................................................................... 67

7 Start-up .................................................................................................................................................. 69

7.1

Checking and Observing before Start-up ......................................................................................... 70

7.2

Mounting Machine on Forage Harvester .......................................................................................... 70

8 Driving and Transport .......................................................................................................................... 71

8.1

Switching off the machine ................................................................................................................ 71

8.2

Lashing the machine ........................................................................................................................ 72

8.3

Lifting the machine ........................................................................................................................... 73

9 Operation ............................................................................................................................................... 75

9.1

From transport into working position ................................................................................................ 75

9.1.1

Working Position ....................................................................................................................... 75

9.2

Removing Machine from Forage Harvester ..................................................................................... 76

9.3

Operating side blades (for the version with “side blades”) ............................................................... 77

9.4

Operating the crop press roller (for "Crop press roller" version) ...................................................... 80

10 Settings ................................................................................................................................................. 83

10.1

Adjusting the distance between the scraper bars and the auger conveyor ..................................... 84

10.1.1

Set Ground Skid ........................................................................................................................ 85

10.2

Setting Infeed Sheets ....................................................................................................................... 85

11 Maintenance .......................................................................................................................................... 87

11.1

Special Safety Instructions ............................................................................................................... 87

11.1.1

Test run ..................................................................................................................................... 88

11.2

Spare Parts ...................................................................................................................................... 88

4

Table of Contents

11.3

Maintenance table ............................................................................................................................ 89

11.4

Tightening torques ............................................................................................................................ 91

11.4.1

Metric Thread Screws with Control Thread .............................................................................. 91

11.4.2

Metric Thread Screws with Fine Thread ................................................................................... 92

11.4.3

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................... 92

11.4.4

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes ........................ 93

11.5

Input gearbox ................................................................................................................................... 94

11.6

Intermediate gearbox ....................................................................................................................... 95

11.7

Cutter bar drive gear ........................................................................................................................ 96

11.8

Oil level check and oil change on the cutter bar .............................................................................. 97

11.8.1

Oil change ................................................................................................................................. 97

11.8.2

Checking the oil level ................................................................................................................ 97

11.8.3

Aligning the Cutter Bar .............................................................................................................. 98

11.9

Releasing star ratchet clutch at the universal shaft ......................................................................... 99

11.10

Checking the Cutter Blades and Blade Holder .............................................................................. 100

11.10.1

Cutter Blades .......................................................................................................................... 100

11.10.2

Blade screw connection .......................................................................................................... 101

11.10.3

Blade Quick-Fit Device ........................................................................................................... 102

11.10.4

Checking the Material Thickness of the Retaining Bolts ......................................................... 102

11.10.4.1

Checking the material thickness of the retaining bolts .................................................... 103

11.10.5

Periodical Inspection of the Leaf Springs ............................................................................... 104

11.10.6

Checking the Material Thickness of the Leaf Springs ............................................................. 104

11.10.6.1

Checking the material thickness of the leaf springs ........................................................ 105

11.10.7

Periodical Inspection of the Cutting Discs / Blade Drums ....................................................... 106

11.10.8

Abrasion Limit ......................................................................................................................... 107

11.11

Blade Changing on Cutting Discs .................................................................................................. 108

11.11.1

Blade Screw Connection ......................................................................................................... 109

11.11.2

Blade Quick-Fit Device ........................................................................................................... 110

11.11.3

Blade change when running "QuickChange tool" ................................................................... 111

11.12

Replacing the linings ...................................................................................................................... 112

11.13

Rotary hub with shear protection ................................................................................................... 113

11.13.1

After shearing off ..................................................................................................................... 115

11.14

Wear plates for trough .................................................................................................................... 117

11.15

Infeed sheets .................................................................................................................................. 117

11.16

Rubber strip .................................................................................................................................... 118

11.17

Drive chains .................................................................................................................................... 118

11.18

Maintenance side blades ............................................................................................................... 119

11.18.1

Checking side blades .............................................................................................................. 119

11.18.2

Changing Blades ..................................................................................................................... 119

11.18.3

Check hydraulic hoses ............................................................................................................ 122

11.18.4

Malfunctions on the side blade ............................................................................................... 122

12 Maintenance – lubrication ................................................................................................................. 124

12.1

Special Safety Instructions ............................................................................................................. 124

12.2

PTO shaft ....................................................................................................................................... 125

12.3

Lubrication Chart ............................................................................................................................ 126

13 Placing in Storage .............................................................................................................................. 128

14 Before the Start of the New Season ................................................................................................. 129

14.1

Special Safety Instructions ............................................................................................................. 129

5

Table of Contents

14.2

Test run. ......................................................................................................................................... 130

15 Disposal of the machine .................................................................................................................... 131

15.1

Disposal of the machine ................................................................................................................. 131

6

This page has been left blank deliberately.

Table of Contents

7

To this Document

2 To this Document

2.1

2.2

2.3

2.4

Validity

These operating instructions are valid for the direct cut header of type:

XDisc 620

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 forage harvester, KRONE

– Operating instructions for transport wagon, KRONE

– Operating instructions of universal shaft(s)

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”.

8

2.5

2.5.1

2.5.2

2.5.3

2.5.4

To this Document

How to use this document

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”

Throughout the rest of this document, the direct cut header will also be 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.

9

To this Document

2.5.5

2.5.6

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

10

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

11

To this Document

Warning signs

Danger!

DANGER! - Type and source of the hazard!

Effect: Danger to life or serious injuries.

• Measures for hazard prevention.

Warning!

WARNING! - Type and source of the hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention.

Caution

CAUTION! - Type and source of hazard!

Effect: Damage to property.

• Measures to avoid damage.

Notes with information and recommendations

Note

Note

Effect: Economic benefit of the machine.

• Measures to be performed.

12

2.5.7

To this Document

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 meter per second kilometer per hour liter milliliter

Weight 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 foot per second miles per hour

0.2642

0.0338

0.0610

US gallon

US ounce cubic inch

2.2046 pound

°F ft/min ft/s mph

US gal.

US oz. in³ lbs

13

To this Document

This page has been left blank deliberately.

14

3

3.1

Ver

3.2

Safety

Safety

Purpose of Use

The KRONE direct cut header XDisc 620 is a harvesting header which is attached to a KRONE forage harvester and is used to mow stalk and leaf material growing on the ground.

Intended use

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

The crops designated for the intended use of this machine are mown stalk and leaf crops growing on the ground.

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.

15

Safety

3.3

3.4

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.

16

3.5

3.5.1

3.5.2

Safety

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.

17

Safety

3.5.3

3.5.4

3.5.5

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.

Connecting front attachments or trailers

If the machine is incorrectly connected to a forage harvester, there is a risk of causing serious accidents.

• When connecting front attachments or trailers, follow all operating instructions:

– The operating instructions for the machine

– The operating instructions for the forage harvester

– The operating instructions for the universal shaft

• Follow the coupling instructions, see chapter Initial start-up, "Adjusting machine to forage harvester" and chapter Start-up, "Attaching to the forage harvester".

• Note the modified driving behaviour of the combination.

18

3.5.6

3.5.7

3.5.8

Safety

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.

19

Safety

3.5.9 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 or fatally injured. The following parts of the machine are particularly important for safety:

– Safety devices

– Connecting devices

– Hydraulic system

– Universal shafts

If there is doubt about the operational reliability of the machine, for example if consumables are leaking out, if there is visible damage or if the operating behaviour unexpectedly changes:

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

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

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

• In case of damage which may affect operational reliability and cannot be repaired according to these operating instructions: Have damage repaired by a qualified specialist workshop.

20

3.5.10

Safety

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 or fatally injured. With regard to safety, it is particularly important to comply with the following technical limit value:

– maximum permitted operating pressure of the hydraulics

– maximum permitted drive speed

– maximum permitted axle loads of forage harvester

• Comply with limit value, see chapter Machine description, "Technical data".

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

21

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.

22

Safety

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.

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

– Cutting discs

– Conveying devices

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

23

Safety

3.5.11

3.5.12

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.

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.

24

3.5.13

3.5.14

Safety

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".

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.

Dangers when driving on roads and in fields

The mounted front attachment changes the handling characteristics of the forage harvester. The handling characteristics also depend on the operational state and on the ground. If the driver of the forage harvester does not consider changed handling characteristics, he may cause accidents.

• Observe procedures for driving on roads and in fields, see chapter "Driving and transportation".

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”.

25

Safety

3.5.15

Dangers when operating the machine on slopes

The machine may tilt when it is used on slopes. As a result, accidents may occur and people may be seriously injured or killed.

• Do not work and drive on a slope unless the ground of the slope is flat and the adhesion of the tyres to the ground is ensured.

• Turn the machine at low speed. Turn in a large arc.

• Avoid driving across a slope because the centre of gravity of the machine will be changed by loading weight and by executing machine functions.

• Avoid jerky steering movements on a slope.

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 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".

26

3.5.16

3.5.17

3.5.18

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.

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.

27

Safety

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".

