Krone EasyCollect 450-2 FP, EasyCollect 600-2 FP, EasyCollect 750-2 FP Operating Instructions


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Krone EasyCollect 450-2 FP, EasyCollect 600-2 FP, EasyCollect 750-2 FP Operating Instructions | Manualzz

EasyCollect 450-2 FP

EasyCollect 600-2 FP

EasyCollect 750-2 FP

(from serial no.: 976 393)

Order no.: 150 000 797 02 us

Maize header

21.06.2018

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 ..................................................................................................................................................... 14

3.1

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

3.2

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

3.3

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

3.4

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

3.5

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

3.5.1

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

3.5.2

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

3.5.3

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

3.5.4

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

3.5.5

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

3.5.6

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

3.5.7

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

3.5.8

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

3.5.9

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

3.5.10

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

3.5.11

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

3.5.12

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

3.5.13

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

3.5.14

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

3.5.15

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

3.5.16

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

3.5.17

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

3.5.18

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

3.5.19

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

3.5.20

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

3.6

Safety routines ................................................................................................................................. 29

3.6.1

Stopping and securing the machine .......................................................................................... 29

3.6.2

Supporting lifted machine and machine parts securely ............................................................ 29

3.6.3

Safely checking the oil level and changing the oil and filter element ........................................ 30

3.7

Position of the Adhesive Safety and Information Labels on the Machine ........................................ 31

3.7.1

Re-Ordering Safety Labels and Information Labels .................................................................. 37

3

Table of Contents

3.7.2

Attaching Safety Labels and Information Labels ...................................................................... 37

3.7.3

Contact for KRONE NORTHAMERICA .................................................................................... 37

4 Machine Description ............................................................................................................................ 38

4.1

Machine overview ............................................................................................................................. 38

4.2

Identification Plate ............................................................................................................................ 43

4.3

Information Required for Questions and Orders .............................................................................. 43

4.3.1

Contact for KRONE NORTHAMERICA .................................................................................... 43

4.4

Adaptations approved ...................................................................................................................... 44

5 Technical data ....................................................................................................................................... 45

5.1

Ballasting of forage harvester .......................................................................................................... 46

5.2

Consumables ................................................................................................................................... 47

5.2.1

Oils ............................................................................................................................................ 47

5.2.2

Lubricating grease ..................................................................................................................... 47

6 Initial operation - Claas ........................................................................................................................ 48

6.1

Adapting Machine to CLAAS Forage Harvester Type 493, Type 494, Type 496, Type 497 ........... 48

6.1.1

Aligning the coupling disc ......................................................................................................... 50

7 Initial operation – John Deere ............................................................................................................. 55

7.1

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ............... 56

7.2

Adapting the machine to the John Deere forage harvester of the 8000 series with universal shaft 58

7.3

Adapting the machine to the John Deere forage harvester of the 8000 series with quick coupler for header 61

7.3.1

Aligning the coupling disc ......................................................................................................... 62

8 Initial operation – New Holland ........................................................................................................... 68

8.1

Adapting the machine to the New Holland forage harvester............................................................ 68

9 Start-up - CLAAS .................................................................................................................................. 72

9.1

Checking and observing before start-up .......................................................................................... 72

9.2

Attachment to the CLAAS forage harvester ..................................................................................... 73

9.3

Coupling ........................................................................................................................................... 73

9.3.1

Connecting Drive Type 491, Type 492 ..................................................................................... 74

9.3.2

Connecting Drive Type 493, Type 494, Type 496, Type 497 ................................................... 74

9.3.3

Connecting the hydraulic lines .................................................................................................. 75

10 Start-up – John Deere .......................................................................................................................... 77

10.1

Checking and observing before start-up .......................................................................................... 77

10.2

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ............... 78

10.3

Coupling ........................................................................................................................................... 78

10.3.1

Connecting drive ....................................................................................................................... 80

10.3.2

Connecting the hydraulic lines .................................................................................................. 81

10.4

Mounting to John Deere forage harvester of 8000 series ................................................................ 83

10.4.1

Connecting drive ....................................................................................................................... 83

10.4.2

Connecting hydraulics and electrics ......................................................................................... 85

11 Start-up - New Holland Start-up - New Holland ................................................................................. 86

11.1

Checking and observing before start-up .......................................................................................... 86

11.2

Mounting on New Holland forage harvesters ................................................................................... 87

11.3

Coupling ........................................................................................................................................... 87

11.3.1

Connecting drive ....................................................................................................................... 89

11.3.2

Connecting the hydraulic lines .................................................................................................. 90

12 Driving and Transport .......................................................................................................................... 92

4

Table of Contents

12.1

Preparing the machine for road travel .............................................................................................. 93

12.2

Switching off the machine ................................................................................................................ 94

12.3

Lifting the machine ........................................................................................................................... 95

13 Operation ............................................................................................................................................... 96

13.1

From transport into working position ................................................................................................ 96

13.1.1

Removing the protective cover ................................................................................................. 96

13.1.2

Support jacks right/left in transport position .............................................................................. 97

13.1.3

Swinging the right-hand / left-hand side parts into working position ......................................... 98

13.2

Using the Machine for Work ............................................................................................................. 99

13.2.1

Inserting Maize Header ............................................................................................................. 99

13.2.2

Setting the rotational speed of the maize header (Claas, John Deere) .................................. 100

13.2.3

Setting the rotational speed of the maize header (New Holland) ........................................... 100

13.2.4

Operating main gearbox (Claas, John Deere) ........................................................................ 101

13.2.5

Operating input gearbox (Claas) ............................................................................................. 102

13.2.6

Operating row detection (for the version with “row detection”) ............................................... 103

13.2.7

Operating active ground contour (for the version with “active ground contour”)..................... 106

13.3

Switching from working position to transport position .................................................................... 110

13.3.1

Swinging the right hand / left hand side parts upward into transport position ........................ 110

13.3.2

Installing guard on the right/left ............................................................................................... 111

13.3.3

Installing the front guard.......................................................................................................... 111

13.3.4

Connecting indicators and position lights on the right/left....................................................... 112

13.4

Detaching the machine................................................................................................................... 113

13.4.1

Moving the right hand / left hand parking supports into parking position ................................ 113

13.4.2

Swinging the right-hand / left-hand side parts into working position ....................................... 114

13.5

Dismantling the machine in case of adaptation to Claas forage harvester .................................... 115

13.5.1

Removing Hydraulic Lines ...................................................................................................... 115

13.5.2

Connecting .............................................................................................................................. 115

13.5.3

For version with universal shaft (e.g. type 491 und 492) ........................................................ 116

13.5.4

For version with header quick coupler (e.g. type 493, 494, 496 und 497) .............................. 116

13.6

Dismantling the machine in case of adaptation to John Deere forage harvester of 6000 and 7000 series 117

13.6.1

Removing Hydraulic Lines ...................................................................................................... 117

13.6.2

Connecting .............................................................................................................................. 117

13.7

Dismantling the machine in case of adaptation to John Deere forage harvester of 8000 series .. 119

13.7.1

Disconnecting hydraulics and electrics ................................................................................... 119

13.7.2

Disconnecting header ............................................................................................................. 120

13.8

Dismantling the machine in case of adaptation to Claas forage harvester .................................... 121

13.8.1

Removing Hydraulic Lines ...................................................................................................... 121

13.8.2

Connecting .............................................................................................................................. 122

13.9

Removing the machine and storing it with supports (for the version with supports) ...................... 123

13.9.1

Support jacks right/left in transport position ............................................................................ 124

13.9.2

Relocating the support jack bracket ........................................................................................ 124

13.9.3

Mounting console support ....................................................................................................... 125

13.9.4

Mounting side guards .............................................................................................................. 126

13.9.5

Setting the lateral supports at rear .......................................................................................... 127

13.9.6

Putting header down ............................................................................................................... 128

14 Settings ............................................................................................................................................... 129

14.1

Setting the Tubular Bars ................................................................................................................ 129

14.1.1

Setting the tubular bar in terms of its inclination (EasyCollect 600-2 FP, 750-2 FP) .............. 130

5

Table of Contents

14.1.2

Setting the tubular bar in terms of its inclination (EasyCollect 450-2 FP, 750-2 FP) .............. 132

14.2

Setting Holding-Down Device Roller .............................................................................................. 133

14.3

Adjusting skids ............................................................................................................................... 133

14.4

Adjusting the plant dividers ............................................................................................................ 134

14.5

Adapting Star-shaped Conveyor Height to Maize Crop ................................................................. 135

14.6

Setting the Star-shaped Conveyor Speed...................................................................................... 136

14.7

Setting the oscillating movement of the header ............................................................................. 137

15 Maintenance ........................................................................................................................................ 139

15.1

Special Safety Instructions ............................................................................................................. 139

15.2

Hydraulic hose line(s) ..................................................................................................................... 139

15.2.1

Test run ................................................................................................................................... 140

15.3

Spare Parts .................................................................................................................................... 140

15.4

Maintenance table .......................................................................................................................... 141

15.5

Tightening torques .......................................................................................................................... 142

15.5.1

Metric Thread Screws with Control Thread............................................................................. 142

15.5.2

Metric Thread Screws with Fine Thread ................................................................................. 143

15.5.3

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................. 143

15.5.4

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes ....................... 144

15.6

Hydraulics ....................................................................................................................................... 145

15.7

Hydraulic circuit diagram ................................................................................................................ 146

15.8

Input gearbox ................................................................................................................................. 147

15.9

Main gearbox .................................................................................................................................. 149

15.10

Collector Gearbox .......................................................................................................................... 150

15.11

Roller Manual Gearbox .................................................................................................................. 152

15.12

Roller Gearbox ............................................................................................................................... 153

15.13

Checking and adjusting the collector tension ................................................................................. 154

15.13.1

Checking the collector pre-tension .......................................................................................... 154

15.13.2

Adjusting the collector pretension ........................................................................................... 154

15.14

Adjusting the Scraper ..................................................................................................................... 155

15.14.1

Checking the gap dimensions of the infeed sheets ................................................................ 157

15.15

Changing the tips ........................................................................................................................... 158

15.16

Adjusting the tips ............................................................................................................................ 158

15.16.1

Adjusting the side tips ............................................................................................................. 159

15.16.2

Adjusting the row tips .............................................................................................................. 159

15.16.3

Adjusting the central tip ........................................................................................................... 159

15.17

Removing and Installing Guide Bracket at Tip Retainer ................................................................ 160

15.18

Converting Tip Retainer for Special Row Distances ...................................................................... 161

15.19

Blade Changing .............................................................................................................................. 162

15.19.1

Changing bow and step blades ............................................................................................... 162

15.19.2

Changing the cutting blades ................................................................................................... 164

15.19.3

Changing the scraper blade .................................................................................................... 165

15.20

Replacing wear plates .................................................................................................................... 165

15.21

Adjusting the tip retainer EC 600-2, 750-2 for 38" row spacing ..................................................... 166

16 Maintenance – lubrication ................................................................................................................. 168

16.1

Special Safety Instructions ............................................................................................................. 168

16.2

Lubrication Chart ............................................................................................................................ 169

17 Placing in Storage .............................................................................................................................. 172

18 Before the Start of the New Season ................................................................................................. 173

6

Table of Contents

18.1

Special Safety Instructions ............................................................................................................. 173

18.2

Test run. ......................................................................................................................................... 174

19 Disposal of the machine .................................................................................................................... 175

19.1

Disposal of the machine ................................................................................................................. 175

20 Index .................................................................................................................................................... 176

7

To this Document

2 To this Document

2.1

2.2

2.3

2.4

Validity

These operating instructions apply to maize headers of the following types:

EasyCollect 450-2 FP; EasyCollect 600-2 FP; EasyCollect 750-2 FP

Re-Ordering

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

The document can additionally be downloaded via the KRONE Media Center http://www.mediathek.krone.de// .

Further applicable documents

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

– Operating instructions of universal shaft(s)

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”

In the further course of this document, the maize 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

1

Explanation

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

Warning

WARNING! - Type and source of hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention.

Caution

CAUTION! - Type and source of hazard!

Effect: Damage to property.

• Measures for risk prevention.

Notes with information and recommendations

Note

Note

Effect: Economic benefit of the machine.

• Measures to be performed.

12

2.5.7

To this Document

Conversion table

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

Quantity SI Units (Metric) Factor Inch-Pound Units

Area

Flow

Force

Length

Power

Pressure

Torque

Velocity

Volume

Weight

Unit Name Abbreviation hectare liters per minute 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

Temperature degree

Celsius meter per minute meter per second kilometer per hour liter milliliter cubic centimeter kilogram

°C m/min m/s km/h

L ml cm³ kg

2.47105

0.2642

4.4029

0.2248

0.03937

3.2808

1.3410

0.1450

145.0377

14.5038

0.7376

Unit Name acre

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

8.8507 pound-inch or inch-pound

°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

Abbreviation acres gpm lbf in. ft. hp psi ft∙lbf in∙lbf

°F ft/min ft/s mph

US gal.

US oz. in³ lbs

13

Safety

3

3.1

Ver

3.2

Safety

Purpose of Use

The KRONE maize header EasyCollect 450-2 FP, EasyCollect 600-2 FP, EasyCollect 750-2 is a maize header including an adaptation for mounting it to certain forage harvester types of the brands Claas, John Deere and New Holland.

The KRONE maize header EasyCollect 450-2 FP, EasyCollect 600-2 FP, EasyCollect 750-2 FP is used for harvesting maize and other thick-stalked forage crops indepently of rows.

Intended use

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

The crops designated for the intended use of this machine are 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.

