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


Add to my manuals
134 Pages

advertisement

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

EasyCollect 450-2

EasyCollect 600-2

EasyCollect 750-2

(from serial no.: 980 501)

Order no.: 150 000 322 04 en

Maize header

31.01.2018

Table of Contents

CV0

EC Declaration of Conformity

We

Maschinenfabrik Krone Beteiligungs-GmbH

Heinrich-Krone-Str. 10, D-48480 Spelle hereby declare as manufacturer of the product named below, on our sole responsibility, that the

Machine:

Maize Header

Type:

EasyCollect 450-2, EasyCollect 600-2, EasyCollect 750-2 to which this declaration refers is in compliance with the following relevant provisions of:

EC Directive 2006/42/EC (machines).

The undersigned Managing Director is authorised to compile the technical documents.

Spelle, 01.08.2017

Dr.-Ing. Josef Horstmann

(Managing Director, Design & Development)

Year of manufacture: Machine no.:

2

Table of Contents

1 Table of Contents

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

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

2.1

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

2.2

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

2.3

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

2.4

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

2.5

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

2.5.1

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

2.5.2

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

2.5.3

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

2.5.4

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

2.5.5

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

2.5.6

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

2.5.7

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

3 Safety ..................................................................................................................................................... 13

3.1

Purpose of Use ................................................................................................................................. 13

3.2

Intended use ..................................................................................................................................... 13

3.3

Reasonably foreseeable misuse ...................................................................................................... 14

3.4

Service life of the machine ............................................................................................................... 14

3.5

Basic safety instructions ................................................................................................................... 15

3.5.1

Importance of the operating instructions ................................................................................... 15

3.5.2

Personnel qualification .............................................................................................................. 15

3.5.3

Personnel qualification of the technicians ................................................................................. 16

3.5.4

Children in danger ..................................................................................................................... 16

3.5.5

Coupling the machine safely ..................................................................................................... 16

3.5.6

Structural changes to the machine ........................................................................................... 17

3.5.7

Additional equipment and spare parts ...................................................................................... 17

3.5.8

Workstations on the Machine .................................................................................................... 17

3.5.9

Operational safety: Technically perfect condition ..................................................................... 18

3.5.10

Danger zones ............................................................................................................................ 19

3.5.11

Keeping safety devices functional ............................................................................................. 21

3.5.12

Personal Protective Equipment ................................................................................................. 22

3.5.13

Safety signs on the machine ..................................................................................................... 22

3.5.14

Traffic safety .............................................................................................................................. 23

3.5.15

Parking the machine safely ....................................................................................................... 23

3.5.16

Consumables ............................................................................................................................ 24

3.5.17

Dangers associated with the operational environment ............................................................. 24

3.5.18

Sources of danger on the machine ........................................................................................... 25

3.5.19

Dangers associated with certain activities: Work on the machine ............................................ 26

3.5.20

Behaviour in hazardous situations and when accidents occur ................................................. 27

3.6

Safety routines ................................................................................................................................. 28

3.6.1

Stopping and securing the machine .......................................................................................... 28

3.6.2

Supporting lifted machine and machine parts securely ............................................................ 28

3.6.3

Safely checking the oil level and changing the oil and filter element ........................................ 29

3.7

Position of the Adhesive Safety and Information Labels on the Machine ........................................ 30

3.7.1

Re-Ordering Safety Labels and Information Labels .................................................................. 34

3

Table of Contents

3.7.2

Attaching Safety Labels and Information Labels ...................................................................... 34

3.7.3

Contact ...................................................................................................................................... 34

4 Machine Description ............................................................................................................................ 35

4.1

Machine overview ............................................................................................................................. 35

4.2

Overview of the different adaptation types ....................................................................................... 37

4.3

Identification Plate ............................................................................................................................ 38

4.4

Information Required for Questions and Orders .............................................................................. 38

4.4.1

Contact ...................................................................................................................................... 38

5 Technical data ....................................................................................................................................... 40

5.1

Consumables ................................................................................................................................... 41

5.1.1

Oils ............................................................................................................................................ 41

5.1.2

Lubricating grease ..................................................................................................................... 41

6 Commissioning ..................................................................................................................................... 42

6.1

Stop points ....................................................................................................................................... 43

6.2

Storage ............................................................................................................................................. 44