Hot surfaces

The following components may become hot during operation and may burn people:

– Gearbox

• Maintain an adequate distance from hot surfaces.

• Leave machine parts to cool down and wear protective gloves.

28

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.

29

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.

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

• Have welding work performed by experienced technicians only.

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.

30

This page has been left blank deliberately.

Safety

31

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.

32

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”.

33

Safety

3.7

GL

Position of the Adhesive Safety Stickers on the Machine

1 3 5 6 34 3 5 6 5

8 2

3 5 8

Fig. 1

1)

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

Ord. no. 27 002 054 0 (1x)

37

2)

CAUTION

Max. PTO speed

750 RPM

27 002 701 0

Ord. no. 27 002 701 0 (1x)

GPS00043_1

34

3)

Ord. no. 27 002 058 0 (4x)

5)

Ord. no. 27 002 056 0 (4x)

7)

DANGER

Blade can cause serious injury or death.

- S tay clear of machine while in operation.

- K eep discharge chute and shields in place.

Ord. no. 27 014 825 0 (1x)

4)

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.

27 002 702 0

Ord. no. 27 002 702 0 (2x)

6)

Ord. no. 27 002 055 0 (2x)

8)

Safety

Ord. no. 949 228 0 (3x)

35

L

Safety

L

L

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 tractor engine is running.

- 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

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.

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

CAUTION

CAUTION

Max. PTO speed 750 RPM.

Max. PTO speed

750 RPM

L

27 002 701 0

3) Order No. 27 002 058 0 (4x)

WARNING

Cutting blade continue to rotate after PTO has been disengaged.

To avoid possible injury.

Look & listen for rotation to stop. Do not open cover until all components have stopped.

4) Order No. 27 002 702 0 (2x)

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

36

GL

1 3 5 6 34 3 5 6

Safety

5

8 2

3 5 8

Fig. 2

1)

CAUTION

To avoid serious injur y or death

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

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

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

- K eep riders off the machine.

- Make certain every one 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 lubricatem, 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.

2 7 0 0 2 0 5 4 0

Ord. no. 27 002 054 0 (1x)

37

2)

CAUTION

Max. PTO speed

750 RPM

27 002 701 0

Ord. no. 27 002 701 0 (1x)

GPS00043_1

37

Safety

3)

Ord. no. 27 002 058 0 (4x)

5)

Ord. no. 27 002 056 0 (4x)

7)

DANGER

Blade can cause serious injury or death.

- S tay clear of machine while in operation.

- K eep discharge chute and shields in place.

Ord. no. 27 014 825 0 (1x)

4)

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.

27 002 702 0

Ord. no. 27 002 702 0 (2x)

6)

Ord. no. 27 002 055 0 (2x)

8)

Ord. no. 949 228 0 (3x)

38

L

L

L

5) Order No. 27 002 056 0 (4x)

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.

6) Order No. 27 002 055 0 (2x)

DANGER

Blade can cause serious injury or death.

– Stay clear of machine while in operation.

– Keep discharge chute and shields in place.

– Replace worn or damaged protective skirting.

7) Order No. 27 014 825 0 (1x)

WARNING

Hot surfaces

- Keep sufficient distance from hot surfaces.

- Allow to cool before servicing.

8) Order No. 949 228 0 (3x)

DANGER

SHIELD MISSING, DO NOT OPERATE

Safety

39

GL

Safety

For the version with "side blades":

1 1

GPS00079

Fig. 3

1) Ord. no. 27 024 762 0 (2x) a) Before starting the machine, read and follow the operating instructions and safety instructions. b) When the machine is running, keep your distance.

1b

1a

40

3.7.1

3.7.2

3.7.3

Safety

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

41

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.

1 4 5 1

2

3 3

1

6 7 8

3

Fig. 4

1

GPS00089

42

L

Safety

1) Order no. 27 023 958 0 (4x)

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

L

L

27 023 958 0

2) Order no. 27 028 779 0 (1x)

Use only Renolin Unisyn CLP 320 hydraulic oil; see chapter

Technical data, "Consumables".

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

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

4) Order no. 27 000 167 0 (1x)

Rope, length app: 6ft. (2x)

Seil, Länge ca: 2m (2x)

Rope, length app: 9ft. (2x)

Seil, Länge ca: 3m (2x)

When you lift the machine, open the central protective cover and attach the appropriate lashing materials to the designated suspension points; see chapter Driving and transport, "Lifting the machine".

Weight of machine: 6200 lb

Maschinengewicht: 2800 kg

2 7 0 0 0 1 6 7 0

43

Safety

2

3

1 4 5 1

3

1

6 7 8

3

Fig. 5

1

GPS00089

44

L

Safety

5) Order no. 27 022 185 0 (1x)

Var 220

580 mm

580

750

Var 210

Var 230

750 mm

27 022 185 0

Depending on the type of forage harvester, the infeed sheets can be mounted at different locations.

The label helps to find the mounting location of the infeed sheets.

See chapter Machine description, "Overview of the individual adaptation types".

6) Order no. 939 567 1 (1x)

This label specifies the order numbers for spare blades.

1 3 9 -8 8 8

1 3 9 -8 8 9

139 888 139 889

For "Blade screw connection" version

7) Order no. 255 498 1 (1x)

Ø 17,5 mm

The label advises that the retaining bolts, for the blade screw connection version, must be checked whenever a blade is changed or following contact with foreign objects and, if required, replaced by authorised specialists. min. 14 mm

255 498 1

For "Blade quick fastener" version

8) Order no. 255 499 2 (1x)

The label advises that the retaining bolts, for the blade quick fastener version, must be checked whenever a blade is changed or following contact with foreign objects and, if required, replaced by authorised specialists.

255 499 2

45

Machine Description

4 Machine Description

4.1 Machine overview

1 6

2

7

8

3

4

5

8

9

1

10

11

12

13

14

12

9

2

1

46

Fig. 6

15 16 8

1) Guard sheet

4) Intermediate gearbox

7) Type plate

10) Pendulum crossbar

13) Infeed sheets

16) Mower drums

2) Rubber strip

5) Drive chains

8) Suspension point

11) Input gearbox

14) Auger conveyor

With "pendulum frame adaptation" design

1

Machine Description

3) Cutterbar gearbox

6) Special key SafeCut

9) Support jacks

12) Locking sheet

15) Guard cloth

Fig. 7

1) Locating bolt

3 2

2) Pendulum frame holder 3) Drive journal

GPS00067

47

Machine Description

4.2 Overview of the different adaptation types

Spherical roller adaptation

1

Pendulum frame adaptation

GPS00077

Fig. 8

The intake plates (1) can be mounted in different positions.

The mounting position of the intake plates (1) can be determined with the aid of the sticker.

Var 220 Var 210

Var 230

750 mm 580 mm

580

750

27 022 185 0

X

Y

X

Y

GPS00078

Fig. 9

The machine can be mounted on different types of forage harvesters:

• The forage harvester types BiG X 480/530/580/630 (variant 220) with a feed width of

X=580 mm and spherical roller adaptation.

• The forage harvester types BiG X 680/780/880/1180 (variant 210) with a feed width of

Y=750 mm and spherical roller adaptation.

• The forage harvester types BiG X 600/700/770/850/1100 (variant 230) with a feed width of

Y=750 mm and pendulum frame adaptation.

48

4.3 Identification Plate

1

Machine Description

GPS00033_1

Fig. 10

The machine data are specified 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. 11 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.

49

Machine Description

4.3.1 Contact

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

50

4.4

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

Fig. 12

A star ratchet clutch (1) on the universal shaft 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".

51

Machine Description

This page has been left blank deliberately.

52

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.

Type

Working width

Number of mower drums (low)

Number of mower drums (high)

Drive speed

Dead weight

Airborne noise emission

Emissions value (sound pressure level) with KRONE forage harvester

XDisc 620

6200 mm

12

2

750 rpm

2800 kg

76.7 dB(A)

Measurement device

Accuracy class

Bruel & Kjaer, Type 2236

2

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

Ambient temperature

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

53

Technical data

5.1 Consumables

5.1.1

5.1.2

Oils

Lubricants

Intermediate gearbox

Filling quantity

2.9 L

Refined lubricants Bio-degradable lubricants

Renolin Unisyn CLP

320, optionally: Shell

Omala S4GX320

On request

Input gearbox

Cutterbar drive gear

1.7 L

0.7 L API GL4 SAE 90

Cutterbar 14 L

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

54

6

6.1

6.2

Commissioning

Commissioning

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

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.

Checklist for Initial Operation

Check and observe the following points.

• Check whether the header for the forage harvester is released (observe the operating licence of the forage harvester).

• Lubricate the header thoroughly.

• Check the oil level in the gearboxes.

• Check the screws for firm attachment.

• Check the cutter blades for damage and make certain they are correctly seated.

• Check the tension of the drive chain(s).

• Mount and lock all protective devices.

• Adapt the position of locking sheets and the clutch discs to the forage harvester.