14

3.3

3.4

Safety

Reasonably foreseeable misuse

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

Such misuse is for example:

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

“Intended use”

– Transportation of people

– Transportation of goods

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

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

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

– Unauthorised modifications to the machine

– Attachment of unauthorised or unapproved additional equipment

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

– Stationary operation of the machine

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

Service life of the machine

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

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

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

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

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

15

Safety

3.5

3.5.1

3.5.2

Basic safety instructions

Non-compliance with the safety instructions and warnings

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

Importance of the operating instructions

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

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

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

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

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

• Hand over the operating instructions to subsequent users.

Personnel qualification

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

– He is physically capable of controlling the machine.

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

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

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

– He is familiar with driving vehicles safely.

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

16

3.5.3

3.5.4

3.5.5

Safety

Personnel qualification of the technicians

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

• Qualified professional, with relevant training.

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

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

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

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

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

Children in danger

Children cannot assess danger and behave unpredictably.

As a result, children are especially at risk.

• Keep children away from the machine.

• Keep children away from consumables.

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

Coupling the machine safely

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

• Observe all operating instructions when connecting:

– The operating instructions of the machine

– The operating instructions of the forage harvester

– The operating instructions of universal shaft

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

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

• Observe the changed driving behaviour of the combination.

17

Safety

3.5.6

3.5.7

3.5.8

Structural changes to the machine

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

Structural changes and enhancements are not permitted.

Additional equipment and spare parts

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

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

Workstations on the Machine

Passengers

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

Ejected objects may strike and injure passengers.

• Never let people ride on the machine.

18

3.5.9

Safety

Operational safety: Technically perfect condition

Operation only when the machine has been started up correctly

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

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

Technically perfect condition of the machine

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

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

Adjustment.

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

Danger resulting from damage to the machine

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

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

– Safety devices

– Connecting devices

– Hydraulic system

– Universal shafts

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

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

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

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

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

Technical limit values

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

– Maximum permitted operating pressure of hydraulics

– Maximum permitted drive speed

– Maximum permitted axle loads of forage harvester

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

19

Safety

3.5.10 Danger zones

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

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

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

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

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

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

The safety clearance is:

For a machine in shunting operation and field mode

In front of the machine

Behind the machine

Laterally to the machine

30 m

3 m

3 m

For machine switched on without driving motion

In front of the machine

Behind the machine

Laterally to the machine

3 m

3 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 working in the danger zone of the machine: Shutdown and safeguard the machine, refer to chapter Safety “Shutting Down and Safeguarding the Machine”. This also applies to brief inspection work.

• Follow the information in all operating instructions concerned:

– The operating instructions of the machine

– The operating instructions of universal shaft

– The operating instructions of header

– The operating instructions of transport wagon

20

Safety

Danger zone universal shaft

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

• Observe the operating instructions of the universal shaft.

• Provide the section tube and universal shaft guards with adequate cover.

• Allow the universal shaft locks to engage.

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

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

• Make sure that the universal shaft guards are attached and functional.

• If the angles between universal shaft and PTO shaft are too large, switch off the PTO shaft.

The machine may be damaged. Parts could be hurled up and hurt people.

Danger zone PTO shaft

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

Before switching on the PTO shaft:

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

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

• Switch off the drives if they are not necessary.

Danger zone between precision forage harvester and header

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

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

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

Danger zone because objects may shoot out

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

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

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

21

Safety

3.5.11

Danger zone when drive is switched on

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

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

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

Danger zone due to coasting machine parts

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

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

– Universal shafts or quick coupler

– Collector

– Rotating towers

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

Keeping safety devices functional

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

• Replace damaged safety devices.

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

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

22

3.5.12

3.5.13

Safety

Personal Protective Equipment

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

Personal protective equipment is for example:

– Suitable protective gloves

– Safety boots

– Tight-fitting protective clothing

– Hearing protection

– Protective goggles

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

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

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

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

Wear suitable clothing

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

• Wear tight-fitting clothing.

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

• Cover long hair with a hairnet.

• Wear sturdy shoes or protective work boots.

Safety signs on the machine

Safety stickers on the machine warn of hazards in danger areas and are an important component of the safety equipment of the machine. Missing safety stickers increase the risk of serious and fatal injuries.

• Clean dirty safety stickers.

• After cleaning, always check that safety stickers are complete and legible.

• Immediately replace missing, damaged and unrecognisable safety stickers.

• Provide spare parts with the designated safety stickers.

Description, explanation and order numbers of the safety stickers, see chapter Safety, "Safety stickers on the machine".

23

Safety

3.5.14

3.5.15

Traffic safety

Dangers in road traffic

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

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

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

Danger when driving on road and field

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

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

Transport”.

Dangers if machine is not prepared properly for road travel

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

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

Transport, “Preparations for Road Travel”.

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 improperly parked machine may move uncontrollably or overturn. As a result, people may be crushed or killed.

• Park the machine on horizontal and level ground capable of bearing the load.

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

• Observe section “Parking the Machine” in chapter Driving and Transport.

Unattended parking

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

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

“Shutting Down and Safeguarding the Machine“.

24

3.5.16

3.5.17

Safety

Consumables

Unsuitable consumables

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

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

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

Environmental protection and disposal

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

• Do not release consumables into the environment.

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

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

Dangers associated with the operational environment

Danger of fire

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

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

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

Check and clean the machine regularly during the working day.

25

Safety

3.5.18 Sources of danger on the machine

Noise may damage your health

The noise development of the machine during operation may cause health damage such as hardness of hearing, deafness or tinnitus. When using the machine at high rotational speed, the noise level also increases.

• Estimate the danger caused by noise before starting up the machine. Depending on the ambient conditions, working hours and the working and operating conditions of the machine, specify and use suitable hearing protection. In doing so, consider the sound pressure level, see chapter Description of Machine, “Airborne Noise Emission”.

• 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 when travelling on the road.

Liquids under high pressure

The following liquids are under high pressure:

– Hydraulic oil

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

• Shut down and safeguard the machine and contact qualified specialist workshop upon suspicion of damaged pressure system.

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

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

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

• If liquids penetrate 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.

26

3.5.19

Safety

Dangers associated with certain activities: Work on the machine

Work on the machine only when it has been shut down

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

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

Machine”.

Maintenance and repair work

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

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

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

Raised machines and machine parts

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

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

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

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

27

Safety

3.5.20

Danger associated with welding work

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

• Never weld on the following components:

– Gearbox

– Components of the hydraulic system

– Components of the electronics

– Frame or bearing component groups

– Running gear

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

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

• Have welding work performed by experienced technicians only.

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

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

Behaviour in hazardous situations and when accidents occur

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

• In principle: Switch off the machine.

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

• Safeguard the accident location.

• Rescue people from the danger zone.

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

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

• Take immediate life-saving measures.

28

3.6

3.6.1

3.6.2

Safety

Safety routines

Stopping and securing 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.

29

Safety

3.6.3 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”.

30

GL

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

Safety

Fig. 1

31

L

L

27 002 701 0

4) Order No. 27 002 057 0 (4x)

Warning

To avoid personal injury.

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

WARNING

To avoid personal injury.

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

27 002 057 0

32

GL

Safety

Fig. 2

33

L

7) 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.

27 002 702 0

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.

34

GL

Safety

Fig. 3

35

L

36

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

37

Machine Description

4 Machine Description

4.1 Machine overview

3 4 5

1

2

13 14

12

15

11

8

10

9

16 15

6

7

17 18 19 11 20 21

EC500131_1

Fig. 4

1) Collector including blades, right

2) Plant divider 3) Crop press roller

4) Infeed sheet 5) Star-shaped conveyor 6) Rotating tower

7) Collector including blades, left 8) Guide bracket 9) Central tip

10) Row tip

13) Tubular bar

16) Document storage tube

19) Main gearbox

11) Support jack

14) Lateral frame, left

17) Coupling disc

20) Lateral frame, right

12) Side tip

15) Folding cylinder

18) Input gearbox

21) Sliding skid

38

For adaptation Claas version

1 2 3

Machine Description

4

6 5

EC500158

Fig. 5: Example: EasyCollect 600-2 FP for Claas forage harvesters

1) Pendulum tension spring 2) Receiving pocket

4) Connecting rod 5) Lower holder

3) Locking lever

6) Intermediate frame

39

Machine Description

For version adaptation John Deere of 6000 and 7000 series

1 2 3 2

4

EC500159

Fig. 6: Example: EasyCollect 600-2 FP for John Deere forage harvesters of 6000 and 7000 series

1) Intermediate frame

4) Locking boreholes

2) Connecting area 3) Pendulum tension spring

40

For version adaptation John Deere of 8000 series

1 2 1

Machine Description

3

EC500174

Fig. 7: Example: EasyCollect 600-2 FP for John Deere forage harvesters of 8000 series

1) Boreholes for connection 2) Intermediate frame 3) Lower holders

41

Machine Description

For adaptation New Holland version

1

3 2

Fig. 8: Example: EasyCollect 750-2 FP for New Holland forage harvesters

1) Adapter frame 2) Locking 3) Cross beam

EC500160

42

4.2 Identification Plate

Machine Description

1

4.3

4.3.1

EC500001

Fig. 9

The machine data are located on the type plate (1).

Information Required for Questions and Orders

Machine number/VIN

Note

The entire identification plate represents a legal document and should not be altered or rendered illegible!

When submitting enquiries about the machine and when ordering spare parts, you must specify the machine number/VIN. You can find the machine number on the type plate on the line

Machine number/VIN. To ensure that these data are always available, we recommend that you enter them in the fields above.

Note

Original KRONE spare parts and accessories authorised by the manufacturer help to ensure safety. The use of spare parts, accessories or additional equipment not manufactured, tested or approved by KRONE will exclude any liability for consequential damage.

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

43

Machine Description

4.4 Adaptations approved

Carrier vehicles for which the maize header is approved in connection with the corresponding adaptation.

Manufacturer Type Accessories kit

Claas

John Deere

Jaguar type 491

Jaguar type 492

Jaguar type 493

Jaguar type 494

Jaguar type 496

Jaguar type 497

6610, 6710, 6810, 6910,

6650, 6750, 6850, 6950,

20 290 186 0

20 290 185 0

20 292 950 1

New Holland

7200, 7300, 7400, 7500,

7250, 7350, 7450, 7550,

7180, 7280, 7380, 7480, 7580

7700, 7800, 20 292 951 1

7750, 7850, 7950

7780, 7980

FR 9040, 9050, 9060, 9080, 9090 20 097 429 0

FR 450, 500, 600, 700, 850

FR 480, 550, 650, 780, 850

In order to adapt the forage harvester types John Deere 8000-8800 a basic adaptation and a supplementary kit suitable for the for forage harvester must have been mounted.

Manufacturer/type Adaptation

John Deere

8000-8800

Basic adaptation JD 8000-8800

Basic adaptation JD 8100-8500

Basic adaptation JD 8600-8800

Accessories kit

20 298 100 0

20 298 101 0

20 298 102 0

44

5

Technical data

Technical data

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

Indication EasyCollect 450-2 FP EasyCollect 600-2 FP

Length

Height in working position

Total width in working position

Working width

Height (folded in)

Width (folded in)

Weight

Drive speed

2190 mm

1500 mm

4650 mm

4500 mm

2560 mm

2900 mm

2600 kg

300 - 700 rpm

Maximum permitted operating pressure

Hydraulic connections

200 bar

1x DA 1

Electrical connection 12V

(lighting)

1 double-acting hydraulic connection

7-pole

2190 mm

1500 mm

6150 mm

6000 mm

3310 mm

2900 mm

3000 kg

300 - 700 rpm

200 bar

1x DA

7-pole

1

Indication EasyCollect 750-2 FP

Length

Height in working position

Total width in working position

Working width

Height (folded in)

Width (folded in)

Weight

Drive speed

2190 mm

1500 mm

7550 mm

7500 mm

4000 mm

2900 mm

3300 kg

300 - 700 rpm

Maximum permitted operating pressure

Hydraulic connections

200 bar

1x DA 1

Electrical connection 12 V

(lighting)

1 double-acting hydraulic connection

7-pole

45

Technical data

5.1 Ballasting of forage harvester

Notice

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

The possible necessary rear weight is not part of the scope of delivery.

Notice

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

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

Notice

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

Germany. This must be checked on a case-by-case basis.

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

46

5.2

5.2.1

5.2.2

Technical data

Consumables

Biodegradable consumables can be used on request.

Oils

Designation

Input gearbox

Adaptation Claas

Input gearbox

Adaptation John Deere

Input gearbox

Adaptation New Holland

Main gearbox

Collector gearbox

Filling quantity

0.85 L

1.3 L

1.3 L

Specification

SAE 90 GL 4,

e. g.:

- Esso Spartan EP 150

- Shell Omala Oil 150

- Fuchs- EP 85 W90

- Castrol EPX 90

1.0 L

2 x 3.3 L

Intermediate gearbox starshaped conveyor

Roller gearbox

0.3 L

2 x 0.06 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

47

Initial operation - Claas

6

6.1

Initial operation - Claas

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.

Preparations for lighting (except Italy)

If the driving headlights of the forage harvester mounted as standard are hidden by the side parts of the maize header in road position, additional driving headlights must therefore be mounted on the cabin.

Adapting Machine to CLAAS Forage Harvester Type 493, Type 494, Type 496, Type 497

Note

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

Note

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

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

48

Mounting coupling disc

4 3 2

Initial operation - Claas

1

EC400109

Fig. 10

To mount the coupling:

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

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

• Tighten the screw (2) to 100 Nm.

Cleaning the coupling disc

1 2

EC400093_2

Fig. 11

To prepare the coupling for attachment of the front attachment:

• Clean the coupling disc (1) on the front attachment and lubricate the coupling surfaces with multi-purpose grease.

• Clean the coupling journal (2) on the forage harvester and lubricate the coupling surfaces with multi-purpose grease.

49

Initial operation - Claas

6.1.1 Aligning the coupling disc

2

1

EC400090

Fig. 12

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

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

II

I

EC4000 94_1

Fig. 13

Correct position of clutch disc

The clutch disc is correctly aligned when:

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

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

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

(I).