6.3

Adjusting machine to the forage harvester BiG X 480/530/580/630 and BiG X 680/780/880 ......... 45

6.3.1

Adjusting the locking plates ...................................................................................................... 46

6.3.2

Aligning the coupling disc ......................................................................................................... 49

6.3.2.1

6.3.2.2

Check orientation of the clutch disc ................................................................................... 49

Align input gearbox ............................................................................................................ 51

6.3.3

Connecting the hydraulic lines .................................................................................................. 54

6.3.4

Setting in the operating terminal ............................................................................................... 55

6.4

Adjusting the machine to the forage harvester BiG X 600-1100 ...................................................... 56

6.4.1

Adjusting the adapter frame ...................................................................................................... 56

6.4.2

Pendulum frame ........................................................................................................................ 57

6.4.3

Connecting the hydraulic lines .................................................................................................. 57

6.4.4

Setting in the operating terminal ............................................................................................... 58

6.5

Spout: Mounting Conical End Flap ................................................................................................... 59

6.5.1

Removing Spout Flap ................................................................................................................ 59

6.5.2

Mounting Spout Flap ................................................................................................................. 60

7 Start-up .................................................................................................................................................. 61

7.1

Checking and observing before start-up .......................................................................................... 61

7.2

Mounting Machine on Forage Harvester .......................................................................................... 61

7.2.1

Support jacks right/left in transport position .............................................................................. 62

8 Driving and Transport .......................................................................................................................... 63

9 Operation ............................................................................................................................................... 65

9.1

From transport into working position ................................................................................................ 65

9.1.1

Removing the protective cover ................................................................................................. 65

9.1.2

Support jacks right/left in transport position .............................................................................. 66

9.1.3

Swinging the right-hand / left-hand side parts into working position ......................................... 67

9.1.4

Swinging the plant divider into working position ....................................................................... 68

9.2

Using the Machine for Work ............................................................................................................. 69

9.2.1

Inserting Maize Header ............................................................................................................. 69

9.2.2

Lifting gear distance control (optional) ...................................................................................... 70

9.2.3

Row detection ........................................................................................................................... 71

9.3

Switching from working position to transport position ...................................................................... 72

9.3.1

Swinging the plant divider into transport position ..................................................................... 72

9.3.2

Swinging the right hand / left hand side parts upward into transport position .......................... 73

4

Table of Contents

9.3.3

Installing guard on the right/left ................................................................................................. 73

9.3.4

Installing the front guard............................................................................................................ 74

9.3.5

Connecting indicators and position lights on the right/left......................................................... 74

9.4

Detaching the machine..................................................................................................................... 76

9.4.1

Moving support jacks on right/left into parking position ............................................................ 76

9.4.2

Swinging the right-hand / left-hand side parts into working position ......................................... 77

9.4.3

Disconnecting Hydraulic Hoses (for version with “pendulum frame adaption”) ........................ 78

9.4.4

Disconnecting Hydraulic Hoses (for version with “pendulum frame adaption”) ........................ 79

9.4.5

Placing the Machine on the Ground .......................................................................................... 80

9.5

Removing the machine and storing it with supports (for the version with supports) ........................ 82

9.5.1

Mounting console support ......................................................................................................... 83

9.5.2

Mounting side guards ................................................................................................................ 84

9.5.3

Setting the lateral supports at rear ............................................................................................ 85

9.5.4

Putting header down ................................................................................................................. 86

10 Settings ................................................................................................................................................. 87

10.1

Setting the Tubular Bars .................................................................................................................. 87

10.1.1

Setting the Inclination of Tubular Bars (EasyCollect 600-2, 750-2) .......................................... 88

10.1.2

Setting the Inclination of the Tubular Bars (EasyCollect 450-2) ............................................... 90

10.2

Setting Holding-Down Device Roller ................................................................................................ 91

10.3

Adjusting skids ................................................................................................................................. 91

10.4

Adjusting the plant dividers .............................................................................................................. 92

10.5

Adapting Star-shaped Conveyor Height to Maize Crop ................................................................... 93

10.6

Setting the Star-shaped Conveyor Speed........................................................................................ 94

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

11.1

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

11.2

Hydraulic hose line(s) ....................................................................................................................... 96

11.2.1

Test run ..................................................................................................................................... 97