Attachment to the forage harvester

Notice

The KRONE XDisc direct cut header is specially designed for attachment to KRONE BiG X forage harvester. Attachment to other harvesters is not permitted without the consent of

KRONE.

55

Commissioning

6.3 Adjusting the machine to the forage harvester BiG X 480/530/580/630 and BiG X

680/780/880/1180

Note

When mounting the machine the first time on a forage harvester as well as each time a forage harvester is changed, the position of the locking plates as well as of the coupling disc must be checked and adapted, if necessary.

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

Cleaning the coupling disc

1 2

GPS00037

Fig. 13

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.

56

6.3.1

Commissioning

Adjusting the locking plates

Note

Set the locking plates the same on the right and on the left.

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

1

3 2

EFL000046_2

Fig. 14

To set the locking plates (4):

• Lower the feed drive (1) of the forage harvester all the way.

• Align the pendulum tube (2) horizontally on the feed drive.

• Loosen the screw connections (5, 6) on header.

57

Commissioning

4

6 7

2

1

5 3

GPS00045 GPS00046

Fig. 15

WARNING!

Crushing hazard due to moving machine parts! Make certain no one remains between machine and header.

• Move forage harvester up to the machine until the roll guides (1) are under the pendulum crossbar (2).

• Unlock the locking pins (3) via the additional keypad, refer to operating instructions of forage harvester.

• Slowly lift the lifting unit and ensure that the pendulum crossbar (2) is taken up correctly and completely by the roll guides (1).

When lifting, the centring triangles (4) rest against the locking sheets (5).

• Ensure that the pendulum tube (6) of the forage harvester touches the contact area (7) of the header.

58

3

Commissioning

4

2 1

GPS00047

Fig. 16

• Release the “Open header locking” key of the additional keypad, refer to operating instructions of forage harvester. Lock the locking pins (1).

• Shut down and safeguard the forage harvester, refer to the operating instructions of the forage harvester.

• Check whether the locking pins (1) run into the boreholes of the both locking sheets (2).

If not:

• Align the locking sheets (2) by using a soft-head hammer until the locking pin (1) can run into the borehole.

• Check whether the centring triangles (3) are positioned in the contour (4) of the locking sheets.

If not:

• Align the locking sheets by using a soft-head hammer until the centring triangles rest against the contour of the locking sheets.

• Tighten the screw connections (5,6).

59

Commissioning

6.3.2 Setting input gearbox

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

2 3 1

GPS00039 GPS00048

Fig. 17

The coupling disc (1) of the front attachment must be aligned with the coupling journal (2) of the forage harvester until the coupling journal (2) is positioned centrally in the housing (3). The coupling disc must be positioned evenly and flat on the coupling journal.

4 6 5 7

GPS00038

Fig. 18

Correct position of clutch disc

The clutch disc is correctly aligned when:

– it rests evenly and with its entire surface against the coupling journal.

– the contact area (4) of the clutch disc or the contact area (5) of the coupling journal is flush

(+/- 5 mm) with the front surface of the coupling housing (6).

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

The inclination (I), the side (II) and the height (III) of the main angular gearbox can be adjusted.

60

Mounting header on forage harvester

• Mount header on forage harvester.

Checking the position of the clutch disc

• Check the position of the clutch disc.

When the clutch disc is correctly aligned:

• The setting is OK, the header can be used with forage harvester.

When the clutch disc is not aligned correctly:

• Set the main angular gearbox.

Inclination setting (I)

3

2

Commissioning

1

GPS00050

Fig. 19

• Unscrew screw connections (1, 2).

• Position main angular gearbox (3) so that the clutch disc rests evenly on the coupling journal.

• Tighten screw connections (1,2).

61

Commissioning

Side and height adjustment (II and III)

2

3 4 5

2

1

GPS00052_1

Fig. 20

• Loosen the 4 screws (1).

• If necessary, add or remove distance sheets (2) under the main angular gearbox housing until the clutch disc (4) and the coupling journal of forage harvester are on the same height.

Remove the required distance sheets (2) under the mounting console (5).

Install surplus distance sheets (2) under the mounting console (5).

• Position main angular gearbox (3) laterally in such a way that the coupling journal is aligned centrally to the housing.

• Tighten the screws (1) again.

Checking the position of the clutch disc

• Connect header to forage harvester and check the position of the clutch disc.

When the clutch disc is correctly aligned:

• The setting is OK and the header can be used together with forage harvester.

When the clutch disc is still not aligned correctly:

• The adjustment of the input gearbox must be carried out once again.

62

6.4

6.4.1

Commissioning

Adapt the machine to the forage harvesters BiG X 600/700/770/850/1100

Adjusting the adapter frame

Note

When attaching the machine for the first time and whenever changing the forage harvester, the adapter frame must be adjusted.

Note

Make the adjustment equally on the right and left of the adapter frame.

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

1

2

Fig. 21

Measure the axle base "a" between holding claw (1) and locking hook (2) on the pendulum frame of the forage harvester.

1 2

4

4

3 3 3

GPS00068

Fig. 22

• Measure the centre distance "a" between the locating bolts (1, 3) on the adapter frame on the front attachment.

The distance "a" on the pendulum frame and adapter frame must be set to the same dimension:

• Loosen the screw connections (2) on the right/left and shift the pendulum frame holders (3) to the correct distance.

• Tighten the screw connections (2).

• Before moving the forage harvester forward, fold down the protective cover (4).

63

Commissioning

6.5 Preparing the pendulum frame for installation of the front attachment

The locating points of the different front attachments must be adapted to the locating points of the pendulum frame before they are installed for the first time.

3 4 I 6 II 6

2

6.6

1

2

EFL000007_1

Fig. 23

• Fully lower the lifting unit of the machine.

• Align the pendulum frame (1) of the lifting unit horizontally.

• The locking hooks (2) must be open. If necessary, open them with the locking lever (4).

• Release the locking of the locking lever (4) by actuating the spring lock (3) and swivel the lever upwards.

• To lock the pendulum frame, slide the bolt (6) into the borehole of the pendulum frame by means of a light rotating movement and secure it.

Mounting the front attachment

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

1

2

BX851033_1

Fig. 24

• Place the cardan shaft supplied with the front attachment onto the PTO shaft (1) on the front left of the machine and secure with the slider pin.

• Place the cardan shaft onto the support / holder (2) provided.

64

Commissioning

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

3

1

2

5

4

Fig. 25

• Drive the forage harvester up to the machine until the pendulum frame is just in front of the adapter frame (1) and the holding bolts (3) are located against the stop surfaces of the holding claws (2).

• Raise the pendulum frame with lifting hydraulics until the locking hooks (4) are in the pendulum frame holder (5) on the adapter frame.

• Stop the machine.

• In order to secure the lifting unit against unintentional lowering, close the stop cocks of the lifting cylinders on forage harvester side, see operating instructions of the forage harvester.

5

2

1

4 3

GPS00070

Fig. 26

• Ensure that the adapter frame is hooked correctly into the locating bolt and the locking hook on both sides.

• Swivel the locking lever (1) down and secure it with the spring lock (2).

• Slide the universal shaft (3) onto the drive journal (4) of the main gearbox until the retaining pin engages.

• Attach the safety chain of the universal shaft guard to the intake of the forage harvester.

• Close the guard sheet (5).

65

Commissioning

I 2 II 2

6.6.1

1

1

EFL000010

Fig. 27

• To unlock the pendulum frame, move the bolt (1) from position “I” to position “II”.

Aligning cutting unit

4

3

2

1

GPS00019_2

Fig. 28

Notice

When attaching the cutting unit for the first time and whenever changing the forage harvester, the cutting unit must be aligned.

The cutting unit (1) must be aligned horizontally to the forage harvester.

• Raise the cutting unit (1) with the lifting hydraulics and check that it is aligned horizontally. If necessary, compensate for any lateral inclination by changing the pretension on the compression spring (2).

DANGER! – Unexpected actions on the machine.

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

• Switch off the engine, remove the ignition key and secure the machine against rolling away.

• Loosen the hexagon nut (3).

• Change the pretension of the tension spring (2) by turning the hexagon nut (4) as appropriate.

• Lock the hexagon nut (3) in place again.

Notice

For additional settings to operate the cutting unit, refer to the operating instructions “Selfpropelled forage harvester BiG X”.

66

6.7

Commissioning

Detaching the machine

DANGER! – Unexpected movement of the machine!

Effect: Danger to life or serious injuries.

• Make sure that there is no one in the danger zone.

• Place the machine on solid and level ground only and with the support jacks extended.

• Only unhitch when the engine is turned off and the ignition key has been removed.

• Secure the forage harvester against rolling away.

• Use extreme caution when attaching implements to or detaching them from the forage harvester! The accident prevention regulations must be strictly observed.

• When dismounting the machine, do not step between forage harvester and machine!

• Lifting cutting system

Note

Stop the machine.

I 2 II 2

1

1

EFL000010

Fig. 29

• To lock the pendulum frame, move the bolt (1) from position “II” to position “I”.