50

Initial operation - Claas

Mounting header on forage harvester

• Dismount the protective cap.

• Mount the header on the forage harvester.

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

Checking position of the coupling disc and input gearbox y

9

13

EC4000 95_2 EC400096

Fig. 14

• Check the position of the clutch disc.

If the clutch disc has been correctly aligned:

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

If the clutch disc has not been correctly aligned:

Inclination setting of the input gearbox:

• Loosen the 4 screws M16 (10).

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

• Retighten the 4 screws (10).

If the input gearbox has to be moved laterally:

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

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

51

Initial operation - Claas

Setting the input gearbox laterally

EC4000 95_2

Fig. 15

• Loosen the 4 screws M16 (10).

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

• Retighten the 4 screws M16 (10).

Checking the position of the coupling disc

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

If the coupling disc has been correctly aligned:

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

If the coupling disc has still not been correctly aligned:

• Repeat the adjustment process of the input gearbox.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

52

Initial operation - Claas

Setting lower holder

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

9

5 6

10

2 4 3 7

11

12

8 13

1 14

EC500127

Fig. 16

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

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

• Lower the intake housing until the holding bracket (3) is positioned under the receiving pockets (4) of the maize header.

• Move the forage harvester forward until the holding brackets (3) engage in the openings of the receiving pockets (4).

• Raise the intake housing via the lifting hydraulics until the lower holders (8) rest on the shaft

(7) of the intake housing.

• Shut down the machine.

• Check whether the shaft (7) is positioned properly in the lower holder (8).

53

Initial operation - Claas

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

• Remove the header again and reverse the forage harvester.

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

• Reattach the header to the forage harvester. In doing so, the lower holders are centred.

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

• Remove the header again and reverse the forage harvester.

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

• Reattach the header to the forage harvester.

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

If the cotter pin can be mounted, the header is correctly mounted.

If it is not possible to mount the cotter pin, the length of the connecting rod (11) must be adjusted:

• Dismount the bolt (14).

• Loosen the counter nut (12) and set it by turning the clevis (13) until the length of the connecting rod is adjusted.

• Tighten the counter nut and mount the bolt.

If the length of the connecting rod is set:

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

Checking the gap dimension of the infeed sheets

• Check the gap dimensions of the infeed sheets and adjust them, if necessary, see chapter

Maintenance, “Checking the gap dimension of the infeed sheets”.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

54

7

Initial operation – John Deere

Initial operation

– John Deere

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.

Preparations for lighting (except Italy)

If the driving headlights of the forage harvester mounted as standard are hidden by the side parts of the maize header in road position, additional driving headlights must therefore be mounted on the cabin.

55

Initial operation – John Deere

7.1 Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series

Notice

When mounting the machine on the forage harvester for the first time and whenever changing the forage harvester, the position of the locking pins must be checked and adjusted, if necessary.

Note

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

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

Setting the holder for the locking pins

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

I II

1 2 3

EC500138

Fig. 17

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

• Move the screw (2) from position II to position I.

• Mount the linch pin (3).

56

Initial operation – John Deere

2

3

4

6

EC500110_1

Fig. 18

• Move the forage harvester up to the maize header so that the intake housing (5) of the forage harvester is parallel in front of the cross tube (1).

• Lower the feed drive housing until the holding bracket (6) is positioned under the cross tube

(1) of the maize header support panel.

• Move the forage harvester forward until the holding brackets (6) engage behind the cross tube (1) of the maize header support panel.

• Ensure that the holding brackets (6) rest with their entire surface at the cross tube (1) of the maize header support panel.

• Raise the intake housing with the lifting hydraulics until the locking pins (2) are in front of the bore hole for the adapter frame holder (4).

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

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

• Check whether the locking pins (2) run into the boreholes of the holders (4).

If not:

• Loosen the screws (3) on the adapter frame.

• Align the holders (4) until the locking pins (2) can run into the boreholes of the holders.

• Lock the locking pins (2).

• Tighten the screws (3).

Checking the gap dimension of the infeed sheets

• Check the gap dimensions of the infeed sheets and adjust them, if necessary, see chapter

Maintenance, “Checking the gap dimension of the infeed sheets”.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

57

Initial operation – John Deere

7.2 Adapting the machine to the John Deere forage harvester of the 8000 series with universal shaft

Note

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

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

Dismounting the clutch disc

1

2

3

EC500162

Fig. 19

• Unscrew the screw (3) and dismount the compression spring (1) and the clutch disc (2).

58

Setting the holder for the catch hook

Initial operation – John Deere

1

EC500184

Fig. 20

• To avoid any collision with the forage harvester, loosen the screws (1) of both holders on the left and right.

• Move the holders on the left and right forwards in the direction of travel.

2

1 3

5

6

4

EC500176

Fig. 21

• Dismount the linch pin (1) and swivel the lever (2) downwards.

• Lower the intake housing.

• Move the forage harvester to the maize header until the locating bolts (3) are under the location holes (4) of the maize header.

• Raise the intake housing with the forage harvester hydraulics until the locating bolts (3) run into the location holes (4) on both sides and the both sheets (5, 6) are contacting against each other.

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

59

Initial operation – John Deere

3

4

1

2

EC500177

Fig. 22

• Move the holder (2) so that the catch hook (1) of the forage harvester can be hooked correctly.

• To secure the header with the catch hook (1) of the forage harvester, swivel the lever (4) upwards and mount the linch pin (3).

1

EC500184

Fig. 23

• Tighten the screws (1) on the left and right holder.

Checking the gap dimension of the infeed sheets

• Check the gap dimensions of the infeed sheets and adjust them, if necessary, see chapter

Maintenance, “Checking the gap dimension of the infeed sheets”.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

60

7.3

Initial operation – John Deere

Adapting the machine to the John Deere forage harvester of the 8000 series with quick coupler for header

Note

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

Note

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

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

Cleaning the coupling disc

1 2

EC500185

Fig. 24

To prepare the coupling for attachment of the front attachment:

• Clean the coupling disc (1) on the front attachment and lubricate the coupling surfaces with multi-purpose grease.

• Clean the coupling journal (2) on the forage harvester and lubricate the coupling surfaces with multi-purpose grease.

61

Initial operation – John Deere

7.3.1 Aligning the coupling disc

1

2

3

EC500163

Fig. 25

The clutch disc with coupling pin (1) on the header must be aligned towards the clutch disc (2) on the forage harvester so that the clutch disc (1) is arranged centrally in the housing.

The clutch disc (1) on the header must be positioned evenly and with the entire surface on the clutch disc (2) on the forage harvester.

Correct position of the clutch disc at the header

The clutch disc at the header has been correctly aligned when:

– the clutch disc is positioned evenly and with the entire surface on the clutch disc at the forage harvester.

– the clutch disc is centrally in the coupling housing, i.e. is not brushing against the coupling housing during operation.

The position of the clutch disc is corrected with the setting of the input gearbox (3).

62

Mounting header on forage harvester

2

Initial operation – John Deere

4

5

1

3

EC500175

Fig. 26

• Dismount the guard (1).

• To avoid any collision with the forage harvester, loosen the screws (3) of the both holders (2) on left and right and the screws (5).

• Move the holders (2) on left and right and the input gearbox (4) forward, in the direction of travel.

2

1 3

5

6

4

EC500176

Fig. 27

• Dismount the linch pin (1) and swivel the lever (2) downwards.

• Lower the intake housing.

• Move the forage harvester to the maize header until the locating bolts (3) are under the location holes (4) of the maize header.

• Raise the intake housing with the forage harvester hydraulics until the locating bolts (3) run into the location holes (4) on both sides and the both sheets (5, 6) are contacting against each other.

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

63

Initial operation – John Deere

3

4

1

2

EC500177

Fig. 28

• Move the holder (2) so that the catch hook (1) of the forage harvester can be hooked correctly.

• To secure the header with the catch hook (1) of the forage harvester, swivel the lever (4) upwards and mount the linch pin (3).

1

EC500178

Fig. 29

• Tighten the screws (1) on the left and right holder.

64

Checking the position of the clutch disc

1 2

Initial operation – John Deere

1

2

EC500179

The clutch disc with coupling pin (1) on the header must be aligned towards the clutch disc (2) on the forage harvester so that the clutch disc (1) is arranged centrally in the housing.

The clutch disc (1) on the header must be positioned evenly and with the entire surface on the clutch disc (2) on the forage harvester.

• Check whether the clutch disc (1) has been aligned correctly.

The clutch disc (1) on the header has been aligned correctly if:

– the clutch disc (1) is positioned evenly and with the entire surface on the clutch disc (2).

– the clutch disc (1) is centrally in the coupling housing, i.e. is not brushing against the coupling housing during operation.

• If the clutch disc (1) has been aligned correctly, adjust the input gearbox by 2-3 mm towards the rear.

• If the clutch disc (1) has not been aligned correctly, adjust the position of the input gearbox.

65

Initial operation – John Deere

Checking the position of the input gearbox

The position of the clutch disc is corrected by setting the input gearbox.

4

2 Y

5

1

3

EC500180

Fig. 30

• Adjust the input gearbox so that the clutch discs (5) are contacting flat against each other.

To do this:

• Loosen the screws (1, 2, 3, 4).

• Adjust the height of the input gearbox.

• Adjust the inclination of the input gearbox so that the deviation of the axles from input gearbox and coupling pin is y=180±2°.

• Tighten the screws (1, 2, 3, 4).

• Check the position of the clutch disc.

• If the clutch disc (1) has not been aligned correctly, adjust the position of the input gearbox.

• If the clutch disc (1) has been aligned correctly, adjust the input gearbox by 2-3 mm towards the rear.

66

Adjusting input gearbox towards the rear

Initial operation – John Deere

1

EC500181

Fig. 31

• Adjust the input gearbox by 2-3 mm towards the rear, in the direction of travel. To do this:

• Move the input gearbox by 2-3 mm towards the rear.

• Tighten screws (1).

• Reinstall the guard.

Checking the gap dimension of the infeed sheets

• Check the gap dimensions of the infeed sheets and adjust them, if necessary, see chapter

Maintenance, “Checking the gap dimension of the infeed sheets”.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

67

Initial operation – New Holland

8

8.1

Initial operation

– New Holland

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.

Preparations for lighting (except Italy)

If the driving headlights of the forage harvester mounted as standard are hidden by the side parts of the maize header in road position, additional driving headlights must therefore be mounted on the cabin.

Adapting the machine to the New Holland forage harvester

Notice

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

Note

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

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

68

Initial operation – New Holland

Setting the locking sleeves

In order to set the locking sleeves the header must be mounted on the forage harvester.

2

1

Fig. 32

• Open the locking hooks (1) with the locking lever (2).

EC500114

69

Initial operation – New Holland

4

3

3

2

EC500112

Fig. 33

• Move the forage harvester up to the maize header so that the intake housing (2) of the forage harvester is parallel in front of the adapter frame (4).

• Lower the feed drive housing until the holder (3) is positioned under the support pipe (1) of the maize header.

• Move the forage harvester forward until the feed drive housing (2) of the forage harvester is resting in front of the maize header adapter frame and the holder (3) of the forage harvester is below the support pipe (1).

• Raise the intake housing with the lifting hydraulics until the adapter frame (4) of the maize header rests against the intake housing (2) of the forage harvester.

• Ensure that the support pipe (1) has the correct position in the holder (3).

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

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

70

Initial operation – New Holland

1

1

6

2

7

2

5

4

3

EC500113

Fig. 34

• Open the locking hooks (1) with the locking lever (6).

• Check whether the locking hooks (1) are hooked appropriately in the locking sleeves (2).

If not:

• Loosen the screws (3).

• Set the locking sleeves (2) by shifting so that they are positioned below the recesses in the locked locking hooks (1).

• Tighten the screws (3).

• Check whether the locking hooks (1) are hooked appropriately in the locking sleeves (2).

If not:

• Set the length of the connecting rod (5) by setting the nut (4) so that the locking hooks

(1) are appropriately locked in the locking sleeves (2).

• Attach the locking lever (6) on the bolt (7) and secure it.

Note

The pendulum frame of the forage harvester can be used to swing the EasyCollect back and forth during operation. To do this, move the hydraulics for swinging on the forage harvester to the float position.

Checking the gap dimension of the infeed sheets

• Check the gap dimensions of the infeed sheets and adjust them, if necessary, see chapter

Maintenance, “Checking the gap dimension of the infeed sheets”.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

71

Start-up - CLAAS

9

9.1

Start-up - CLAAS

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!

• There must be nobody between the forage harvester and the front attachment.

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

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

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

• During operation there must be nobody within the danger zone of the machine.

• 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 open or remove the safety devices while the engine is running.

• No one is permitted in the swivel range while the machine is being swivelled from the transport into the working position or vice versa.

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

• On public roads the maize header EasyCollect 450-2 FP, 600 2 FP, 750 2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting to the transport position, make certain the EasyCollect 450-2 FP, 600 2 FP,

750 2 FP does not collide with the driver's cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

72

9.2

9.3

Start-up - CLAAS

Attachment to the CLAAS forage harvester

Coupling

9 10

2 4 3

5 6

7

11

12

8 13

1 14

EC500127

Fig. 35

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

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

• Lower the intake housing until the holding bracket (3) is positioned under the receiving pockets (4) of the maize header.

• Move the forage harvester forward until the holding brackets (3) engage in the openings of the receiving pockets (4).

• Raise the intake housing via the lifting hydraulics until the lower holders (8) rest on the shaft

(7) of the intake housing.

• Shut down the machine.

• Check whether the shaft (7) is positioned properly in the lower holder (8).

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

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

If the cotter pin cannot be mounted:

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

73

Start-up - CLAAS

9.3.1 Connecting Drive Type 491, Type 492

10

9.3.2

11 9

EC4000 85

Fig. 36

• Fold down the guard sheet (9).