11.3

Spare Parts ...................................................................................................................................... 97

11.4

Maintenance table ............................................................................................................................ 98

11.5

Tightening torques ............................................................................................................................ 99

11.5.1

Metric Thread Screws with Control Thread............................................................................... 99

11.5.2

Metric Thread Screws with Fine Thread ................................................................................. 100

11.5.3

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................. 100

11.5.4

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes ....................... 101

11.6

Hydraulics ....................................................................................................................................... 102

11.7

Hydraulic circuit diagram ................................................................................................................ 103

11.8

Input gearbox ................................................................................................................................. 104

11.9

Main gearbox .................................................................................................................................. 105

11.10

Collector Gearbox .......................................................................................................................... 106

11.11

Roller Manual Gearbox .................................................................................................................. 108

11.12

Roller Gearbox ............................................................................................................................... 109

11.13

Checking and adjusting the collector tension ................................................................................. 110

11.13.1

Checking the collector pre-tension .......................................................................................... 110

11.13.2

Adjusting the collector pretension ........................................................................................... 110

11.13.3

Checking the collector pre-tension .......................................................................................... 111

11.13.4

Adjusting the collector pretension ........................................................................................... 111

11.13.5

Checking the Collector Tensioning Function .......................................................................... 112

11.13.6

Setting the collector tensioning function ................................................................................. 112

11.14

Adjusting the Scraper ..................................................................................................................... 113

5

Table of Contents

11.15

Changing the tips ........................................................................................................................... 115

11.16

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

11.16.1

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

11.16.2

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

11.16.3

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

11.17

Removing and Installing Guide Bracket at Tip Retainer ................................................................ 118

11.18

Converting Tip Retainer for Special Row Distances ...................................................................... 119

11.19

Blade Changing .............................................................................................................................. 120

11.19.1

Changing bow and step blades ............................................................................................... 120

11.19.2

Changing the cutting blades ................................................................................................... 122

11.19.3

Changing the scraper blade .................................................................................................... 123

11.20

Replacing wear plates .................................................................................................................... 123

12 Maintenance – lubrication ................................................................................................................. 125

12.1

Special Safety Instructions ............................................................................................................. 125

12.2

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

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

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

14.1

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

14.2

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

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

15.1

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

16 Index .................................................................................................................................................... 132

6

2

2.1

2.2

2.3

2.4

To this Document

To this Document

Validity

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

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

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”.

7

To this Document

2.5 How to use this document

2.5.1

2.5.2

2.5.3

2.5.4

Directories and References

Table of contents/headers:

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

Index directory:

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

Cross references:

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

Example:

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

Torques”.

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

Direction Information

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

Term “Machine”

In the 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.

8

2.5.5

2.5.6

To this Document

Scope of Document

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

Means of representation

Icons in the text

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

Action step

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

• Set the left outside mirror.

Sequence of actions

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

• Loosen counter nut.

• Set the screw.

• Tighten counter nut.

List

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

– Brakes

– Steering

– Lighting

9

To this Document

Symbols in figures

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

Icon

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

10

Warning signs

Warning

WARNING! - Type and source of hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention.

Caution

CAUTION! - Type and source of hazard!

Effect: Damage to property.

• Measures for risk prevention.

Notes with information and recommendations

Note

Note

Effect: Economic benefit of the machine.

• Measures to be performed.

To this Document

11

To this Document

2.5.7 Conversion table

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

Quantity 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

12

3

3.1

Ver

3.2

Safety

Safety

Purpose of Use

The KRONE maize header EasyCollect 450-2, EasyCollect 600-2 and EasyCollect 750-2 is a harvesting attachment with adapter frame for attachment to forage harvesters and is used for harvesting maize and other forage crops with thick stalks independently of the 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 mown stalk and leaf crops growing on the ground.

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

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

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

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

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

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

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

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

13

Safety

3.3

3.4

Reasonably foreseeable misuse

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

Such misuse is for example:

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

“Intended use”

– Transportation of people

– Transportation of goods

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

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

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

– Unauthorised modifications to the machine

– Attachment of unauthorised or unapproved additional equipment

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

– Stationary operation of the machine

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

Service life of the machine

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

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

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

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

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

– Theoretically, the service life of this machine is unlimited as all worn or damaged parts can be replaced.