Fig. 30

• Dismount the socket pins (3) and pull the support jacks (1) downwards from the machine.

• Secure the position by means of socket pins (3).

• Pull the joint fork (5) off the drive journal (6) of the main gearbox.

• Lower the cutting unit with the forage harvester hydraulics to the ground.

Note

Additional information on uncoupling is available in the forage harvester's operating instructions.

67

Commissioning

This page has been left blank deliberately.

68

7

Start-up

Start-up

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

DANGER! – Attaching / removing and operating the machine

Effect: Danger to life or serious injuries.

• The machine may only be attached to the forage harvester for which it is intended!

• Use extreme caution when attaching the machine to or detaching it from the forage harvester! The accident prevention regulations must be complied with absolutely.

• The machine is suitable for and intended for cutting crops growing on the ground!

• Maintain an adequate safety distance from the cutting tools during operation.

• The glide skids must rest on the ground before start-up and during work!

• Stones and other objects may be hurled up, even when the machine is used as intended.

For this reason, no one is permitted in the danger zone. Special care should be taken when working near roads and buildings.

• Check the guard cloths regularly. Worn or damaged guard cloths must be replaced!

• The protective equipment on the machine, e.g. cloths and hoods, protects against flying stones and similar objects, and prevents access to hazardous areas. For this reason you must always move them to their protective position before starting work.

• Do not enter the area between the forage harvester and the machine while the machine is being converted from the transport to the working position and vice versa.

69

Start-up

7.1

7.2

Checking and Observing before Start-up

• Check the oil level in the gearboxes.

• Lubricate the header thoroughly before start-up.

• Check the screws for firm attachment.

• Check the cutter blades for damage and make certain they are correctly seated.

• Check the tension of the drive chain(s).

• Mount and lock all protective devices.

• Adapt the position of locking sheets and the clutch discs to the forage harvester.

• Lock the locking pins of the forage harvester.

• Align the cutting unit.

• Before starting to move, make certain there are no loose parts on the vehicle. Parts, which may be lost while the vehicle is being driven, must be attached or covered.

• Parts, which may be lost while the vehicle is being driven, must be attached or covered.

• Never allow the machine to run unsupervised.

Mounting Machine on Forage Harvester

• To mount the header on the forage harvester, refer to operating instructions of the forage harvester.

70

8

8.1

Driving and Transport

Driving and Transport

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

Warning! – Road travel, carrying passengers, driving conduct

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

• The direct cut header may only be carried on public roads and paths with the transport wagon provided for this purpose. The transport wagon is described in separate operating instructions.

• Carrying passengers on the machine is not permitted.

• When driving on roads, the general requirements / special conditions of the Road Traffic

Type Approval Law (StVZO) and the Road Traffic Law (StVO) must be observed.

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

Switching off the machine

Fig. 31

• Park the direct cut header (1) with the support jacks (2) extended and secured on firm and level ground.

71

Driving and Transport

8.2 Lashing the machine

Warning! – Danger to life due to uncontrolled movement of the machine.

If the machine is not properly lashed during transport (e.g. on a lorry or ship), the machine may move in an uncontrolled manner and endanger people.

• Before transporting the machine, secure it properly and use suitable lashing material at the lashing points provided.

1

2

GPS00087_1

2) Frame lashing point

Fig. 32:

1) Lashing point adapter frame

Prerequisites:

– The machine has been shut down and safeguarded (see chapter Safety, "Shutting down and safeguarding the machine").

– The machine has been parked (see chapter Driving and Transport, "Parking the machine").

72

1

8.3

Driving and Transport

Lifting the machine

Warning! - Stop and transportation equipment inadequately dimensioned.

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

Use only adequately dimensioned stop and transportation equipment (crane, ropes)!

1

2

GPS00040_1

Fig. 33

To prepare the machine for internal transport (e.g. loading):

• Attach the hoist to the rear suspension points (1).

• Open the centre protective cover and attach the hoist (2) to the front suspension points.

73

Driving and Transport

This page has been left blank deliberately.

74

9

9.1

9.1.1

Operation

Operation

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

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.

Working Position

Fig. 34

Lower the cutting system (1) down to the ground.

Note

• Check guard cloth (2) and rubber strip (3) (right-hand and left-hand machine side) before every use. Replace damaged safety devices (2, 3) immediately.

75

Operation

Driving in the headland:

• Set the lifting height on the forage harvester terminal to maximum 40 cm, see operating instructions for the forage harvester, chapter Terminal menus, "Lifting unit menu".

Warning! – Quickly rotating cutting discs/mower drums

Effect: Danger to life or serious injuries.

• During mowing, the lifting height of the cutting unit must be set to maximum 40 cm

(measured between ground and cutterbar front edge).

• Set the bearing pressure on the forage harvester terminal as low as possible between

3 and 5 %, see operating instructions for the forage harvester, chapter Terminal menus,

"Lifting unit menu".

Notice

The lower the bearing pressure, the lower the wear on the ground skids.

Warning! – Observe the drive speed

Effect: Danger to life or serious injuries

• Do not exceed the stipulated drive speed of 750 rpm.

• Set max. drive speed (750 rpm) of the front attachment drive on the forage harvester via the display (see operating instructions for the forage harvester).

• Switch on cutting drum (see operating instructions for the forage harvester).

• Switch on drive of the cutting system / feed drive rollers.

• Drive into the crop with the forage harvester.

• The driving speed depends on the particular application conditions (ground conditions, the height and nature of the crop).

9.2 Removing Machine from Forage Harvester

• To dismount the header from the forage harvester, refer to chapter Initial operation,

"Dismounting the machine".

76

9.3

Operation

Operating side blades (for the version with “side blades”)

The XDisc 620 can be equipped with side blades with hydraulic drive. When harvesting, the side blades can be used to separate heavily entwined crops.

The side blades on the XDisc can only be used on forage harvesters BiG X with spherical roller adaptation (BiG X 480/530/580/630 and BiG X 680/780/880/1180).

WARNING!

Risk of injury from sharp-edged side blades.

If the side blades are not covered with protective strips, people may be injured.

• If the side blades are not operated, mount the protective strips on the side blades.

NOTICE!

Damage to the machine.

If the side blades are operating in the lowered horizontal position on the machine, the machine may be damaged.

• Ensure that the side blades are not operating in the lowered position.

Operating side blades

1 2 3

4

GPS00071

Fig. 35

• Grab the side blades (4) on the handles (2) and swivel them forward into horizontal position.

• Remove the protective profiles (1) from the side blades (4) and attach them to the mounting profile (3) at the top of the hood.

77

Operation

Connecting hydraulic hoses

1

GPS00076

Fig. 36

• Connect the hydraulic hoses of the forage harvester to the corresponding plug-in connectors (1) of the XDisc with side blades. Connect the hydraulic hose I to the plug-in connector I and the hydraulic hose II to the plug-in connector II.

Releasing side blades on the terminal

GPS00073 GPS00074

Fig. 37

• To operate the side blades, set the parameter “Side blades installed” in the Crop flow ->

Header -> Settings menu of the forage harvester terminal with the selection window to

“active”, refer to the operating instructions of the forage harvester.

• Switch on the header drive.

The side blades are driven, as well.

Notice

If the forage harvester is switched off, the parameter “Side blades installed” automatically resets to “inactive”. If the side blades should be used again, the parameter must be reset to

“active” before use.

78

Operating left/right side blade separately

1 2

Operation

GPS00072

Fig. 38

The side blades can be switched on or off individually by means of three-way stopcocks on the machine.

The three-way stopcock (1) switches the left side blade and the three-way stopcock (2) switches the right side blade.

• To switch on the drive for the side blade, set the respective three-way stopcock to the position “I”.

• To switch off the drive for the side blade, set the respective three-way stopcock to the position “0”.

The side blade which is not driven can be placed on the machine.

Placing side blades on the machine

1

2 3 6

4

5

GPS00075_1

Fig. 39

If the side blades should not be used, they can be placed on the machine.

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

• Remove the protective profiles (3) from the mounting profile (2) at the top of the hood and place them on the side blades (5).

• Grip the side blades (5) on the handles (1), swivel backwards into a horizontal position, lower onto the cutting blade support (4) and secure with the spring cotter pin (6).

Notice

Before transporting the machine on the transport wagon, the side blades must be lowered into a horizontal position on the machine.

79

Operation

9.4 Operating the crop press roller (for "Crop press roller" version)

The XDisc 620 can be equipped with a crop press roller. To optimise the crop flow with bulky or high crops during the harvest, the crop press roller can be used to hold the crop in front.

WARNING!

Risk of injury due to the crop press roller in working position when moving on a transport wagon on the road.

If the crop press roller is in working position when it is on a transport wagon on the road, persons can be injured by the crop press roller.

• Ensure that the crop press roller is put down in transport position when the XDisc 620 is moved on a transport wagon on the road.

Swivelling the crop press roller

1 2

GPS00092

Fig. 40

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

• Remove the spring cotter pin (1) and take the pivoted lever (2) out of the rectangular tube at the left side of the machine.