• Push the universal joint (10) onto the drive journal of the forage harvester gearbox until the lock engages.

• Push the universal joint (11) on the gearbox of the maize header until the lock engages.

• Close the guard sheet (9).

Note

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

Connecting Drive Type 493, Type 494, Type 496, Type 497

2

1

EC400090

Fig. 37

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

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

Note

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

74

9.3.3

Start-up - CLAAS

Connecting the hydraulic lines

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

75

Start-up - CLAAS

2 1

EC400147

Fig. 38

A double-action hydraulic connection is required to operate the maize header.

• Connect the hydraulic hoses (1) to the plug-in connections provided for this purpose on the forage harvester.

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

Note

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

76

10

10.1

Start-up – John Deere

Start-up

– John Deere

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!

• There must be nobody between the forage harvester and the front attachment.

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

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

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

• During operation there must be nobody within the danger zone of the machine.

• 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 open or remove the safety devices while the engine is running.

• No one is permitted in the swivel range while the machine is being swivelled from the transport into the working position or vice versa.

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

• On public roads the maize header EasyCollect 450-2 FP, 600 2 FP, 750 2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting to the transport position, make certain the EasyCollect 450-2 FP, 600 2 FP,

750 2 FP does not collide with the driver's cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

77

Start-up – John Deere

10.2 Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series

10.3 Coupling

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

I II

1 2 3

EC500138

Fig. 39

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

• Move the screw (2) from position II to position I.

• Mount the linch pin (3).

1

2

6 1

EC500111_1

Fig. 40

• Move the forage harvester up to the maize header so that the intake housing (5) of the forage harvester is parallel in front of the cross tube (1).

• Lower the feed drive housing until the holding bracket (6) is positioned under the cross tube

(1) of the maize header support panel.

78

2

Start-up – John Deere

4

6

EC500146

Fig. 41

• Move the forage harvester forward until the holding brackets (6) engage behind the cross tube (1) of the maize header support panel.

• Ensure that the holding brackets (6) rest with their entire surface at the cross tube (1) of the maize header support panel.

• Raise the intake housing with the lifting hydraulics until the locking pins (2) are in front of the bore hole for the adapter frame holder (4).

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

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

I II

1 3 2

EC500139

Fig. 42

Lock the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

• Move the screw (2) from position I to position II.

• Mount the linch pin (3).

79

Start-up – John Deere

10.3.1 Connecting drive

1 5

2

EC500136

Fig. 43

• Push the universal joint (2) onto the gearbox of the maize header until the fuse engages.

• Push the universal joint (1) onto the gearbox drive journal of the forage harvester until the fuse engages.

• Close the protective cover (5).

80

Start-up – John Deere

10.3.2 Connecting the hydraulic lines

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

81

Start-up – John Deere

2

1

EC500135

Fig. 44

A double-action hydraulic connection is required to operate the maize header.

• Connect the hydraulic hoses (1) to the plug-in connections provided for this purpose on the forage harvester.

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

Note

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

82

10.4

10.4.1

Mounting to John Deere forage harvester of 8000 series

Connecting drive

2

1 3

4

Start-up – John Deere

5

6

EC500176

Fig. 45

• Dismount the linch pin (1) and swivel the lever (2) downwards.

• Lower the intake housing.

• Move the forage harvester to the maize header until the locating bolts (3) are under the location holes (4) of the maize header.

• Raise the intake housing with the forage harvester hydraulics until the locating bolts (3) run into the location holes (4) on both sides and the both sheets (5, 6) are contacting against each other.

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

4

3

1

2

EC500177

Fig. 46

• To secure the header with the catch hook (1) of the forage harvester, swivel the lever (4) upwards and mount the linch pin (3).

83

Start-up – John Deere

Forage harvester with quick coupler for header

1 2

1

2

EC500179

Fig. 47

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

• Check after coupling whether the clutch disc (2) of the forage harvester is positioned evenly on the clutch disc (1) of the header.

• Move the support jacks of the header into transport position.

Forage harvester with universal shaft

• Push the universal joint onto the input gearbox drive journal of the header until the lock engages.

• Move the support jacks of the header into transport position.

84

Start-up – John Deere

10.4.2 Connecting hydraulics and electrics

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

2

3

4

1

EC500167

Fig. 48

Prerequisites:

– The forage harvester is shut down and secured, see the operating instructions of the forage harvester.

– The forage harvester hydraulics is depressurised, see the operating instructions of the forage harvester.

• Connect the connections (2) of the header to the connections (4) of the forage harvester by means of the lever (1). Make certain that the safety button (3) engages.

Note

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

85

Start-up - New Holland Start-up - New Holland

11

11.1

Start-up - New Holland Start-up - New Holland

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!

• There must be nobody between the forage harvester and the front attachment.

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

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

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

• During operation there must be nobody within the danger zone of the machine.

• 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 open or remove the safety devices while the engine is running.

• No one is permitted in the swivel range while the machine is being swivelled from the transport into the working position or vice versa.

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

• On public roads the maize header EasyCollect 450-2 FP, 600 2 FP, 750 2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting to the transport position, make certain the EasyCollect 450-2 FP, 600 2 FP,

750 2 FP does not collide with the driver's cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

86

11.2

11.3

Start-up - New Holland Start-up - New Holland

Mounting on New Holland forage harvesters

Coupling

Danger! - Coupling

Effect: Danger to life or serious injuries.

When making the coupling, ensure there is no one between the forage harvester and the machine.

2

1

Fig. 49

• Open the locking hooks (1) with the locking lever (2).

EC500114

87

Start-up - New Holland Start-up - New Holland

4

3

3

2

EC500112

Fig. 50

• Move the forage harvester up to the maize header so that the intake housing (2) of the forage harvester is parallel in front of the adapter frame (4).

• Lower the feed drive housing until the holder (3) is positioned under the support pipe (1) of the maize header.

• Move the forage harvester forward until the feed drive housing (2) of the forage harvester is resting in front of the maize header adapter frame and the holder (3) of the forage harvester is below the support pipe (1).

• Raise the intake housing with the lifting hydraulics until the adapter frame (4) of the maize header rests against the intake housing (2) of the forage harvester.

• Ensure that the support pipe (1) has the correct position in the holder (3).

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

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

1

1

6

2

7

2

5

4

3

EC500113

Fig. 51

• Close the locking hooks (1) with the locking lever (6).

• Attach the locking lever (6) on the bolt (7) and secure it.

• Make sure that the lock holders are hooked correctly into the locating bolt and the locking hook on both sides.

Note

The pendulum frame of the forage harvester can be used to swing the EasyCollect back and forth during operation. To do this, move the hydraulics for swinging on the forage harvester to the float position.

88

11.3.1 Connecting drive

1 5

Start-up - New Holland Start-up - New Holland

2

EC500136

Fig. 52

• Push the universal joint (2) onto the gearbox of the maize header until the fuse engages.

• Push the universal joint (1) onto the gearbox drive journal of the forage harvester until the fuse engages.

• Close the protective cover (5).

89

Start-up - New Holland Start-up - New Holland

11.3.2 Connecting the hydraulic lines

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

90

1

Start-up - New Holland Start-up - New Holland

2

5

ECFH0019

Fig. 53

The maize header is equipped with a quick coupler for hydraulic systems.

Connect the quick coupler for hydraulic systems (1) to the connection provided for this purpose on the forage harvester.

• Secure the quick coupler for hydraulic systems (1) with the lever (5).

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

Note

Other adjustments for operating the maize header are described in the "Forage Harvester" operating instructions

Note

The pendulum frame of the forage harvester can be used to swing the EasyCollect back and forth during operation. To do this, move the hydraulics for swinging on the forage harvester to the float position.

91

Driving and Transport

12 Driving and Transport

Danger! - Road travel, carrying passengers, driving conduct

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

• It is forbidden to carry passengers on the machine.

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

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

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

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

• On public roads, the maize header EasyCollect 450-2, FP , 600-2 FP, 750-2 FP must always be in transport position.

Note

Operating licence

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

Notice

When the header is in transport position, oscillating movements are mechanically blocked.

92

12.1 Preparing the machine for road travel

Driving and Transport

EC500143

Fig. 54:

During transportation / road travel the maize header must be folded up.

To do this:

• Swing up side parts right / left into transport position.

• Switch off the engine and remove the ignition key.

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

“Support jacks right/left in transport position”.

• Mount the guards on right/left and the front guard, refer to chapter Operation “Mounting guard on right/left” or “Mounting guard”.

• Connect the lighting, refer to chapter Operation “Connecting direction indicator lamps and position lamps on right/left”.

EasyCollect 750-2 FP

EC500144

Fig. 55:

To ensure that the maximum permissible height of 4 m is not exceeded:

• Using the lifting unit on the forage harvester, lower the front attachment so that the dimension of X = 400 mm is reached, see the operating instructions of the forage harvester.

93

Driving and Transport

12.2 Switching off the machine

1

2

EC500004

Fig. 56:

• Set the maize header (1) down on solid and level ground with the support jacks (2) extended and park it in a dry and clean place, see chapter Operation, “Bringing support jacks right/left into parking position”.

Storage with supports (for the version with supports)

1

2 3

EC500 152

Fig. 57:

• Set the folded up maize header (1) down on solid and level ground with the supports (2, 3) and park it in a dry and clean place, refer to chapter Operation, “Removing the machine and storing it with supports”.

94

12.3

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)!

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

Fig. 58:

Note

Check the chain length!

95

Operation

13 Operation

13.1

13.1.1

From transport into working position

Danger! - Lowering the machine in a working position

Effect: Risk of death, injuries or damage to the machine.

• Lower the machine only when you are absolutely sure that neither persons, animals nor objects are in the swivel range of the machine.

• Keep all persons away from the danger area. If any persons approach the danger area, immediately shut down the machine.

• Never allow the machine to operate unsupervised.

• Check safety devices before each use. Replace damaged safety devices immediately.

• As a general rule, work on the header only when the engine has been shut down and the ignition key removed. All operating levers should be in a neutral position and no hydraulic line should be pressurised.

• Inspect the header for signs of any hindrance before each use and after retracting it. Any worn, damaged or deformed blades must be replaced immediately . This applies to the components holders too.

• Only switch on the drive when the header is folded down into the working position.

Removing the protective cover

2 2

Fig. 59:

• Stop the machine.

• Remove the lighting cable.

• Remove front guard (1).

• Remove the guards (2) right and left.

1

96

13.1.2 Support jacks right/left in transport position

Note

Stop the machine.

6

3

5

1

2

2

Operation

4

Fig. 60

Support jacks at rear on right/left:

EC500125_1

Notice

Ensure that the rear support jacks (4) are inserted into the holders (5) of the lateral frames so that no plant residues may accumulate in the area (6) above the support jacks and that the position of the rear support jacks is secured with the spring locking pins (2).

Support jacks at front on right/left:

Notice

Ensure that the front support jacks (1) are moved in the holders on the lateral frames, pushed onto the guide pins (3) and secured with the spring locking pins (2).

97

Operation

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

7 7

1 2

EC500121

Fig. 61

The process of folding down the side parts is prescribed by the hydraulic control.

For EasyCollect machines of series 450-2 FP, 600-2 FP and 750-2 FP, the side parts (1, 2) are lowered first. Then the side parts move to the middle and the tubular bars (7) swing upwards at the same time.

Notice

If the header is in transport position for a longer period, it is possible that the side parts are no longer in the upper position and thus cannot be folded down.

• To move the side parts into the upper position, press the actuation key of the doubleacting control unit which brings the side parts into transport position.

Swivelling side parts

Only swivel the side parts when the forage harvester is at a standstill.

Swivel the side parts via forage harvester hydraulics.

To do this:

• Press and hold down the actuation key of the double-acting control unit until the side parts

(1, 2) are folded down and the tubular bars (7) are folded up.

After swivelling

To ensure that the interlock ratchet mechanisms are engaged:

• Press the actuation key of the double-acting control unit for 2 seconds.

Note

To operate the maize header, refer to “Forage Harvester” operating instructions.

98

Operation

13.2

13.2.1

Using the Machine for Work

Danger! - Lowering the machine in a working position

Effect: Risk of death, injuries or damage to the machine.

• Lower the machine only when you are absolutely sure that neither persons, animals nor objects are in the swivel range of the machine.

• Keep all persons away from the danger area. If any persons approach the danger area, immediately shut down the machine.

• Never allow the machine to operate unsupervised.

• Check safety devices before each use. Replace damaged safety devices immediately.

• As a general rule, work on the header only when the engine has been shut down and the ignition key removed. All operating levers should be in a neutral position and no hydraulic line should be pressurised.

• Inspect the header for signs of any hindrance before each use and after retracting it. Any worn, damaged or deformed blades must be replaced immediately . This applies to the components holders too.

• Only switch on the drive when the header is folded down into the working position.

Inserting Maize Header

Note - clean cut

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

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

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

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

• Drive into the crops with the forage harvester.

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

Note

When the plant height is low and the chopping speed is thus high, it may be useful to deactivate the dynamic speed adaption on the forage harvester so that the plants can be conveyed uniformly to the intake rollers.

Note regarding resonance vibrations

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

Note - Reversing

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

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

99

Operation

13.2.2 Setting the rotational speed of the maize header (Claas, John Deere)

Claas:

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

Four rotational speed values can be set for the Claas forage harvesters 493, 494, 496, 497.

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

Actuating lever of input gearbox

Actuating lever of main gearbox

Speed ratio

13.2.3

Pos.

II

Pos.

H

Speed

120 %

II

I

I

L

H

L

100 %

83 %

70 %

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

• Switch the actuating lever of the input gearbox and main gearbox to the indicated position, see chapter Operation, “Operating Main Gearbox” and “Operating Input Gearbox”.