14

3.5

3.5.1

3.5.2

Safety

Basic safety instructions

Non-compliance with the safety instructions and warnings

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

Importance of the operating instructions

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

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

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

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

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

• Hand over the operating instructions to subsequent users.

Personnel qualification

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

– He is physically capable of controlling the machine.

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

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

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

– He is familiar with driving vehicles safely.

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

15

Safety

3.5.3

3.5.4

3.5.5

Personnel qualification of the technicians

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

• Qualified professional, with relevant training.

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

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

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

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

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

Children in danger

Children cannot assess danger and behave unpredictably.

As a result, children are especially at risk.

• Keep children away from the machine.

• Keep children away from consumables.

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

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.

16

3.5.6

3.5.7

3.5.8

Safety

Structural changes to the machine

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

Structural changes and enhancements are not permitted.

Additional equipment and spare parts

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

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

Workstations on the Machine

Passengers

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

Ejected objects may strike and injure passengers.

• Never let people ride on the machine.

17

Safety

3.5.9 Operational safety: Technically perfect condition

Operation only when the machine has been started up correctly

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

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

Technically perfect condition of the machine

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

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

Adjustment.

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

Danger resulting from damage to the machine

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

As a result, people may be seriously 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”.

18

3.5.10

Safety

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: Shut down 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

19

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.

20

3.5.11

Safety

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.

21

Safety

3.5.12

3.5.13

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".

22

3.5.14

3.5.15

Safety

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”.

Risk of tipping on slopes

The machine may overturn when driving on slopes. As a result, accidents may occur and people may be seriously injured or killed. The risk of tipping over depends on many factors.

• Observe procedures for driving, see chapter “Driving and Transport”.

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“.

23

Safety

3.5.16

3.5.17

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 operating conditions, dust, impurities and crop residues may ignite on hot parts and cause fires that can seriously injure or kill people.

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

Check and clean the machine regularly during the working day.

24

3.5.18

Safety

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.

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

Depending on the ambient conditions, working hours and the working and operating conditions of the machine, specify and use suitable hearing protection. In doing so, consider airborne noise emission, refer to chapter Technical Data.

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

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

• Remove hearing protection for road travel.

Liquids under high pressure

The following liquids are under high pressure:

– Hydraulic oil

Liquids under pressure

The following liquids are under high pressure:

– Hydraulic oil

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

• If a damaged pressure system is suspected, immediately contact a qualified service centre.

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

• Keep body and face away from leaks.

• If liquids penetrate the body, immediately consult a doctor. The liquid must be removed from the body as quickly as possible. Danger of infection!

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.

25

Safety

3.5.19 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.

26

3.5.20

Safety

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 parts:

– Gearbox

– Parts of hydraulics

– Parts of the electronics

– Frame supporting component groups

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

• Have welding work performed by experienced technicians only.

• 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.

27

Safety

3.6

3.6.1

3.6.2

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.

28

3.6.3

Safety

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

WARNING!

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

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

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

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

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

“Securely Supporting Raised Machine and Machine Parts”.

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

Safeguarding the Machine”.

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

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

Technical Data, “Consumables”.

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

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

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

29

Safety

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

8

5

6

3 9 3 6 5 8

7 7

2 3

4

Fig. 1

3

2

1

4

EC500003_2

30

L

Safety

1) Order no. 939 471 1 (1x)

Danger due to incorrect operation and lack of knowledge

Incorrect operation and lack of knowledge of the machine as well as incorrect behaviour in hazardous situations is risking the life of the operator and third parties.

• Before starting up the machine, read and follow the operating instructions and safety instructions.

2) Order no. 942 312 0 (2x)

Danger due to crushing.

There is a risk of being crushed between the front attachment and forage harvester.

• Ensure that there is nobody between the front attachment and forage harvester.

L

3) Order no. 942 459 0 (4x)

942 459- 0

4) Order no. 939 469 1 (2x)

Danger due to crushing or shearing

Risk of injury due to crushing or shearing points on moving machine parts.

• While parts are moving, never reach into areas where there is a risk of being crushed.

Danger due to impacts or crushing

Danger to life from machine parts folding down or lowering.

• Ensure that there is nobody in the swivel range of the machine parts.

• Maintain distance from moving machine parts.

5) Order no. 27 003 023 0 (2x)

Danger from being pulled into the front attachment.