80

1 2 3 4

Operation

GPS00093

Fig. 41

• Ensure that the side blades (1) are put down on the machine; see chapter "Operation",

"Putting down the side blades on the machine".

WARNING! Risk of injury from moving crop press rollers (2). Ensure that there is nobody in the swivel range of the crop press roller (2) or reaches into the swivel range.

• Connect the pivoted lever (4) with the hexagon head (3) and swivel the pivoted lever (4) up or down.

• Supported by a gas spring, the crop press roller (2) moves up or down.

• Remove the pivoted lever (4) from the hexagon head (3).

1 2

GPS00092

Fig. 42

• Insert the pivoted lever (2) into the rectangular tube at the left machine side and secure it with the spring cotter pin (1).

81

Operation

This page has been left blank deliberately.

82

10

Settings

Settings

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

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

• Move machine into the working position and lower it to the ground

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• Switch off the PTO shaft and disengage it.

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

• 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.

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO shaft.

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• When working under or on the raised machine, always secure it with suitable supporting elements.

• Close the stop cock on the lifting cylinder of the forage harvester!

• When all repair, maintenance or cleaning tasks are complete, all guard sheets and safety devices must be re-attached.

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

83

Settings

10.1 Adjusting the distance between the scraper bars and the auger conveyor

Fig. 43

The hopper has two scraper bars (3), one on the right and one on the left of the transfer opening. They remove the crop from the auger. To ensure the best result when removing the crop, the scraper bars can be set via oblong holes.

Before setting the scraper bars:

• Make sure that the auger or rocker arm (1) rests on the bump stop (2).

To set the lower scraper bar (3):

• Unscrew screw connections (5) and set the distance from scraper bars (3) to auger spiral

(7) to dimension a=3-6 mm.

• Tighten screw connections (5).

To set the upper scraper bar (4):

• Unscrew screw connections (6) and set the distance from scraper bars (4) to auger spiral

(7) to dimension b=4-7 mm.

• Tighten screw connections (6).

After setting the scraper bars:

• Turn auger manually and check whether the auger can be rotated freely and does not collide with the scraper bars.

The scraper bars (3, 4) are subject to natural wear. Therefore they must be checked once a year at the latest before the beginning of the season and they must be replaced, if necessary.

84

10.1.1

Settings

Set Ground Skid

Note

The height of the skids must be adapted to the tyre size of the forage harvester in that way that the skids in the rear skid area are still resting evenly on the ground.

The position of the ground skid does not influence the cutting height. Adjust all skids equally.

I

10.2

1

2

GPS00028

Fig. 44

• Lift the front attachment

• Take note of the danger warnings at the beginning of the chapter

• Loosen screw connections (2) and assemble the ground skid (1) in the desired position (I)

• Tighten screw connections

Setting Infeed Sheets

Fig. 45

When harvesting short crop, it may be useful to mount the infeed sheets (1) further outside on the auger conveyor to optimise crop flow.

• Unscrew screws (2).

• Move infeed sheets (1) by one hole pattern to the outside.

• Mount and tighten screws (2).

85

Settings

This page has been left blank deliberately.

86

11

11.1

Maintenance

Maintenance

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

Special Safety Instructions

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO shaft.

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• When working under or on the raised machine, always secure it with suitable supporting elements.

• Close the stop cock on the lifting cylinder of the forage harvester!

• When all repair, maintenance or cleaning tasks are complete, all guard sheets and safety devices must be re-attached.

Warning! – If the cutter blades and retaining bolts are not checked at regular intervals

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

• Always check the mowers for damaged, missing or worn blades, retaining bolts, leaf springs and cutting discs/mower drum before starting operation; replace if required!

• Replace missing and damaged blades in sets only to prevent an imbalance!

• Never mount unequally used blades on a drum/disc!

• When changing blades, also check attachment parts; replace if required!

87

Maintenance

11.1.1

11.2

Test run

Warning! - 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 on the ground and ensure that there are no people, animals or objects 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.

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.

88

11.3 Maintenance table

Maintenance work

Maintenance

Maintenance interval

Input gearbox

Oil level check

Oil change

Intermediate gearbox

Oil level check

Oil change

Cutterbar drive gear

Oil level check

Oil change

Cutterbar

Oil level check

Oil change (not required)

Blades

Check/change

Cutting discs/mower drums

Check/change

Retaining bolts

Check/change (for blade screw connection)

Check/change (for blade quick fastener)

Leaf springs

Check/change (for blade quick fastener)

Rotary hub

Check

Drive chains

Check the pretension

X

X

X

X X

X X

X X

X X

X X

X X

X X

X X

X

X

X

X X

X

X X

X

X

X

X

89

Maintenance

Maintenance work Maintenance interval

Tighten screws/nuts

All screws

Wear plates for trough

Check for wear

Scraper bars

Check the distance between scraper bars and auger conveyor

Infeed sheets

Check for wear

Safety devices

Check guard cloth for damage and wear

Check rubber strips for damage and wear

Cleaning the machine

Check for soiling and clean if required

Coupling

Check coupling for wear

Adaptation to the forage harvester

Check that the locking sheets rest against the centring triangle free of play (for version "adaptation with spherical roller"). If necessary, re-adjust the locking sheets, see chapter Commissioning, "Adjusting locking sheets".

For the version with "side blades"

Check the blades for damage and grind or replace them, if necessary

Check blade guides

Check all screws and nuts to make certain they are tight and retighten them, if necessary.

Check the hydraulic hoses for leaks and, if necessary, have them replaced by a KRONE service partner

Lubricate machine according to lubrication chart

X

X X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

90

11.4

11.4.1

Maintenance

Tightening torques

Deviating tightening torques

All screw connections must in general be tightened with the listed tightening torques following.

Deviations from the tables are marked accordingly.

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

29

42

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

3.0 4.4 5.1

5.9 8.7 10

10

25

15

36

18

43

49

85

135

210

425

571

730

72

125

200

310

610

832

84

145

235

365

710

972

1050 1220

1100 1550 1800

1450 2100 2450

91

Maintenance

11.4.2

11.4.3

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

92

11.4.4

Maintenance

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes

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.

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

Self-locking nuts must always be replaced.

93

Maintenance

11.5 Input gearbox

Note

Check the oil level and change the oil while the gearbox is in a horizontal position!

Fig. 46

1) Inspection screw / inspection hole

3) Filler plug / oil filling hole

2) Drain plug

• 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.

• Screw out oil drain plug and drain the oil.

• Screw out inspection screw and filler plug.

• Screw in oil drain plug and tighten it securely.

• Top up new oil via oil filling hole until the control hole is reached.

• Screw in the inspection screw and the filler plug and tighten them securely.

94

11.6

Maintenance

Intermediate gearbox

Note

Check the oil level and change the oil while the gearbox is in a horizontal position!

Fig. 47

1) Inspection screw / inspection hole

3) Filler plug / oil filling hole

2) Drain plug

• 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.

• Screw out oil drain plug and drain the oil.

• Screw out inspection screw and filler plug.

• Screw in oil drain plug and tighten it securely.

• Top up new oil via oil filling hole until the control hole is reached.

• Screw in the inspection screw and the filler plug and tighten them securely.

95

Maintenance

11.7 Cutter bar drive gear

Note

Check the oil level and change the oil while the gearbox is in a horizontal position!

Fig. 48

1) Viewing glass

3) Filler plug / oil filling hole

2) Drain plug

• 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:

• Oil level to the centre of the viewing glass.

If the oil does not reach the centre of the viewing glass:

• Screw out filler plug.

• Top up oil via oil filling hole until the centre of the viewing glass is reached.

• Screw in filler plug and tighten it securely.

Oil change:

Collect escaping oil in a suitable container.

• Screw out filler plug.

• Screw out oil drain plug and drain the oil.

• Screw in oil drain plug and tighten it securely.

• Top up new oil via oil filling hole until the centre of the viewing glass is reached.

• Screw in filler plug and tighten it securely.

96

11.8

11.8.1

11.8.2

Maintenance

Oil level check and oil change on the cutter bar

Oil change

Note

No oil change is required on the cutter bar.

Checking the oil level

Danger! - Rapidly rotating cutting discs/blade drums.

Effect: Danger to life or serious injuries.

Lower guards. Nobody should be in the danger zone around the machine.

Danger! - Rapidly rotating cutting discs/blade drums.

Effect: Danger to life or serious injuries.

• Switch off the engine and remove the ignition key.

• The cutting discs/blade drums continue to run!

• Do not leave the driver’s cab until the cutting discs/blade drums have come to a complete stop.

Note

Tighten the locking screws on the gearboxes with the prescribed tightening torques, refer to chapter Maintenance “Tightening Torques for Locking Screws and Bleed Valves on

Gearboxes”.

97

Maintenance

11.8.3 Aligning the Cutter Bar

Fig. 49

Oil level check

• Align the cutter bar using a spirit level (1).

Crosswise

• Lay the spirit level on top of the cutting disc hub parallel to the direction of travel.