John Deere:

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

Four rotational speed values can be set by using the two-gear gearbox of the forage harvester.

Notice

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

Setting the rotational speed of the maize header (New Holland)

Influenced by the rotational speed of the forage harvester, the rotational speed of the maize header can be se to different values.

• Adapt the header rotational speed to the harvesting conditions.

100

13.2.4 Operating main gearbox (Claas, John Deere)

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

– Position L = low speed

– Position H = high speed

Operation

2

1

3

H L

EC500108_1

Fig. 62

To switch the main gearbox:

• Swivel up the side parts on the right/left into transport position.

• Dismount the linch pin (3).

• Move one of both star-shaped conveyors (1) back and forth during switching process.

• Swivel the actuating lever (2) of the main gearbox to the other side and fasten it by means of the linch pin (3).

101

Operation

13.2.5 Operating input gearbox (Claas)

Different speeds can be selected when switching the input gearbox.

– Position I = lower speed

– Position II = higher speed

2

1

EC400071

Fig. 63

To switch the input gearbox:

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

3

I 3

4 II

EC400072_2

Fig. 64

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

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

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

EC400073_1

102

13.2.6

Operation

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

When the row detection is used, the forage harvester can be guided automatically between 2 rows of thin-stemmed plants.

X

2

2

EC903091

Fig. 65

For Claas forage harvesters from type 494.

By means of the row tracers (2) on the maize header, the “CLAAS AUTOPILOT” takes over automatic guidance of the forage harvester between 2 rows of thin-stemmed plants.

1 2

Fig. 66

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

– The forage harvester is fitted with the “CLAAS AUTOPILOT” system for using the row detection.

– The accessories kit B338 “Row detection CL” is mounted.

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

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of “CLAAS AUTOPILOT”.

103

Operation

For John Deere forage harvesters of 6000 and 7000 series

By means of the row tracers on the maize header, the “John Deere automatic steering system

Row-Trak II” takes over automatic guidance of the forage harvester between 2 rows of thinstemmed plants.

2 1

EC500166

Fig. 67

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

– The forage harvester is fitted with the “John Deere automatic steering system Row-Trak II” system for using the row detection.

– The accessories kit B339 “Row detection JD 7000” is mounted.

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

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of “John Deere automatic steering system Row-Trak II”.

John Deere forage harvesters of 8000 series

By means of the row tracers on the maize header, the “John Deere automatic steering system

Row-Trak II” takes over automatic guidance of the forage harvester between 2 rows of thinstemmed plants.

1 2

EC500170

Fig. 68

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

– The forage harvester is fitted with the “John Deere automatic steering system Row-Trak II” system for using the row detection.

– The accessories kit B367 “Row detection and ground contour JD 8000” is mounted.

– Connect the connections (1) of the header to the connections (2) of the forage harvester.

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of “John Deere automatic steering system Row-Trak II”.

104

Operation

For New Holland forage harvesters

By means of the row tracers on the maize header, the “New Holland automatic row guidance for maize headers” takes over automatic guidance of the forage harvester between 2 rows of thinstemmed plants.

1 2

EC500171

Fig. 69

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

– The forage harvester is fitted with the “New Holland automatic row guidance for maize headers” system for using the row detection.

– The accessories kit B340 “Row detection and ground contour NH” is mounted.

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

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of “New Holland automatic row guidance for maize headers”.

105

Operation

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

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

2

1

EC500010

Fig. 70

For Claas forage harvesters from type 494.

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

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

Notice

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

1 2 3 4

6 5

Fig. 71

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

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

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

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

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

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

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

106

Operation

For John Deere forage harvesters of 6000 and 7000 series

When the ground contour is active, the ground tracers scan the ground under the header. The unevenness of the ground is compensated by the forage harvester in the direction of travel and at right angles to the direction of travel by the hydraulic cylinder on the intermediate frame of the header.

Notice

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

1 2

3 4

5 6

EC500172

Fig. 72

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

– The forage harvester is equipped with the system “John Deere automatic header guidance

AHC”.

– The accessories kit B339 “Row detection JD” and the accessories kit B342 “Active ground contour JD7000” are mounted.

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

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

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

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of the „Automatic header guidance AHC“ system.

107

Operation

John Deere forage harvesters of 8000 series

When the ground contour is active, the ground tracers scan the ground under the header. The unevenness of the ground is compensated by the forage harvester in the direction of travel and at right angles to the direction of travel by the hydraulic cylinder on the intermediate frame of the header.

Notice

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

1 2

EC500170

Fig. 73

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

– The forage harvester is equipped with the system “John Deere automatic header guidance

AHC”.

– The accessories kit B367 “Row detection and active ground contour JD8000” are mounted.

– Connect the connections (1) of the header to the connections (2) of the forage harvester.

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of the „Automatic header guidance AHC“ system.

108

Operation

For New Holland forage harvesters

When the ground contour is active, the ground tracers scan the ground under the header. The unevenness of the ground is compensated by the forage harvester in the direction of travel and at right angles to the direction of travel by the hydraulic cylinder on the intermediate frame of the header.

Notice

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

1 2

5

EC500168

Fig. 74

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

– The forage harvester is equipped with the “New Holland AutoFloat™” system.

– The accessories kit B340 “Row detection and active ground contour NH FR” are mounted.

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

– Connect the connections (1) of the header to the connections (5) of the forage harvester and secure by means of the lever (5).

• Observe the operating instructions of the forage harvester, in particular the chapter concerning the operation of “AutoFloat”.

109

Operation

13.3 Switching from working position to transport position

Note

Before folding the maize header into its transporting position, turn off the drive. The maize header must not be folded in until the drive is at a standstill.

Note

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

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

1 2

EC500141

Fig. 75

• Swivel up the side parts (1,2) to the transport position by pressing the actuation keys of the double-acting control unit.

Notice

The hydraulic folding up process of the side parts is predetermined by the hydraulic control.

First, the tubular bars on the right and left sides swivel downwards. At the same time, the side parts are pushed to the outside and then they are swivelled upwards.

• Raise the maize header with the forage harvester hydraulics high enough to ensure sufficient ground clearance for travel on the road.

EasyCollect 750-2 FP

110

EC500144

Fig. 76:

To ensure that the maximum permissible height of 4 m is not exceeded:

• Using the lifting unit on the forage harvester, lower the front attachment so that the dimension of X = 400 mm is reached, see the operating instructions of the forage harvester.

13.3.2 Installing guard on the right/left

2 1

4

4

Operation

5

13.3.3

3

EC50044_1

Fig. 77

• Insert both hexagon head screws (1) to the contact sheets (2) of the side parts into the bore holes of the tips (3).

• Fasten the guard cloths (4) to the frame with tension springs (5).

Installing the front guard

5

3

2 1

4

Fig. 78

• Attach the front guard (1) on the right and left to the support on the guards as well as on the centre of the central tip. Pay attention to the stipulated position of the warning stripes (2)

(the hatching must point downwards and outwards).

• Secure front guard (1) on the right and left with spring cotter pin (3) and hook tension spring

(4) on the central tip.

Note

If the central tip has been re-adjusted due to reasons concerning the harvest, it may be necessary to move the holding plates (5) in the side part within the arrangement of holes.

111

Operation

13.3.4 Connecting indicators and position lights on the right/left

For adaptation Claas version and adaptation New Holland version

3

2 1

EC500045_1 EC500124

Fig. 79

• Connect the connector cable (2) of the direction indicator lamps and position lamps (1) to the socket (3) on the forage harvester.

• Check the lighting for function.

For version adaptation John Deere of 6000 and 7000 series

2 1

3

EC500045_1 EC500123_1

Fig. 80

• Connect connection cable (2) of the indicators and position lights (1) in the socket (3) on both sides of the maize header.

• Check the lighting for function.

Caution! - Lighting cables not laid properly.

Effect: Lighting system no longer functions.

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

112

Operation

13.4

13.4.1

Detaching the machine

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

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

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

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

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

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

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

• Swing up the maize header into transport position.

Note

Stop the machine.

Moving the right hand / left hand parking supports into parking position

3

2 6

5

1 4

2

2

2

1

4

EC500026 EC500116_1

Fig. 81

Support jacks at front on right/left:

• Dismount the spring locking pins (2) and pull the front support jacks (1) down from the guide pins (3) and remove them from the holders on the lateral frames.

• Push the front support jacks (1) into the front guidances on the lateral frames.

• Secure the position of the front support jacks (1) with the spring locking pins (2).

Support jacks at rear on right/left:

• Dismount the spring locking pins (2) and pull the rear support jacks (4) out of the holders (5) on the lateral frames.

• Push the rear support jacks into the rear guidances (6) on the lateral frame.

• Secure the position of the rear support jacks with the spring locking pins (2).

Notice

Push the support jacks into the guidances on the lateral frames so that the bottom plates of the support jacks are parallel to the ground when parking the machine.

Note

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

113

Operation

1

2

13.4.2

EC500165

Fig. 82

To ensure that the forage harvester can accommodate the maize header, the height of the holder elements on the forage harvester must be matched to the height of the holder elements on the maize header.

For this purpose, the rear parking supports can be differently aligned when parking by means of spring locking pins (1) in the hole pattern (2) depending on the tire diameter.

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

7 7

1 2

EC500121

Fig. 83

• Swivel side parts (1, 2) into working position, see operating instructions of the forage harvester.

• Keep the actuation key pressed until the interlock ratchet mechanisms are engaged.

• Shut down and safeguard the machine, refer to chapter Safety, “Shutting down and safeguarding the machine”.

114

Operation

13.5 Dismantling the machine in case of adaptation to Claas forage harvester

13.5.1 Removing Hydraulic Lines

Caution! - Danger of accident and damage!

Place the hydraulic hoses and electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

2 1

13.5.2

EC400147

Fig. 84

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

• Disconnect the lighting cable (2).

Connecting

Prerequisites:

– The forage harvester is shut down and secured, refer to the operating instructions of the forage harvester.

– The support jacks are in the support position.

5

2 4 3

6

7

1

8

EC500128

Fig. 85

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

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

115

Operation

13.5.3 For version with universal shaft (e.g. type 491 und 492)

10

13.5.4

11 9

EC4000 85

Fig. 86

• Open the guard sheet (9).

• Pull the universal joint (11) down from the maize header gearbox.

• Pull the universal joint (10) down from the drive journal of the forage harvester gearbox.

• Put aside the universal shaft for later use.

• Reverse the forage harvester.

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

For version with header quick coupler (e.g. type 493, 494, 496 und 497)

2

1

EC400090

Fig. 87

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

• Reverse the forage harvester.

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

116

13.6

Operation

Dismantling the machine in case of adaptation to John Deere forage harvester of 6000 and 7000 series

13.6.1 Removing Hydraulic Lines

Caution! - Danger of accident and damage!

Place the hydraulic hoses and electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

2

1

13.6.2

EC500135

Fig. 88

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

• Disconnect the lighting cable (2).

Connecting

Prerequisites:

– The forage harvester is shut down and secured, refer to the operating instructions of the forage harvester.

– The support jacks are in the support position.

2 10

1

EC500137

Fig. 89:

• Open the protective cover (10).

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

• Pull the universal joint (1) down from the maize header gearbox.

• Put the universal shaft aside to use it for a later reinstallation.

117

Operation

I II

1 2 3

EC500138

Fig. 90

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

• Move the screw (2) from position II to position I.

• Mount the linch pin (3).

6 1

EC500140

Fig. 91

• Lower the intake housing until the holding bracket (6) is positioned under the cross tube (1) of the maize header support panel.

• Move the forage harvester backwards.

118

13.7

Operation

Dismantling the machine in case of adaptation to John Deere forage harvester of 8000 series

13.7.1 Disconnecting hydraulics and electrics

Caution! - Danger of accident and damage!

Place the hydraulic hoses and electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

Prerequisites:

– The forage harvester is shut down and secured, refer to the operating instructions of the forage harvester.

– The forage harvester hydraulics is depressurised, refer to the operating instructions of the forage harvester.

2

3

4

1

EC500167

Fig. 92

• To disconnect the connections (2) of the header from the connections (4) of the forage harvester, press down the safety button (3) and swivel the lever (1).

119

Operation

13.7.2 Disconnecting header

Prerequisites:

– The forage harvester is shut down and secured, refer to the operating instructions of the forage harvester.

– The support jacks are in the support position.

For a forage harvester with universal shaft version:

– The universal joint has been disconnected from the gearbox of the header.

4

2

1 3

EC500182

Fig. 93

• To release the catch hook, dismount the linch pin (1) and swivel the lever (2) downwards.

• Lower the intake housing until the locating bolts (3) are under the cross tube (4) of the header support panel.

• Move the forage harvester backwards.

120

Operation

13.8 Dismantling the machine in case of adaptation to Claas forage harvester

13.8.1 Removing Hydraulic Lines

Caution! - Danger of accident and damage!

Place the hydraulic hoses and electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

1

2

5

ECFH0019

Fig. 94:

• Disconnect the coupler for hydraulic systems (1) from the connection at the forage harvester.

• Disconnect the lighting cable (2).

121

Operation

13.8.2 Connecting

Prerequisites:

– The forage harvester is shut down and secured, refer to the operating instructions of the forage harvester.

– The support jacks are in the support position.

1

ECFH0004_1

Fig. 95

• Pull the PTO shaft (1) down from the drive journal of the forage harvester gearbox.

1 3

4

5

EC500119

Fig. 96

• Open the locking hooks (5) with the locking lever (1).

• Lower the intake housing (3) with the lifting hydraulics until the holder (4) is positioned under the support pipe (2).

• Move the forage harvester backwards.

122

13.9

Operation

Removing the machine and storing it with supports (for the version with supports)

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

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

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

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

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

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

EC5001 64

Fig. 97

To save space, the header can be lowered into transport position. To do so, mount additional supports on the header.