• While the machine is operating, maintain an adequate safety distance from the crop attachment.

27 003 023 0

31

Safety

8

5

6

3 9

7

4

Fig. 2

3

2

1

2 3

3 6 5 8

7

4

EC500003_2

32

6) Order no. 939 410 2 (2x)

Danger due to rotating machine parts.

After switching off the machine, there is a risk of injury from coasting machine parts.

• Do not touch any moving machine parts.

• Wait until the machine parts have come to a standstill.

Safety

STOP

939 410 2

7) Order no. 27 003 022 0 (2x)

Danger due to exposed running mowing blades.

• While the machine is operating, maintain an adequate safety distance from the mowing blade.

27 003 022 0

8) Order No. 939 408 2 (2x)

Danger from rotating machine parts.

When getting on the machine while the PTO shaft is running, there is a danger of entanglement caused by rotating machine parts.

• Switch off PTO shaft and engine before getting on the machine.

939 408 2

9) Order No. 939 529 0 (1x) only with "pendulum frame adaptation" design

Danger due to high-pressure liquid.

The accumulator is under gas and oil pressure. If the accumulator is not removed or repaired properly, there is a risk of injury.

• Before removing and repairing the accumulator, follow the information in the operating instructions.

• The accumulator may be removed and repaired by a service centre only.

33

Safety

3.7.1

3.7.2

3.7.3

Re-Ordering Safety Labels and Information Labels

Note

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

Attaching Safety Labels and Information Labels

Note - Attaching a label

Effect: Adhesion of label

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

Contact

Maschinenfabrik Bernard Krone GmbH & Co. KG

Heinrich-Krone-Strasse 10

D-48480 Spelle (Germany)

Telephone: + 49 (0) 59 77/935-0 (Head Office)

Fax.: + 49 (0) 59 77/935-339 (Head Office)

Fax.: + 49 (0) 59 77/935-239 (Spare parts - domestic)

Fax.: + 49 (0) 59 77/935-359 (Spare parts - export)

34

4

4.1

Machine Description

Machine overview

For the "spherical roller adaptation" design

3 4 5

Machine Description

2 6

7

1

12

13 14

11

8

10

9

15 14

16 17 18 19 18 11 20

EC500002_1

Fig. 3 Example: EasyCollect 600-2 for BiG X 480/530/580/630

1) Collector including blades, right

2) Plant divider

16) Clutch disc

19) Main gearbox

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

11) Support jack

14) Folding cylinder

12) Side tip

15) Pendulum crossbar

17) Input gearbox

20) Sliding skid

18) Locking sheet

35

Machine Description

With "pendulum frame adaptation" design

2 1 2

4 3 3

Fig. 4 Example: EasyCollect 750-2 for BiG X 600-1100

1) Stop cock

4) Drive journal

2) Locating bolt

EC500106

3) Pendulum frame holder

36

4.2 Overview of the different adaptation types

Spherical roller adaptation

1

Machine Description

Pendulum frame adaptation

EC500150

Fig. 5

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

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

5 5 7

7 8 8 5 0 0 0

0 m m

Var 220 Var 210

Var 230

750 mm 580 mm

580

750

27 022 185 0

X

Y

X

Y

EC500 151

Fig. 6

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

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

X=580 mm and spherical roller adaptation.

• The forage harvester types BiG X 680/780/880 (variant 210) with a feed width of Y=750 mm and spherical roller adaptation.

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

Y=750 mm and pendulum frame adaptation.

37

Machine Description

4.3 Identification Plate

1

4.4

4.4.1

EC500001

Fig. 7

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

Maschinenfabrik Bernard Krone GmbH & Co. KG

Heinrich-Krone-Strasse 10

D-48480 Spelle (Germany)

Telephone: + 49 (0) 59 77/935-0 (Head Office)

Fax.: + 49 (0) 59 77/935-339 (Head Office)

Fax.: + 49 (0) 59 77/935-239 (Spare parts - domestic)

Fax.: + 49 (0) 59 77/935-359 (Spare parts - export)

38

This page has been left blank deliberately.

Machine Description

39

Technical data

5 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.

Information EasyCollect 450-2

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 min -1

Maximum permitted operating pressure

Hydraulic connections

Electr. connection (lighting) *

200 bar

2 x double-action

7-pole

* depending on forage harvester 12 V or 24 V.