Lengthwise

• Lay the spirit level (1) on top of two mower discs.

• Allow the machine to run briefly. Do not leave the driver’s cab until the cutting discs/blade drums have come to a complete stop

EC-0-001

EC-0-003

Fig. 50:

Check the oil level before every use

• Remove the oil level inspection screw (1) from the cutting disc hub

• The oil level must be up to the bore hole. If required, top up the oil (SAE 90)

• Screw in the oil level inspection screw (1) again and tighten securely

98

11.9

Maintenance

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.

99

Maintenance

11.10

11.10.1

Checking the Cutter Blades and Blade Holder

Warning! - Missing and damaged cutter blades and cutter blade retainers.

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

• Check cutter blades at least once per day and check retaining bolts every time you change the blades or after contact with foreign objects.

• Immediately replace missing or damaged cutter blades and cutter blade retainers

Cutter Blades

The borehole on the cutter blades may spread due to wear.

Danger! - Insufficient thickness of material on the cutter blades.

Effect: Danger to life or serious injuries.

• The cutter blades must be replaced at the latest when the wear limit is reached (see mark

(1) on the cutter blade; dimension a less than or equal to 13 mm). a

1

EC 253 0

Fig. 51

Note - The cutter blades can be turned around and used on both sides.

• When cutter blades are missing or damaged, they must be replaced as a complete set.

This prevents dangerous unbalanced rotation

100

11.10.2

Maintenance

Blade screw connection

Danger! - Insufficient thickness of material on the retaining bolts.

Effect: Danger to life or serious injuries.

• At every blade changing check the thickness of the holding bolts material.

• Damage or worn retaining bolts must always be replaced by sets on each cutting disc/blade drum!

• The material thickness of the retaining bolts must not be less than 14 mm at the weakest point.

Fig. 52 min. 14 mm EC-240-0

101

Maintenance

11.10.3 Blade Quick-Fit Device

Danger! - Insufficient thickness of material on the retaining bolts.

Effect: Danger to life or serious injuries.

• At every blade changing check the thickness of the holding bolts material.

• Damage or worn retaining bolts must always be replaced by sets on each cutting disc/blade drum!

• The material thickness of the retaining bolts must not be less than 14 mm at the weakest point.

• The material thickness of the leaf spring must not be less than 3 mm at the weakest point.

11.10.4 min. 14 mm EC-239-0

Fig. 53

Checking the Material Thickness of the Retaining Bolts

2 1 a b

EC-241-0

Fig. 54

The material thickness of the retaining bolts and the leaf springs is checked using the supplied gauge (1). The gauge (1) is located on the special tool (2) {blade key}.

Section (a) of the gauge is used to check the material thickness of the retaining bolts.

Section (b) of the gauge is used to check the contour of the leaf springs.

102

11.10.4.1 Checking the material thickness of the retaining bolts

2

1

Maintenance

EC-242-0

Fig. 55

• Remove the cutter

• Clean the area to be checked

• Place the gauge (1) with section (a) against the retaining bolt (2).

• Rotate the gauge (1) by 90 degrees.

• If it is not possible to slide the gauge over the retaining bolt during the rotation, then the retaining bolt is still in working order.

• If it is possible to slide the gauge (2) over the retaining bolt during the rotation, the retaining bolt must be replaced immediately.

103

Maintenance

11.10.5 Periodical Inspection of the Leaf Springs

Danger! - Worn application seam on the leaf springs.

Effect: Danger to life or serious injuries.

• Check the leaf springs for damage at least once a day or after contact with foreign objects.

• The wear limit of the leaf springs is reached when the application seam (1) is worn away at one point. The wear limit must be checked with the gauge (2).

1 1

11.10.6

EC 225 0

Fig. 56

Note

Use only original Krone spare parts to replace the leaf springs.

Checking the Material Thickness of the Leaf Springs

2 1 a b

EC-241-0

Fig. 57

The material thickness of the retaining bolts and the leaf springs is checked using the supplied gauge (1). The gauge (1) is located on the special tool (2) {blade key}.

Section (a) of the gauge is used to check the material thickness of the retaining bolts.

Section (b) of the gauge is used to check the contour of the leaf springs.

104

11.10.6.1 Checking the material thickness of the leaf springs

2

Maintenance

1

EC-243-0

Fig. 58

• Remove the cutter

• Clean the area to be checked

• Push the gauge (1) with section (b) over the retaining bolt of the leaf spring (2), as far as it will go.

1

2

IC

1

2 IIC

EC-244-0

Fig. 59

• If the contour of the leaf spring (2) in section (IC) aligns completely with the contour of the gauge (1), the leaf spring has not yet reached its wear limit.

• If the contour of the leaf spring disappears at any point in section (IIc) behind the contour of the gauge, the leaf spring has reached its wear limit. The leaf spring must be replaced.

105

Maintenance

11.10.7 Periodical Inspection of the Cutting Discs / Blade Drums

Danger! - Deformed Cutting Discs / Blade Drums

Effect: Danger to life or serious injuries.

• Check the cutting discs or blade drums for damages at least once per day or after contact with foreign objects.

• In case of deformed cuttings discs or drums, the dimension of A = 48 mm must never be exceeded.

1

A

EC-0-211

Fig. 60

Note

The cutting discs or drums must be replaced by Original Krone spare parts only.

106

11.10.8

Maintenance

Abrasion Limit

Danger! - Abrasion on the cutting discs / blade drums

Effect: Danger to life or serious injuries.

• The abrasion limit (2) will be achieved if the min. material thickness of 3 mm is no longer given.

2

2

EC-226-0

Fig. 61

Note

If cutting discs or blade drums show deformations or wear in form of abrasions (2) or similar, these components have to be replaced by Original Krone spare parts .

107

Maintenance

11.11 Blade Changing on Cutting Discs

Danger! - Rapidly rotating cutting discs/blade drums.

Effect: Danger to life or serious injuries.

• Switch off the engine and remove the ignition key.

• The cutting discs/blade drums continue to run!

• Do not leave the driver’s cab until the cutting discs/blade drums have come to a complete stop.

Danger! - Cutter blades coming loose

Effect: Danger to life or serious injuries.

• After changing the blades check that they fit perfectly and that they can move freely.

• Whenever a blade is changed, also inspect the fasteners and replace them, if necessary!

• Always replace missing and damaged blades in sets to prevent unbalanced rotation!

• Never mount unevenly worn blades on a drum/disc!

108

11.11.1 Blade Screw Connection

Maintenance

EC-0-250

Fig. 62

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

• Fold up the safety device.

WARNING! Risk of injury due to sharp blades! Wear suitable protective gloves.

• Clean the area around the blades, the cutting discs and the mower drums.

• Dismount the damaged or worn blade.

• To fit the new blade (5), insert it between the wear skid (2) and the cutting disc (1).

• Insert the retaining bolt (3) from below through the wear skid (2), the blade (5) and the cutting disc (1).

• Turn the locknut (4) from above onto the retaining bolt (3) and tighten it.

• Repeat the process for all blades.

• After fitting the blades, fold the safety device down again.

Notice

• The blades for anti-clockwise and clockwise rotating cutting discs/mower drums differ.

When installing the blades, ensure that the direction of rotation is correct!

• The arrow on the blades must match the direction of rotation of the corresponding cutting discs/mower drums.

• The locknut (4) for securing the retaining bolts may be used once only.

Clockwise rotating blade order no.: 139-889

Anti-clockwise rotating blade order no.: 139-888

109

Maintenance

11.11.2 Blade Quick-Fit Device

1

2 3

4

3

4

5

2

EC-251-1

Fig. 63

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

• Fold up the safety device.

WARNING! Risk of injury due to sharp blades! Wear suitable protective gloves.

• Clean the area around the blades, the cutting discs and the mower drums.

• To remove the blade (2), insert the blade wrench (1) between the cutting disc (4) and blade carrier (3) as far as it will go, press it down with one hand and hold it.

Insert the blade wrench (1) between the cutting disc (4) and leaf spring (3) as far as it will go, press it down with one hand and hold it.

• Guide a new blade (2) onto the retaining bolt (5) and release the blade wrench (1) in a controlled manner with your hand.

• Repeat the process for all blades.

• After fitting the blades, fold the safety device down again.

Notice

• The blades for anti-clockwise and clockwise rotating cutting discs/mower drums differ.

When installing the blades, ensure that the direction of rotation is correct!

• The arrow on the blades must match the direction of rotation of the corresponding cutting discs/mower drums.

Clockwise rotating blade order no.: 139-889

Anti-clockwise rotating blade order no.: 139-888

110

11.11.3 Blade change when running "QuickChange tool"

1

2

3

I

Maintenance

II

1

5 4

GPS00088

Fig. 64

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

• Fold up the safety device.

WARNING! Risk of injury due to sharp blades! Wear suitable protective gloves.

• Clean the area around the blades, the cutting discs and the mower drums.

WARNING! Crush hazard due to lowering machine parts! When actuating the lift valve, hands may be crushed. Do not place hands between cutting disc and QuickChange tool.