Condition: The header is mounted on the forage harvester.

• Move the maize header into transport position.

• Shut down and safeguard the forage harvester, see chapter Safety, “Shutting down and safeguarding the machine”.

123

Operation

13.9.1 Support jacks right/left in transport position

13.9.2

6

2

5 4

2

3

1

2

2

4

1

Fig. 98

EC500017_1 EC500016

Support jacks at rear on right/left:

• Unscrew the spring locking pins (2) and pull the rear support jacks (4) out of the guidance.

• Push the rear support jacks (4) into the holders (5) of the lateral frame frames so that no plant residues can collect in the area (6) above the support jacks.

• Secure the position of the support jacks at rear (4) by means of spring locking pins (2).

Support jacks at front on right/left:

• Dismount the spring locking pins (2) and pull the front support jacks (1) out of the guidance.

• Push the base of the front support jacks onto the guide pins (3) in the holders on the lateral frame.

• Secure the position of the front support jacks (1) by means of the spring locking pins (2).

Relocating the support jack bracket

1 2

3

4

2

1

EC500169 EC500173

Fig. 99

• Dismount the screws (2) and remove the support jack bracket (1) from the lateral frame.

• Put the support jack bracket (2) from below on the support jack (3) and secure it by means of the spring locking pin (4).

• Mount the screws (2) in the boreholes of the support jack bracket (1).

124

13.9.3 Mounting console support

1 2

Operation

5 3 5 4

EC500153

Fig. 100

• Push the rear console of the support jack (1) into the rear support jack holder (3) and secure it with the socket pin (5).

• Push the front console of the support jack (2) into the front support jack holder (4) and secure it with the socket pin (5).

125

Operation

13.9.4 Mounting side guards

6

3

2

5

4

1

EC500154

Fig. 101

• Insert the lower holder (2) of the side support (1) into the tip (3) on the lateral frame (on both sides of the machine).

• Raise the lateral support (1), push the upper profile (4) over the front and rear console (5) and secure it with the socket pin (6) (on both sides of the machine).

126

13.9.5 Setting the lateral supports at rear

Operation

2

1

EC500155

Fig. 102

To ensure that the forage harvester can pick up the maize header which is held by the support jacks, the height of the holder on the forage harvester and the height on the maize header need to be adjusted.

For this purpose, the support jacks can be set differently in terms of height and inclination.

• As required, mount the support jacks in both hole patterns (1, 2).

Notice

After being reinstalled on the forage harvester the support jack brackets must be mounted on their former lateral frame position so that they can be connected with the support jacks.

127

Operation

13.9.6 Putting header down

CAUTION! - Risk of tipping over

The parked header may tip over. As a result, accidents may occur and people may be seriously injured or killed.

• Park the machine in transport position with the supports on level and firm ground

(concrete/paving) only.

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

• Close the stop cock of the header.

• Depressurise the forage harvester hydraulics, see the operating instructions of the forage harvester.

• Disconnect the hydraulic hoses, refer to chapter Operation, “Disconnecting the hydraulic hoses”.

• Lower the header to the ground by using the supports.

• Move the forage harvester back and shut it down.

• Make sure that the maize header is supported by the two supports after it has been lowered.

If this is not the case:

• Raise the maize header by using the forage harvester hydraulics and put it down at another place.

128

14

14.1

Settings

Settings

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

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

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

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

• Switch off PTO shaft and disconnect it.

• Before working under or on the raised machine: Secure machine or machine parts with hydraulic shut-off device (e.g. stop cock) on machine side against lowering, refer to operating instructions of forage harvester!

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

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

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

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

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

Setting the Tubular Bars

1

2

1

EC500048

Fig. 103

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

To do this:

• Swivel tubular bars (1) in the working position.

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

• Tighten screw connections (2).

Note

If the tubular bar is set too low, long maize plants could slip out of the collector and tilt to the rear over the bracket.

If the tubular bar is set too high, small maize plants cannot be guided properly.

129

Settings

14.1.1 Setting the tubular bar in terms of its inclination (EasyCollect 600-2 FP, 750-2 FP)

Depending on harvesting conditions, the inclination of the tubular bars can be set. Due to this, the tubular bar can be inclined somewhat to the front in order to press the plants to be cut slightly into the crop.

If the inclination of the tubular bar is changed, the contact pressure of the tubular bars in transport position changes, as well. An indicator for this is a rattling noise e.g. when driving on the road. The contact pressure must be set, if necessary; refer to “Setting the Contact Pressure of the Tubular Bars”.

1 3

4

5

2

6

7

EC500070_2

Fig. 104

To adjust the inclination of the tubular bar:

• Move the header to the working position.

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

Safeguarding the Machine”.

• Unscrew the screw (2) and loosen the screw (3).

• Loosen the counter nut (4).

• Set the desired inclination of tubular bar by turning the threaded rod (5).

3

8

2

6

7 4

EC500073_3

Fig. 105

• Mount screw (2) by means of hole pattern (8) so that the rubber buffer (6) rests on the stop

(7) with low tension.

• Tighten screws (2, 3) again.

• Tighten counter nut (4).

130

Settings

Setting the contact pressure of tubular bars

If the tubular bars rattle during road travel, change the contact pressure to remedy this problem.

If the contact pressure of tubular bars is changed in transport position, the inclination of the tubular bars changes, as well. The inclination and the contact pressure of the tubular bar supports must be checked and set, if necessary; refer to “Setting the Inclination of the Tubular

Bars”.

9

X

11

12

10

EC500072_2

Fig. 106

The contact pressure of tubular bar is set via compression spring (9).

• Move header to transport position.

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

Safeguarding the Machine”.

• Measure current spring length “X” of compression spring (9) and equalize with the prescribed setting dimension of 75 ± 5mm.

The compression spring must be set if the current dimension does not correspond to the prescribed dimension.

• Dismount bolt (10).

• Loosen counter nut (11).

• Adjust threaded piece (12) by difference dimension (the spring length is reduced by screwing in, the contact pressure is increased).

• Tighten counter nut (11).

• Mount bolt (10).

• Repeat the adjustment procedure, if necessary.

Note

The lower bolts (10) are designed as shear pins. They shear off if excessive forces are induced into the system via tubular bar.

131

Settings

14.1.2 Setting the tubular bar in terms of its inclination (EasyCollect 450-2 FP, 750-2 FP)

Depending on harvesting conditions, the inclination of the tubular bars can be set. Due to this, the tubular bar can be inclined somewhat to the front in order to press the plants to be cut slightly into the crop.

If the inclination of the tubular bars is changed, the contact pressure of the tubular bars in transport position changes, as well. An indicator for this is a rattling noise e.g. when driving on the road. The inclination and the contact pressure must be checked after each setting.

1

3

2

EC500082

Abb. 107

To adjust the inclination of the tubular bar:

• Move header to working position.

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

Safeguarding the Machine”.

• Hold tubular bar (1) in place and loosen the screws (2).

• Move the adjustment (3) in the oblong holes until the desired inclination is reached.

• Tighten the screws (2).

1

2

EC500083

Abb. 108

• Move header to transport position.

• Check whether the rubber buffers (2) rest with slight pressure on EasyCollect.

Setting bearing pressure:

• Move header to working position.

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

Safeguarding the Machine”.

• Dismount nut (1) and remove rubber buffer (2).

• To increase the bearing pressure, insert rubber buffer with additional washers and mount with nut (1).

• To reduce the bearing pressure, remove washers, insert rubber buffer and mount with nut

(1).

132

14.2 Setting Holding-Down Device Roller

1

Settings

I

II

2

14.3

III

2 2

EC500024

Fig. 109

The holding-down device roller (1) is mounted as standard in position I. The holding-down device roller can be adapted to the plant height.

To do this:

• Loosen screw connections (2) and move holding-down device roller in position II or III.

Adjusting skids

Note

The skids are set depending on the tyre sizes of the forage harvester.

Set the skids so that they are flat on the ground in the rear skid area.

Fig. 110:

• Raise header.

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

• Loosen screw connections (2) and mount glide skid (1) in the desired position (I).

• Tighten screw connections.

133

Settings

14.4 Adjusting the plant dividers

Notice

Adapt the height of the plant divider (1) to the respective crops so that the plants are guided at

60-70% of their plant height by the tubular bars when being drawn into the chopper unit.

1

2 3

2

Fig. 111

• The height of the plant divider (1) can be adjusted by relocating the bolt (2).

• Secure the bolt (2) in the desired borehole by means of a spring cotter pin (3).

EC500120_1

134

14.5

Settings

Adapting Star-shaped Conveyor Height to Maize Crop

The star-shaped conveyors additionally drive the crop and thus improve the crop flow to the intake rollers of the forage harvester, especially when the maize plants are short.

It could be advantageous to replace the upper star-shaped conveyor segment on both sides by the cover included with delivery in case the maize plants are extremely high. Thus the crop flow is improved and excess lengths in the chopping crops can be avoided.

Replacing star-shaped conveyor segment

3 4

1

2

EC500080

Fig. 112

• Move the header to transport position/road travel.

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

• Unscrew the screws (1) and remove the scraper edge (2) including support.

• Move roller gearbox to “neutral” position so that the star-shaped conveyors can be turned manually, see chapter Settings “Setting the Star-shaped Conveyor Speed”.

• Unscrew the screws (3) and remove star-shaped conveyor segment (4).

• Insert cover included with delivery instead of star-shaped conveyor segment and mount with screws (3).

• Insert scraper edge (2) including support and mount with screws (1). In doing so, the gap dimension between scraper edge and star-shaped conveyor is 1 to 3 mm.

• Move the roller gearbox into the desired position “H” or “L”.

135

Settings

14.6 Setting the Star-shaped Conveyor Speed

To improve crop flow, especially when the maize plants are short or when the collector transports crop to the front again, the speed of the star-shaped conveyors can be changed.

Thus the speed ratio between collector and star-shaped conveyor changes and reduces the amount of crop that is taken along by the collector.

Setting the speed

3

2

1

EC500081

Fig. 113

• Move header to transport position / road travel.

• Shut down and safeguard the machines, refer to chapters Safety “Shutting Down and

Safeguarding the Machine”.

• Remove linch pin (1).

• Move lever (2) to desired position:

– „L“ (Low) = low speed (standard)

– „H“ (High) = high speed (+25%)

– The neutral position is between “L” and “H”.

• Mount linch pin (1) in the borehole of the retaining sheet (3).

136

14.7

Settings

For version with pendulum frame on header

Setting the oscillating movement of the header

The header may adapt to the ground contour of the field by the oscillating movement.

In this process, the height of the header is aligned permanently relative to the ground by means of the sliding skids.

The pendulum springs (1) counteract the oscillating movement of the header and thus cushion the oscillating movement.

The pendulum spring housing is designed with an inner and an outer tube. They ensure that the movement takes place in the opposing oblong hole (9) when pivoting.

1 Z 2 3 4 5 6

7

9

8

EC400110_2

Fig. 114

Move the pendulum compensation to the basic position:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Unscrew the screw connection (8).

• Tighten the feed shaft (7) hand-tight.

• Tighten the feed shaft (7) by 4 further rotations and then ensure that the feed shaft (7) can be secured against turning using the screw (8).

• Secure the feed shaft (7) against turning using the screw (8) and mount the screw connection (8).

• Tighten the nut (5) on the bar (6) hand-tight.

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Tighten the counter nut (4).

• Tighten the counter nut (3).

137

Settings

1 Z 2 3 4 5 6

7

9

8

EC400110_2

Fig. 115

If the header swings up too quickly or does not adapt quickly enough to the contour of the field, the force of the pendulum springs (1) can be set. The spring force counteracts the oscillating movement of the header and thus cushions the oscillating behaviour.

To do this, on both sides of the machine:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Unscrew the screw connection (8).

To reduce the force for the pendulum compensation:

• Loosen the feed shaft (7). In doing so, ensure at the same time that the nut (2) which is connected to the inner spring housing does not rotate.

To increase the force for the pendulum compensation:

• Tighten the feed shaft (7) securely. In doing so make sure that the nut (2) which is connected to the inner spring housing does not rotate.

If the pendulum springs are adjusted:

• Secure the feed shaft (7) with the screw (8) against turning and mount the screw connection

(8).

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Tighten the counter nut (4).

• Tighten the counter nut (3).

138

15

15.1

15.2

Maintenance

Maintenance

Special Safety Instructions

Danger! - When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving (caution, cutters continue to run).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

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

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

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

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

Hydraulic hose line(s)

WARNING! – Hydraulic hose lines are subject to ageing

Effect: Danger to life or serious injuries

The characteristics of the lines change depending on pressure, heat load and the effect of UV rays.

The date of manufacture appears on the hydraulic hoses. This way the age can be ascertained quickly.

By law the hydraulic lines must be replaced after six years.

Use original spare parts when replacing hydraulic hoses!

250 BAR 43/2010

250 BAR 43/2010

EFL000026

Fig. 116

• Check the hydraulic hose lines at regular intervals and replace them if damaged or worn!

The new hoses must fulfill the technical requirements set by the manufacturer of the implement!

139

Maintenance

15.2.1

15.3

Test run

Danger! - Testing the machine after repair, maintenance or cleaning work and after technical intervention.

Effect: Danger to life or serious injuries

• The machine must be in working position

• Do not switch on the drives until the machine is in cutting height and you are absolutely sure that neither persons, animals nor objects are in the danger zone.

• Start a trial run of the machine from the driver’s seat only.

Spare Parts

Warning! - Using non-approved spare parts.

Effect: Danger to life, serious injuries or loss of warranty claims as well as exclusion of liability

• Use only authentic KRONE spare parts and accessories authorised by the manufacturer.

The use of spare parts, accessories or additional equipment not manufactured, tested or approved by KRONE will exclude any liability for consequential damage.