Information EasyCollect 750-2

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

3200 kg

300 – 700 min -1

Maximum permitted operating pressure

Hydraulic connections

Electr. connection (lighting) *

200 bar

2 x double-action

7-pole

* depending on forage harvester 12 V or 24 V.

EasyCollect 600-2

2190 mm

1500 mm

6150 mm

6000 mm

3310 mm

2900 mm

2900 kg

300 – 700 min -1

200 bar

2 x double-action

7-pole

40

5.1

5.1.1

5.1.2

Technical data

Consumables

Oils

Designation Filling quantity Specification

Input gearbox

Main gearbox

Collector gearbox

Roller shifting gearbox

0.5 L

1.0 L

2 x 3.3 L

0.3 L

2 x 0.06 L

Gearbox oil API GL4 SAE 90,

e. g.:

- Esso Spartan EP 150

- Shell Omala Oil 150

- Fuchs- EP 85 W90

- Castrol EPX 90 Roller gearbox

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

41

Commissioning

6 Commissioning

Danger! - Incorrect assembly

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

• Only authorised service centres may assemble the machine.

• The machine must be assembled with special care.

• Always heed the applicable accident prevention regulations.

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

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

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

42

6.1

Commissioning

Stop points

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)!

Fig. 8:

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

Note

Check the chain length!

43

Commissioning

6.2 Storage

1

2

EC500004

Fig. 9:

• 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. 10:

• 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”.

44

6.3

Commissioning

Adjusting machine to the forage harvester BiG X 480/530/580/630 and BiG X 680/780/880

Note

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

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.

Preparing quick coupler (for version with “Hydraulic comfort header locking with quick coupler” on the forage harvester)

1 2

EC500030_1

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.

45

Commissioning

6.3.1 Adjusting the locking plates

Note

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

1 2

BX480566_1

Fig. 12

Prerequisites:

• The forage harvester and the maize header must be on an even, horizontal and firm surface.

• The tire pressure of the forage harvester has been checked.

• The forage harvester is shut down and secured.

To set the locking plates (4):

• Align pendulum tube (2) parallel to intake (1), refer to operating instructions of forage harvester.

• On the "Mechanical header locking with cardan shaft" design, dismount the locking pins (3).

46

2 4 6

Commissioning

7

1

5 3

EC500013 EC400036_1

Fig. 13

WARNING!

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

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

Note

For version with “Hydraulic comfort header locking with quick coupler”

Before the lifting unit is raised, the hydraulic header locking (3) must be unlocked.

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

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

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

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

47

Commissioning

3

3

6

4

2

1 5

EC400119 XC000025

Fig. 14

• For instructions on shutting down and securing the forage harvester, see the operating instructions of the forage harvester.

For the hydraulic comfortable header locking:

• Lock the locking pins (1).

• Check whether the locking pins (1) are inserted in the holes of the locking sheets (2) on the left and right sides of the machine.

• Check whether the locking sheets (2) are in contact with the centring triangles (3) on the left and right sides of the machine.

For mechanical header locking

• Check that the hole patterns in the locking sheets (2) and in the pendulum tube (4) are aligned on the left and right sides of the machine so that the locking pins (5) can be mounted and secured with a linch pin (6).

• Check whether the locking sheets (2) are in contact with the centring triangles (3) on the left and right sides of the machine.

4

3

5

6

7

2

1

EC400006_1

Fig. 15

If not:

• Loosen the screw connections (5, 6, 7) on the header.

• Using a soft-head hammer, align the locking sheets until the locking pins can run into the boreholes.

When the locking pins have run into the boreholes of the locking sheets, on the right and left sides of the machine:

• Turn the lower eccentric cam (7) (key size 46) until the bulge (4) on the locking sheet (2) is positioned on the centring triangle (3). In doing so, note the direction of rotation in which the lower eccentric cam was turned.

• Tighten the screw connections of the lower eccentric cam (7) and the distance sheet (6) to a tightening torque of 210 Nm.

• Turn the upper eccentric cam (5) in the opposite direction towards the lower eccentric cam.

• Tighten the screw connections of the upper eccentric cam (5) to a tightening torque of 210

Nm.