• Push the Quickchange tool (2) onto the cutting disc (4).

• Push the lift valve (1) into position (I).

The expansion claws (5) press the spring plate of the blade support downwards.

The blade is exposed on one side.

• Replace the damaged or worn blade (3) with a new blade.

• Check the attachment parts of the blade (2), see chapter Maintenance, "Checking the mowing blades and blade support / holder". Also replace worn or damaged fastening parts.

Notice

• The blades for anti-clockwise and clockwise rotating cutting discs/mower drums differ.

When installing the blades, ensure that the direction of rotation is correct!

• The arrow on the blades must match the direction of rotation of the corresponding cutting discs/mower drums.

• Push the lift valve (1) into position (II) to relieve pressure on the cutting disc (4).

• Pull the QuickChange tool (2) off the cutting disc (4).

• Repeat the process for all blades.

• After fitting the blades, fold the safety device down again.

Clockwise rotating blade order no.: 139-889

Anti-clockwise rotating blade order no.: 139-888

111

Maintenance

11.12 Replacing the linings

Caution! - If the linings are checked irregularly.

Effect: Damage to the machine

• Always check the mowing unit for damaged linings prior to start-up and replace linings, if necessary!

• Adjust the welding current and the welding material to the cutter bar material and to the lining or carry out a trial welding if necessary.•

EC-0-012

Fig. 65

• Open the welding seams of the old lining.

• Remove the lining

• Deburr the contact surface.

EC-252-0

Fig. 66

• Adapt the new lining (3).

• Weld short I seams on the upper surface of the cutter bar in the areas marked (1) (each should be approx. 30 mm).

• Do not weld the edges (2).

• On the lower surface of the cutter bar, weld the lining (3) to the cutter bar along the whole length in area (5).

• Do not weld the edges (4).

112

11.13 Rotary hub with shear protection

Maintenance

Fig. 67

A= Direction of rotation to the middle (not provided)

113

Maintenance

Danger! - Rapidly rotating cutting discs/blade drums.

Effect: Danger to life or serious injuries.

• Switch off the engine and remove the ignition key.

• The cutting discs/blade drums continue to run!

• Do not leave the driver’s cab until the cutting discs/blade drums have come to a complete stop.

Explanation of abbreviations:

A= Direction of rotation "A" to the middle

B= Direction of rotation "B" in pairs

RE= Eccentric bearing housing (clockwise threading, without identifying groove).

LE= Eccentric bearing housing (anticlockwise threading), with identifying groove.

For protection against overload on the mowing units, the rotary hubs (1) are secured with nuts

(2) and shear pins (3).

If the machine strikes obstacles (for example stones), the 2 shear pins in the rotary hub will be sheared off. The rotary hub and nut turn upward on the pinion shaft.

• The cutting discs or drums which move crop to the left (as seen in the direction of travel)

(LE) have left-handed threading.

• The cutting discs or drums which move crop to the right (in the direction of travel) (RE) have right-handed threading.

To distinguish between right-hand (clockwise) threading (RE) and left-hand (anti-clockwise) threading (LE), the nuts (2) and pinion shaft (4) for left-hand threading (LE) have a distinctive grove (a, b).

• Left-handed (LE) nuts (2) have distinctive grooves (a) on the bevel.

• Left-handed (LE) pinion shafts (4) have a distinctive groove (b) on the face.

114

11.13.1

Maintenance

After shearing off

Caution! - The correct installation position of the bearing housings is not observed.

Effect: Damage to the machine

• Right-hand cutting (RE) cutting discs and chopping drums always have right-handed pinion shafts and nuts (no groove mark on the pinion shaft and nut).

• Left-hand cutting (LE) cutting discs and chopping drums always have left-handed pinion shafts and nuts (with groove nut on the pinion shaft and nut).

7

8 a

9

2

3

3a

3a

3

3a

4 d b c

1

10

EC-255-1

Fig. 68

115

Maintenance

• Dismount the cutting disc or the chopping drum.

• Remove the retaining ring (7).

• Unscrew the hexagon head screws (8).

• Dismount the nut (2) by means of the provided special key (10).

• Dismount the hub (1).

• Remove the damaged shear pins (3).

• Check nut and hub for damage. Replace damaged parts by KRONE original spare parts.

• Fill the area above the bearing with grease (c).

• Place the hub on the pinion shaft.

• Drive the new shear pins (3) through the hub (1) and the shaft (4).

Note - Observe the position of shear pins!

• Drive the shear pins (3) from outside into the hole until the end of the pin reaches the surface of the hub (d).

• The slots of the shear pins (3) must be mounted facing each other horizontally (see detail

(I)).

• Mount the nut (2) by means of the provided special key (10) (tighten to a tightening torque of 300 Nm.)

• Mount the hexagon head screws (8) with detent edged washers and tighten them.

• Mount the retaining ring (7).

• Mount the cutting disc (5) or the chopping drum (6).

Note

The special key SafeCut is located in a support behind the right protective cover of the machine.

116

11.14

Maintenance

Wear plates for trough

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

1 1

3

3

2

11.15

GPS00062

Fig. 69

The wear plates (1,2) of the trough are subject to natural wear caused by the crops und must therefore be checked for wear once a year, at the latest before the start of the season, and replaced if required.

In case of increased abrasive crops, the wear plate must be checked for wear several times a year and replaced if required.

To do this:

• Loosen the screw connections (3).

• Replace worn wear plate with a new wear plate.

• Ensure that the wear plate (1) is positioned fully on the wear plate (2).

• Tighten the screw connections (3).

Infeed sheets

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

Fig. 70

The infeed sheet (1) on the conveying auger are subject to natural wear caused by the crops und must therefore be checked for wear once a year, at the latest before the start of the season, and replaced if required.

In case of increased abrasive crops, the infeed sheets must be checked for wear several times a year and replaced if required.

To do this:

• Loosen the screw connections (2).

• Replace worn guide plates with new infeed sheet.

• Tighten the screw connections (2).

117

Maintenance

11.16 Rubber strip

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

11.17

GPS00030

Fig. 71

The rubber strips (1) (right and left sides of machine) are subject to natural wear caused by the crops und must therefore be checked for wear once a year, at the latest before the start of the season, and replaced if required.

Replacing rubber strips:

• Loosen the screw connections (2) and replace the rubber strips with new rubber strips.

• Tighten the screw connections (2).

Drive chains

Note

Check the pretension of the drive chains every 10 hours of operation and correct if necessary.

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

2

3

1

4

3

2

GPS00027

Fig. 72

• Open the protective cover (1) on the right-hand side of the machine

• Loosen the counter nut (2) and turn the hexagonal nut (3) to correct the pretension of the chain in the upper and lower areas so that the spring path between the eye screw is 150-

180 mm

• Tighten the counter nut (2)

118

11.18

11.18.1

Maintenance side blades

Checking side blades

Maintenance

1

2

1

11.18.2

GPS00081

Fig. 73

Prerequisite:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

WARNING! Danger of cuts from sharp blades. Wear suitable protective gloves.

• Check the blades for damage.

• Grind or replace the blades, if necessary; refer to chapter Maintenance, "Maintenance side blades".

• Ensure that the blade guides (1) are adjusted so that they are free from backlash and that they do not jam.

• Adjust the blade guides by means of the screws (2), if necessary. A gap of up to 3 mm between the blade tips and the both blades lying on top of each other does not negatively influence the cutting quality.

Changing Blades

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

Dismounting blades

1 1

3

2

GPS00082

Fig. 74

Prerequisites:

– The machine has been shut down and safeguarded, refer to chapter Safety, "Shutting down and safeguarding the machine".

– The side blades are placed on the machine, refer to chapter Maintenance, "Side blades".

• Remove the protective profile.

WARNING! Danger of cuts from sharp blades. Wear suitable protective gloves.

• To dismount the cover (1), remove the screws (2).

119

Maintenance

1

2

4

3 5

GPS00083

Fig. 75

• To dismount the internal blade, remove the screws (1, 3) and lay them aside with the angle sheet (2).

• Push the blade out of the guide strips (4).

1 4

2 3

Fig. 76

• To dismount the external blade, dismount the screw connections (2).

• Push the blade (3) out of the guide strips (1).

Mounting blade

1

GPS00084

4

2 3

Fig. 77

• Insert the new or ground, external blade (3) through the guide rails (1).

• Ensure that the crankshaft (4) is at its dead centre.

• Mount the screw connections (2).

GPS00084

120

1

2

4

5

Maintenance

6

Fig. 78

• Insert the new or ground, internal blade (7) through the guide rails (4).

• Ensure that the crankshaft (6) is at its dead centre.

• Mount the angle sheet (2) with the screw connections (3).

• Mount the connecting rod (5) with the screw (1) on the angle sheet (2).

1

3

1

3

2

7

GPS00085

GPS00082

Fig. 79

• Mount the cover (1) with the screws (2).

• Attach the protective profile (3).