140

15.4 Maintenance table

Maintenance work

Maintenance

Maintenance interval

Blades

Check fixed blades (bow blade, step blade, tip blade) and replace damaged or bent blades.

Check cutting blades (collector blades), replace damaged or bent blades.

Collector

Check collector tension.

Check whether the collector rests on the fixed blades. *1)

Check insertion fingers, replace damaged or bent insertion fingers.

X

X

X

X

X

X

Tightening screws / nuts

Check if the screws on the swivel-joint of the side parts (left and right) are seated firmly.

Check all other screws.

X X

X X

Gearbox

Density control

Oil level check

Oil change

X

X

X

Cleaning the machine

Check the soiling in the collector compartment (inside) and clean it, if necessary.

X

Coupling

Check coupling for wear.

Grease coupling disc.

X

X

X

X

Lubricate machine according to lubrication chart

*1) To do this, move the machine to working position and let it run forward for approx. 1 minute.

141

Maintenance

15.5 Tightening torques

15.5.1 Metric Thread Screws with Control Thread

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

M4

M5

M6

M8

M10

M12

M14

M16

M20

M22

M24

M27

M30

Stability class

29

42

5.6 8.8 10.9 12.9

Tightening torque (Nm)

3.0

5.9

4.4

8.7

5.1

10

10

25

49

85

15

36

72

125

18

43

84

145

135

210

425

571

730

200

310

610

832

235

365

710

972

1050 1220

1100 1550 1800

1450 2100 2450

Note

Regularly check that nuts and bolts are tightly in place (approx. every 50 hours) and tighten them if necessary.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

142

Maintenance

15.5.2

15.5.3

Metric Thread Screws with Fine Thread

Tightening torque in Nm (unless otherwise stated)

Stability class

A

M12 x 1.5

M14 x 1.5

5.6 8.8 10.9 12.9

Tightening torque (Nm)

88

145

130

213

152

249

M16 x 1.5

M18 x 1.5

M20 x 1.5

M24 x 2

M27 x 2

222

368

465

787

327

525

662

382

614

775

1121 1312

1148 1635 1914

M30 x 1.5 800 2100 2650

A = thread size

(stability class can be seen on screw head)

Metric Thread Screws with Countersunk Head and Hexagonal Socket

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

M4

M5

M6

M8

M10

M12

M14

M16

M20

Stability class

23

34

5.6 8.8 10.9 12.9

Tightening torque (Nm)

2.5

4.7

3.5

7

4.1

8

8

20

39

68

12

29

58

100

15

35

67

116

108 160 188

168 248 292

340 488 568

A

BM 400 0234

Note

Regularly check that nuts and bolts are tightly in place (approx. every 50 hours) and tighten them if necessary.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

143

Maintenance

15.5.4 Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes

This table applies only to locking screws with external hex in connection with copper seal ring for bleed valves made of brass with shaped seal ring.

Thread Locking screw and viewing glass with copper ring*)

Ventilation/breather filter made of steel

Steel and cast Aluminium

Bleed valve made of brass

Ventilation and breather filter made of brass

Steel and cast Aluminium

M10x1

M12 x 1.5

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

G3/4“

M33x2

G1“

M42x1.5

G1 1/4“

Maximum tightening torque (Nm) (±10%)

40

45

*) Always replace copper rings

35

60

60

80

80

100

100

24

30

32

32

8

14

14

16

24

30

NOTE

The tightening torques only apply to assembly of locking screws, viewing glasses, ventilation and breather filters and bleed valves in gearboxes with cast housings or aluminium or steel housings. The term “locking screw” includes the drain plug, the inspection screw as well as the ventilation and breather filters.

144

15.6

Maintenance

Hydraulics

WARNING!

Risk of injury from incorrect handling of liquids under high pressure. Escaping highpressure liquids may penetrate the skin and cause serious injury.

• Repair work on the hydraulic system may only be performed by authorised KRONE professional workshops.

• Depressurise the system before disconnecting lines.

• When working on the hydraulic system, wear personal protective equipment (protective goggles and protective gloves).

• High-pressure liquid that is escaping from a small opening is virtually invisible. Therefore use a piece of cardboard or something similar when searching for leaks.

• If liquid penetrates the skin, consult a doctor immediately. The liquid must be removed from the body as quickly as possible. Danger of infection! Physicians who are not familiar with this area must consult appropriate information from a competent medical source.

• Check the hydraulic hoses at regular intervals and replace them if damaged or worn! Only original KRONE spare parts are permitted to be used as replacement lines as they correspond to the technical requirements of the manufacturer.

• Before the pressure in the system builds up again, ensure that all line connections are tight.

145

Maintenance

15.7 Hydraulic circuit diagram

1) Verriegelung

links

2) Seitenteil links

schieben

3) Seitenteil rechts

schieben

4) Verriegelung

rechts

5) Steuerblock

Ein-/Ausklappen E-Col xxx-2

6) Seitenteil links

ein-/ausklappen

7) Seitenteil rechts

ein-/ausklappen

8) 1x doppeltwirkendes

Steuergerät am Feldhäcksler

Fig.117: The working position is represented.

1) Locking on the left 2) Push side part on the left

4) Locking right

7) Folding in/out side part on the right

5) Fold in/out control block E-

Col xxx-2

8) 1x double-acting control unit on the forage harvester

3) Push side part on the right

6) Fold in/out side part on the left

146

15.8

Maintenance

Input gearbox

For adaptation Claas version

Note

Check the oil level, top up oil and drain oil when the gearbox is in the horizontal position.

1

3

4

2

Fig. 118

1) Filler plug / filling hole

EC400099_1

3) Inspection screw / inspection hole

2) Drain plug

4) Guard sheet

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

• The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw with the specified tightening torque, refer to chapter

Maintenance “Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes”.

If the oil does not reach the inspection hole:

• Unscrew the filler plug.

• Top up oil via the filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug with the specified tightening torque, refer to chapter Maintenance “Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes”.

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheet.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheet.

147

Maintenance

For adaptation Claas version and adaptation New Holland version

Note

Check the oil level, top up oil and drain oil when the gearbox is in the horizontal position.

1

2

EC500109_1

Fig. 119

1) Inspection screw/inspection 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.

• Oil level up to inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

148

15.9

Maintenance

Main gearbox

Note

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

1

3

2

Fig. 120

1) Filler plug/filling hole

3) Inspection screw/inspection hole

EC500050_1

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.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

149

Maintenance

15.10 Collector Gearbox

Notice

Check the oil level and refill oil in the transport position of the header with gearbox in vertical position!

Drain the oil in the working position of the header with gearbox in horizontal position!

3

1 2

2 3

EC500052_1 EC500051_1

Fig. 121

1) Guard plate 2) Inspection- and drain plug/

Inspection- and drain hole

3) Drain plug/drain hole

• 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.

• Oil level up to inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

150

Maintenance

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheets.

• Move the collectors to the working position. Make certain as you do this that the collector gearboxes are in the horizontal position.

• Unscrew the drain plugs (2, 3) and drain the oil.

• Once the oil has drained, mount the drain plugs, tightening torque see chapter

Maintenance, “Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes”.

• Move the collectors to the transport position. Make certain as you do this that the collector gearboxes are in the horizontal position.

• Unscrew the lower inspection screw (2) and refill with new oil up to the lower inspection hole via the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil via the inspection holes up to the lower inspection holes.

• Mount the inspection screws, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheets.

151

Maintenance

15.11 Roller Manual Gearbox

Note

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

4

3

1

2

EC500053_1

Fig. 122

1) Filler screw / filling hole

3) Inspection screw / inspection bore

2) Drain screw

4) Guard plate

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

• The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw with the specified tightening torque, refer to chapter

Maintenance “Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes”.

If the oil does not reach the inspection hole:

• Unscrew the filler plug.

• Top up oil via the filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug with the specified tightening torque, refer to chapter Maintenance “Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes”.

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheet.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheet.

152

15.12

Maintenance

Roller Gearbox

Note

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

1

2

Fig. 123

1) Inspection screw / control hole

EC500054

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.

• Oil level up to inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

153

Maintenance

15.13 Checking and adjusting the collector tension

DANGER! – Unexpected movements of the machine!

Effect: Danger to life, serious injuries

For inspection and adjustment work, swivel the header into the “field position” and support it securely with support jacks.

EasyCollect 600-2 / EasyCollect 750-2

1

2 3

4 5 a

EC500060

15.13.1

Fig. 124

Checking the collector pre-tension

15.13.2

Note

Check the collector pretension after the first 10 operating hours, then every 50 operating hours.

• Remove the cover plate (1).

• Measure dimension a between the pressure disc (2) and the spring housing (3).

If the dimension a = 2 ± 1 mm:

The collector pre-tension is OK.

• Mount the cover sheet (1).

Adjusting the collector pretension

If the dimension is smaller than or greater than 2 ± 1 mm:

The collector pre-tension must be re-adjusted.

• Loosen the counter nut (4)

To increase the collector pre-tension:

• Tighten the nut (5) until the dimension a = 2 ± 1 mm is reached.

To reduce the collector pre-tension:

• Loosen the nut (5) until the dimension a = 2 ± 1 mm is reached.

• Tighten the counter nut (4).

• Mount the cover sheet (1).

154

15.14

Maintenance

Adjusting the Scraper

Note

The distance between back of the collector (2) and scraper (1) must not exceed dimension

“a = 3 mm”.

4

6

1

2

1

4

3

EC500064_1

Fig. 125

• Loosen the screw connections (3) a little and push the scraper (1) in the direction of the collector back (2).

• Set the distance to a = 0 to 3 mm

.

When adjusting the scrapers/cover sheets, set the gap dimensions as low as possible (almost 0 mm) to ensure that the machine functions as optimally as possible.

Gap dimensions (b): x y

5

1 b

7

EC500065

Fig. 126

In area “X”, the scrapers (1) must be centrally aligned with the collector fingers (4). In area “Y”, the gap between the scrapers must be widened conically to the rear (a+4). If necessary, loosen the screws (7) and adjust the height of the scraper.

Note

If necessary, align the cover (5) by loosening the screws (6).

• Tighten the screw connections (3, 6 and 7).

155

Maintenance

Gap dimensions (c) and (d):

3 d

1

4

2

2

EC500092_1

Fig. 127

The scrapers (2) must be centrally aligned with the star-shaped conveyors (1). The distance must be at least c=1 mm.

The distance from the scraper (2) to the star-shaped conveyor rotor (3) must be d = 0 - 3 mm.

When adjusting the scrapers/cover sheets, set the gap dimensions as low as possible (almost 0 mm) to ensure that the machine functions as optimally as possible.

• Loosen the screws (4) a little.

• Move the scraper (2) so that the gap dimensions are adhered to.

• Tighten the screws (4).

156

15.14.1

Maintenance

Checking the gap dimensions of the infeed sheets

Prerequisites:

– The header is raised, see operating instructions of the forage harvester.

– The machine is shut down and secured, see operating instructions of the forage harvester.

1

2

3

5 4

EC500183

Fig. 128

Perform the following check on the left-hand and right-hand side:

• Ensure that the gap between the rotating tower (5) and the infeed sheet (1) is set to

5-15 mm

. Ensure that the gap is parallel to the rotating tower (5).

• Ensure that the gap between the star-shaped conveyor (3) and the scraper edge (2) is set to

2-3 mm

. Ensure that the gap is parallel to the star-shaped conveyor (3) or increases in conveying direction.

• Ensure that the gap between the cover sheet (4) and the infeed sheet (1) is set to

2-5 mm

.

Ensure that the gap is parallel to the cover sheet (4).

157

Maintenance

15.15 Changing the tips

How to change the tips in the outriggers is described below; the central tip and the side tips are changed similarly.

2

3

15.16

1

EC500061_2

Fig. 129

• Detach the row registration sensor (on central tip only) from the cable harness.

• Unscrew the cylinder screws (2) and remove the tip (1).

• Remove the bearing rings (3) from the tip (1) and insert them into the new tip. If necessary, renew worn bearing rings (3).

• Mount the new tip (1) with the cylinder screw (2) and secure with the locknut.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

Adjusting the tips

Fig. 130:

Adjust the bottom edges of the side tips (1) approx. y = 30 mm

higher than the bottom edges of the row tips (2).

The bottom edge of the central tip (3) should be approx. x = 30...50 mm

lower than the bottom edges of the other tips (a = distance to the ground in working position/close to ground).

If necessary, correct the height adjustment of the side and row or rather central tip.

158

Maintenance

4

15.16.1

15.16.2

15.16.3 b a

2

1

Fig. 131

Adjusting the side tips

The height of the side tips (a) can be adjusted with the screw (1).

To do this:

• Unscrew the counter nut (2)

• Adjust the height of the tips with the screw (1)

• Tighten the counter nut (2)

Adjusting the row tips

The height of the row tips (b) can be adjusted by moving the sliding piece (3)

To do this:

• Loosen the screw (4).

• Adjust the height of the row tip by moving the sliding piece (3).

• Tighten the screw (4).

Adjusting the central tip

1

2

EC500078

3

EC500107

Fig. 132

• Loosen the screw connections (2) slightly.

• Adjust the central tip (1) so that the lower edge of the central tip is approximately x = 30...50 mm below the lower edges of the other tips.

• Tighten the screw connections (2).

159

Maintenance

15.17 Removing and Installing Guide Bracket at Tip Retainer

For use in lodged maize, it may be helpful to dismount the guide brackets (1, 2). This improves the crop flow to the forage harvester.

1

1 2

5

3

4

6

EC500 156

Fig. 133

The both inner row tips of each lateral frame are equipped with split guide brackets (2). The other rows are equipped with single guide brackets (1).

Removing upper guide bracket (3)

• Unscrew the screws (6) and remove the upper guide bracket (3) and the lower guide bracket (4) upwards.

• Reinstall the lower guide bracket (4) by using screws which are 15mm shorter

.