121

Maintenance

11.18.3 Check hydraulic hoses

250 BAR 43/2010

11.18.4

250 BAR 43/2010

EFL000026

Fig. 80

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.

Malfunctions on the side blade

Malfunction: The blade guides melt

Possible causes Remedy

The blades are bent.

The blade guides have been overtightened.

• Align bent blades and replace them, if necessary; refer to chapter Maintenance, "Checking side blades/replacing blades".

• Adjust the blade guides so that they are free from backlash, refer to chapter Maintenance, "Checking side blades/changing blades".

Malfunction: 1 blade or both blades stop.

Possible causes Remedy

Overload due to high density of the crops

• Switch off the side blade which is not used, refer to chapter Operation, "Operating side blades".

• Reduce the driving speed.

122

This page has been left blank deliberately.

Maintenance

123

Maintenance – lubrication

12

12.1

Maintenance – lubrication

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

Special Safety Instructions

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

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

• Move machine into the working position and lower it to the ground

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• Switch off the PTO shaft and disengage it.

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

• 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.

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.

124

12.2 PTO shaft

Maintenance – lubrication

100 h

250 h

GPS00060_1

Fig. 81

Lubricate the universal shafts with multi-purpose grease at the intervals indicated in the figure.

Follow the operating instructions of the universal shaft manufacturer.

For "Pendulum frame adaptation" and "Mechanical universal shaft coupling" (in conjunction with BiG X 480-630 or BiG X 680-1180, each for variant 2700)

Universal shaft for the forage harvester:

100 h

100 h

GPS00086_1

Fig. 82

Lubricate the universal shaft with multi-purpose grease at the intervals indicated in the figure.

Follow the operating instructions of the universal shaft manufacturer.

125

Maintenance – lubrication

12.3 Lubrication Chart

The lubrication points mentioned below must be lubricated after the operating hours indicated.

25 h

25 h

250 h

25 h

250 h

250 h

Fig. 83

25 h 10 h 25 h 25 h

GPS00061_1

126

For the version with "side blades"

Maintenance – lubrication

10 h

1

10 h

2

GPS00080

Fig. 84

1 Lubricate between the both blades lying on top of each other. In doing so, ensure that the blade tips are not wetted with lubricating grease.

127

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.

128

14

14.1

Before the Start of the New Season

Before the Start of the New Season

WARNING!

If the basic safety instructions are not followed, people may be seriously injured or killed.

• To avoid accidents, the basic safety instructions in the chapter Safety must have been read and followed, see chapter Safety "Basic safety instructions".

WARNING!

If the safety routines are not adhered to, people may be seriously injured or killed.

• To avoid accidents, the safety routines in the chapter Safety must be read and followed, see chapter Safety "Safety routines".

Special Safety Instructions

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

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

• Move machine into the working position and lower it to the ground

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• Switch off the PTO shaft and disengage it.

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

• 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.

Warning! - When performing repair, maintenance or cleaning work or in case of technical intervention on the machine, drive elements may start moving (caution: cutting discs continue running).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO shaft.

• Switch off the forage harvester engine and remove the ignition key.

• Secure the forage harvester against unintentionally starting up and rolling away.

• When working under or on the raised machine, always secure it with suitable supporting elements.

• Close the stop cock on the lifting cylinder of the forage harvester!

• When all repair, maintenance or cleaning tasks are complete, all guard sheets and safety devices must be re-attached.

129

Before the Start of the New Season

14.2 Test run.

Warning! - 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 on the ground and ensure that there are no people, animals or objects in the danger zone.

• Start a trial 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.

130

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.

131

16 Index

A

Abrasion Limit ................................................... 107

Adapt the machine to the forage harvesters BiG X

600/700/770/850/1100 .................................... 63

Additional equipment and spare parts ................ 19

Adjusting machine to the forage harvester BiG X

480/530/580/630 and BiG X 680/780/880/1180

........................................................................ 56

Adjusting the locking plates ................................ 57

After shearing off .............................................. 115

Aligning cutting unit ............................................. 66

Aligning the Cutter Bar ........................................ 98

Attaching Safety Labels and Information Labels 41

B

Basic safety instructions ..................................... 17

Before the Start of the New Season ................. 129

Behaviour in hazardous situations and when accidents occur ............................................... 30

Blade change when running ............................. 111

Blade Changing on Cutting Discs ..................... 108

Blade Quick-Fit Device ............................. 102, 110

Blade screw connection .................................... 101

Blade Screw Connection .................................. 109

C

Changing Blades .............................................. 119

Checking side blades ........................................ 119

Checking the Cutter Blades and Blade Holder . 100

Checking the material thickness of the leaf springs

...................................................................... 105

Checking the Material Thickness of the Leaf

Springs .......................................................... 104

Checking the material thickness of the retaining bolts .............................................................. 103

Checking the Material Thickness of the Retaining

Bolts .............................................................. 102

Children in danger .............................................. 18

Commissioning ................................................... 55

Connecting front attachments or trailers ............. 18

Consumables ................................................ 27, 54

Contact ............................................................... 50

Contact for KRONE NORTHAMERICA .............. 41

Conversion table ................................................. 13

Cutter Blades .................................................... 100

D

Danger zones ..................................................... 21

Dangers associated with certain activities

Work on the machine ...................................... 29

132

Dangers associated with the operational environment ................................................... 27

Detaching the machine ...................................... 67

Direction Information ............................................ 9

Directories and References ................................. 9

Disposal of the machine ............................... 131

Driving and Transport ........................................ 71

F

From transport into working position .................. 75

Further applicable documents ............................. 8

H

How to use this document ................................... 9

I

Identification Plate .............................................. 49

Importance of the operating instructions............ 17

Infeed sheets ................................................... 117

Information Required for Questions and Orders 49

Input gearbox ..................................................... 94

Intended use ...................................................... 15

Intermediate gearbox ......................................... 95

K

Keeping safety devices functional ..................... 24

L

Lashing the machine .......................................... 72

Lifting the machine ............................................. 73 location and meaning of the information labels on the machine ................................................... 42

Lubricating grease ............................................. 54

Lubrication Chart .............................................. 126

M

Machine overview .............................................. 46

Maintenance ...................................................... 87

Maintenance - lubrication ................................. 124

Maintenance side blades ................................. 119

Maintenance table .............................................. 89

Malfunctions on the side blade ........................ 122

Means of representation .................................... 10

Notes with information and recommendations 12

Warning signs ................................................. 12

Means of Representation

Figures ............................................................. 9

Metric Thread Screws with Control Thread ....... 91

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................... 92

Metric Thread Screws with Fine Thread ............ 92

Mounting Machine on Forage Harvester ............ 70

Mounting the front attachment ............................ 64

O

Oil level check and oil change on the cutter bar . 97

Oils ...................................................................... 54

Operating side blades (for the version ................ 77

Operating the crop press roller (for version ........ 80

Operation ............................................................ 75

Operational safety: Technically perfect condition

........................................................................ 20

Overload protection ............................................ 51

Overview of the different adaptation types ......... 48

P

Parking the machine safely ................................ 26

Periodical Inspection of the Cutting Discs / Blade

Drums ........................................................... 106

Periodical Inspection of the Leaf Springs ......... 104

Personal protective equipment ........................... 24

Personnel qualification........................................ 17

Placing in Storage ............................................. 128

Position of the Adhesive Safety Stickers on the

Machine .......................................................... 34

Preparing the pendulum frame for installation of the front attachment ........................................ 64

PTO shaft .......................................................... 125

Purpose of Use ................................................... 15

R

Reasonably foreseeable misuse ........................ 16

Releasing star ratchet clutch at the universal shaft

........................................................................ 99

Removing Machine from Forage Harvester ........ 76

Re-Ordering Safety Labels and Information Labels

........................................................................ 41

Re-Ordering this Document .................................. 8

Replacing the linings ......................................... 112

Rubber strip ...................................................... 118

S

Safely checking the oil level and changing the oil and filter element ........................................... 33

Safety ................................................................. 15

Safety routines ................................................... 32

Safety signs on the machine .............................. 25

Scope of Document ........................................... 10

Service life of the machine ............................. 16

Set Ground Skid ................................................. 85

Setting Infeed Sheets ........................................ 85

Setting input gearbox ......................................... 60

Settings .............................................................. 83

Shutting down and safeguarding the machine .. 32

Sources of danger on the machine .................... 27

Spare Parts ........................................................ 88

Start-up .............................................................. 69

Structural changes to the machine .................... 19

Supporting lifted machine and machine parts securely .......................................................... 32

Switching off the machine .................................. 71

T

Target group of this document ............................. 8

Technical data .................................................... 53

Term ..................................................................... 9

Test run ............................................................ 130

Test run .............................................................. 88

Tightening torques ............................................. 91

Tightening Torques for Locking Screws and Bleed

Valves on the Gearboxes .............................. 93

Traffic safety ...................................................... 25

W

Wear plates for trough ..................................... 117

Working Position ................................................ 75

Workstations on the Machine ............................ 19

133

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]

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