Removing upper guide bracket (3) and lower guide bracket (4)

• Unscrew the screws (6) and remove the upper guide bracket (3) and the lower guide bracket (4) upwards.

Removing single guide bracket (1)

• Unscrew the screws (5) and remove the single guide bracket (1) upwards.

Installing guide bracket

Installation is in reverse order to removal.

160

15.18

Maintenance

Converting Tip Retainer for Special Row Distances

To ensure that the maize header achieves an optimum collection result even with special row spacings (e.g. 70 cm row spacing), the outer row tips can be mounted 125 mm closer to the middle of the machine. The altered position of the row tip means that the cutter blades in this area must also be adjusted.

2

5 6 7

1

8

EC500094

3 4

EC500093

8 5 6 7

EC500095

Fig. 134

To convert the row tip from the original position (1) to the position for special row distances (2):

• Dismount the cover sheet (3).

• Dismount the outer row tip (4).

• Dismount the blades (5, 6, 7, 8).

• Mount the three outer blades (5, 6, 7) respectively by 125 mm towards the middle of the machine.

• Mount the blade (8) onto the space vacated by the cutter blade (5).

• When fitting the cutter blade, make sure that no impact stops are created. If necessary, compensate with distance sheets.

• Mount the outer row tip (4) in the position for special row distances.

• Mount the cover sheet (3) on the freed screw connection points of original position.

CAUTION!

After replacement of the blades, ensure that there are no linings and that the cutting blades of the collector rest on all cutting edges of the fixed blades.

• If necessary, remove or add shims to compensate height differences between adjacent blades or grind protruding edges.

161

Maintenance

15.19

15.19.1

Blade Changing

DANGER! – Danger from sharp blades!

Serious injuries, in particular to the hands, may occur.

• Wear protective gloves when performing any work on the collector to avoid being cut by the blades.

Note

Always check the blades before use and after driving into an obstacle. Worn, damaged or deformed blades must be replaced immediately.

Changing bow and step blades

Note

When replacing observe the right / left cutting direction!

CAUTION!

After replacement of the blades, ensure that there are no linings and that the cutting blades of the collector rest on all cutting edges of the fixed blades.

• If necessary, remove or add shims to compensate height differences between adjacent blades or grind protruding edges.

Changing the inner bow blade

2

1

EC500063

Fig. 135:

• Unscrew hexagon head screws (2) and pull out the inner bow blade (1) to the front.

• Insert new bow blade (1) and fasten it with hexagon head screws (2).

162

Changing the outer bow blade

1

Maintenance

2

EC500066_1

Fig. 136

• Unscrew hexagon head screws (2) and pull out the outer bow blade (1) to the front.

• Insert new bow blade (1) and secure with hexagon head screws (2).

Changing the step blade

3

4

6

5

EC500067_1

Fig. 137

• Unscrew the hexagon head screws (4) and remove covering panel (5).

• Unscrew hexagon head screws (6) and pull out the corresponding bow blade (3) to the front.

• Insert a new step blade (3) and secure with the two hexagon head screws (6).

• Mount the covering panel (5) with the hexagon head screws (4).

Note

Use a “high-strength” screw locking agent (for example Loctite).

163

Maintenance

15.19.2 Changing the cutting blades

Note

When replacing, observe the right/left cutting direction!

6

2

1

5

4

1

1

3

EC500068_3

Fig. 138

• Unscrew the screws (5) and remove the cover (6).

• To dismount the cutting blades (1), unscrew the internal hexagon head screw (2) in the straight area.

• Push up the collector on the step blade (4) with the mounting lever (3) and first pull the cutting blade (1) off the cam downwards and then remove it to the back.

Installation is in reverse order to removal.

Notice

Tightening torque of hexagon head screws M12 (2) with a strength of 10.9 = 110 Nm.

Tightening torque of hexagon head screws M8 (5) = 45 Nm.

164

15.19.3 Changing the scraper blade

1

Maintenance

15.20

2

Fig. 139:

• Screw out the both hexagon head screws (2) and dismount the scraper blades (1).

• The new scraper blades (1) are mounted in reverse order to removal.

Note

The scraper blade must be adjusted so that the cutting edge rests on the collector. However, the collector should not be raised!

Replacing wear plates

1

EC500097

Fig. 140

Notice

Check the wear plates (1) at the side parts on the right and left every 100 operating hours or at least after the season to ensure they are correctly seated and for wear. If necessary, correct and/or replace them.

• Loosen the corresponding screw connection.

• Replace the wear plate.

• Tighten the screws.

165

Maintenance

15.21 Adjusting the tip retainer EC 600-2, 750-2 for 38" row spacing

To ensure that the maize header also achieves an optimum collection result at row spacings of 38", the second row tip from the inside on the EasyCollect 600-2 and 750-2 can be mounted

270 mm closer to the middle of the machine.

2 1

EC500098

Fig. 141

To convert the row tip, the wear plate in this area must be separated and the guide bracket for the row tip must be shortened.

5 8 6 9

166

4

X

3

10

EC500099

12

7

EC500100

11

X

EC500101 EC500102

Fig. 142

To convert the row tip from the original position (1) to the position for the 38" row spacing (2):

• Remove the cover plate (3).

• Dismount the second row tip (4) from the inside.

• Dismount the wear plate (5) and separate the points (6) identified by notches.

• Dispose of the waste piece (7).

• Re-mount the wear plate, which now consists of two parts (8, 9).

• Shorten the guide bracket (10) of the dismounted row tip by the dimension X = 270 mm.

• Mount the dismounted row tips (11) in the position for 38" row spacings.

• Mount the cover sheet (12) on the screwing points vacated at the original position.

Maintenance

167

Maintenance – lubrication

16 Maintenance

– lubrication

16.1 Special Safety Instructions

DANGER! – When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving.

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

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

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

• Switch off the PTO and disengage it.

• Before working under or on the raised machine, support the machine securely. Close shutoff valve on the forage harvester!

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

• Before working on the hydraulic system, depressurise it. Hydraulic liquid escaping under high pressure can penetrate the skin and cause severe injuries.

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

• In the event of injuries or burns due to oils, cleaning agents or solvents, contact a doctor immediately.

• All other safety instructions 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

Lubrication

Oiling

Multi-purpose grease

Multi-purpose grease

Unless otherwise prescribed, use oils based on vegetable matter.

– 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.

168

16.2

Maintenance – lubrication

Lubrication Chart

• The lubrication points mentioned below must be lubricated according to the operating hours indicated.

25 h

25 h 25 h

25 h

250 h

250 h

25 h 250 h

25 h

250 h

25 h

Fig. 143:

250 h

EC500023_2

169

Maintenance – lubrication

50 h 250 h 50 h

Fig. 144:

50 h 50 h

25 h

50 h

EC500022_3

170

Claas and John Deere

250 h

Maintenance – lubrication

250 h

EC500130_1

Fig. 145

171

Placing in Storage

17 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.

172

18

18.1

Before the Start of the New Season

Before the Start of the New Season

Special Safety Instructions

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

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

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

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

• Switch off PTO shaft and disconnect it.

• Before working under or on the raised machine: Secure machine or machine parts with hydraulic shut-off device (e.g. stop cock) on machine side against lowering, refer to operating instructions of forage harvester!

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

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

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

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

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

Danger! - When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving (caution, cutters continue to run).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

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

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

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

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

173

Before the Start of the New Season

18.2 Test run.

Danger! - Testing the machine after repair, maintenance or cleaning work and after technical intervention.

Effect: Danger to life or serious injuries

• The machine must be in working position

• Do not switch on the drives until the machine is in cutting height and you are absolutely sure that neither persons, animals nor objects are in the danger zone.

• Start a trial run of the machine from the driver’s seat only.

• Lubricate the machine thoroughly. Remove any condensation water which may have collected in the bearings.

• Check oil level in the gearbox(es) and top up if necessary.

• Check all screws to make certain they are tight or retighten them 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 necessary.

• Re-read the operating instructions thoroughly.

Note

Use vegetable oils and greases.

174

19

19.1

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.

175

20 Index

A

Adaptations approved ......................................... 44

Adapting Machine to CLAAS Forage Harvester

Type 493, Type 494, Type 496, Type 497...... 48

Adapting Star-shaped Conveyor Height to Maize

Crop .............................................................. 135

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ........... 56

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ........... 78

Adapting the machine to the John Deere forage harvester of the 8000 series with quick coupler for header ....................................................... 61

Adapting the machine to the John Deere forage harvester of the 8000 series with universal shaft

........................................................................ 58

Adapting the machine to the New Holland forage harvester ......................................................... 68

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

Adjusting the central tip .................................... 159

Adjusting the collector pretension ..................... 154

Adjusting the tip retainer EC 600-2, 750-2 for 38

...................................................................... 166

Adjusting the tips .............................................. 158

Aligning the coupling disc ............................. 50, 62

Attaching Safety Labels and Information Labels 37

B

Ballasting of forage harvester ............................. 46

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

Before the Start of the New Season ................. 173

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

Blade Changing ................................................ 162

C

Changing the cutting blades ............................. 164

Changing the tips .............................................. 158

Checking the gap dimensions of the infeed sheets

...................................................................... 157

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

Collector Gearbox ............................................. 150

Connecting ....................................... 115, 117, 122

Connecting drive .....................................80, 83, 89

Connecting Drive Type 491, Type 492 ............... 74

Connecting Drive Type 493, Type 494, Type 496,

Type 497 ......................................................... 74

Connecting hydraulics and electrics ................... 85

Connecting the hydraulic lines ................75, 81, 90

Consumables ................................................ 25, 47

176

Contact for KRONE NORTHAMERICA ....... 37, 43

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

Converting Tip Retainer for Special Row

Distances ..................................................... 161

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

D

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

Dangers associated with certain activities

Work on the machine ..................................... 27

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

Detaching the machine .................................... 113

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

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

Disconnecting header ...................................... 120

Disconnecting hydraulics and electrics ............ 119

Dismantling the machine in case of adaptation to

Claas forage harvester......................... 115, 121

Dismantling the machine in case of adaptation to

John Deere forage harvester of 6000 and 7000 series............................................................ 117

Dismantling the machine in case of adaptation to

John Deere forage harvester of 8000 series 119

Disposal of the machine................................... 175

Driving and Transport ........................................ 92

F

From transport into working position .................. 96

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

H

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

Hydraulic circuit diagram.................................. 146

Hydraulic hose line(s) ...................................... 139

Hydraulics ........................................................ 145

I

Identification Plate .............................................. 43

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

Information Required for Questions and Orders 43

Initial operation - Claas ...................................... 48

Initial operation – John Deere ............................ 55

Initial operation – New Holland .......................... 68

Input gearbox ................................................... 147

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

K

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

L

Lifting the machine ............................................. 95

Lubricating grease .............................................. 47

Lubrication Chart .............................................. 169

M

Machine overview ............................................... 38

Main gearbox .................................................... 149

Maintenance ..................................................... 139

Maintenance - lubrication.................................. 168

Maintenance table ............................................ 141

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

Notes with information and recommendations 12

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

Means of Representation

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

Metric Thread Screws with Control Thread ...... 142

Metric Thread Screws with Countersunk Head and Hexagonal Socket.................................. 143

Metric Thread Screws with Fine Thread ........... 143

Mounting console support................................. 125

Mounting side guards ....................................... 126

Mounting to John Deere forage harvester of 8000 series .............................................................. 83

O

Oils ...................................................................... 47

Operating active ground contour ...................... 106

Operating input gearbox (Claas) ...................... 102

Operating main gearbox (Claas, John Deere) .. 101

Operating row detection.................................... 103

Operation ............................................................ 96

Operational safety: Technically perfect condition

........................................................................ 19

P

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

Personal protective equipment ........................... 23

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

Placing in Storage ............................................. 172

Position of the Adhesive Safety and Information

Labels on the Machine.................................... 31

Preparing the machine for road travel ................ 93

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

Putting header down ......................................... 128

R

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

Removing and Installing Guide Bracke at Tip

Retainer ........................................................ 160

Removing Hydraulic Lines ............... 115, 117, 121

Removing the machine and storing it with supports ........................................................ 123

Re-Ordering Safety Labels and Information Labels

........................................................................ 37

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

Replacing wear plates...................................... 165

Road travel

Preparing machine ......................................... 93

Roller Gearbox ................................................. 153

Roller Manual Gearbox .................................... 152

S

Safely checking the oil level and changing the oil and filter element ........................................... 30

Safety ................................................................. 14

Safety routines ................................................... 29

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

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

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

Setting Holding-Down Device Roller ................ 133

Setting the holder for the catch hook ................. 59

Setting the holder for the locking pins................ 56

Setting the lateral supports at rear ................... 127

Setting the oscillating movement of the header137

Setting the rotational speed of the maize header

(Claas, John Deere) ..................................... 100

Setting the rotational speed of the maize header

(New Holland) .............................................. 100

Setting the Star-shaped Conveyor Speed ....... 136

Setting the tubular bar in terms of its inclination

(EasyCollect 600-2 FP, 450-2 FP) ............... 132

Setting the tubular bar in terms of its inclination

(EasyCollect 600-2 FP, 750-2 FP) ............... 130

Setting the Tubular Bars .................................. 129

Settings ............................................................ 129

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

Spare Parts ...................................................... 140

Start-up - CLAAS ............................................... 72

Start-up – John Deere........................................ 77

Stopping and securing the machine .................. 29

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

Supporting lifted machine and machine parts securely .......................................................... 29

Switching from working position to transport position ......................................................... 110

Switching off the machine .................................. 94

T

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

Technical data .................................................... 45

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

Test run ............................................................ 174

Test run ............................................................ 140

Tightening torques ........................................... 142

Tightening Torques for Locking Screws and Bleed

Valves on the Gearboxes ............................ 144

177

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

U

Using the Machine for Work ............................... 99

W

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

178

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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