48

6.3.2

6.3.2.1

Commissioning

Aligning the coupling disc

Check orientation of the clutch disc

For version with “Hydraulic comfort header locking with quick coupler”

Removing protective cap

3 1 2

5

4

EC500031 EC500032

Fig. 16

• Loosen the screw (1) and remove the coupling disc (2) from the profile.

• Loosen the hose clamp (3) on the protective cap and remove the protective cap (4).

• Push the coupling disc onto the profile until the coupling disc can be secured with the screw

(1) in the groove (5) on the profile.

• Tighten the screw (1).

Mounting header on forage harvester

• Mount header on forage harvester.

3

2

EC400051_1

Fig. 17

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

49

Commissioning y

3 2

1

EC500037_2

Fig. 18

Correct position of the clutch disc

The clutch disc has been correctly aligned when:

– the clutch disc is positioned evenly and flat on the coupling pin.

– the bearing surface (1) of the clutch disc or the contact surface (2) of the coupling pin is flush (± 5 mm) with the front surface of the clutch housing (3).

– the coupling pin is positioned centrally in the coupling housing (3), i.e. it is not brushing against the coupling housing (3) during operation.

– the deviation of the axes from the input gearbox (5) and coupling pin (6) is y = 180 ° ± 2 °.

If the position of the clutch disc is correct:

• Install the protective cap, see chapter on Commissioning, "Installing the protective cap".

50

6.3.2.2 Align input gearbox

2 y

Commissioning

3

1

EC500038_1

Fig. 19

Prerequisite:

• The header is removed, refer to chapter Operation, “Removing the machine”.

Height adjustment of input gearbox:

• Loosen the screws (3).

• Add washers to the screw connections (3) or remove washers until the clutch disc (4) and the coupling pin (6) are in alignment. Make certain as you do this that always the same number of washers is used for the screw connections (3).

• Retighten the screws (3).

Inclination adjustment of input gearbox:

• Loosen the screws (1), on both sides of the input gearbox.

• Adjust the inclination of the input gearbox (2) until the deviation of the axles of the input gearbox (2) and the coupling pin (6) is y=180 +/- 2°.

• Retighten the eight screws (1), on both sides of the input gearbox.

Axial adjustment of the input gearbox

2

3

EC500149

Fig. 20

• Loosen the four screws (3).

• Move the input gearbox (2) in the axial direction until the dimension determined is reached.

• Retighten the screws (3).

51

Commissioning

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.

52

Fitting the protective cap

2

1

3 1

EC500087

2

Commissioning

5 x

EC500032

4

EC500031 EC500040_1

Fig. 21

• Remove the screw (1) and remove the clutch disc (2) from profile.

• Slide on the guard cup (4).

• Slide the clutch disc on the profile until it can be secured with the screw (1) in the groove (5) on the profile.

• Tighten the screw (1).

• Align the guard cup (4) so that the gap between the guard cup and the housing (6) is x = 5 mm.

• Tighten the hose clamp (3) on the guard cup (4).

53

Commissioning

6.3.3 Connecting the hydraulic lines

Warning! - Connecting the hydraulic line

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

• When searching for leaks use suitable aids because of the risk of injury and wear protective goggles.

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

• Check hydraulic hoses at regular intervals and replace them in case of damage or ageing!

The replacement hoses must fulfil the technical requirements set by the equipment manufacturer.

Warning! - If the hydraulic hoses are interchanged when connecting them to forage harvester hydraulics, the functions are interchanged, as well.

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

• Always ensure correct connection between machine and forage harvester.

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.

EC400019

Fig. 22:

• Connect the hydraulic hoses (1) to the corresponding plug-in connections on the maize header. Connect the hydraulic hose I to the plug-in connection I etc.

• Connect the plug (2), which supplies the lighting and the sensors, to the socket (3) on the maize header.

Note

The marking on the plug-in connections (I – IV) on the machine is also on the hydraulic hoses of the forage harvester.

54

6.3.4

Commissioning

Setting in the operating terminal

Warning! – Machine damage caused by wrongly configured header type.

If the header type is wrongly configured, the incorrect on-off switching behaviour may increase the stress on the overload protection devices.

Effect: Increased stress on the drive chain.

• Insert the correct header type into the forage harvester terminal.

To ensure the maize header can be operated with the forage harvester, the season settings for the forage harvester terminal must be checked.

Procedure:

• Call up the “Season setting” menu on the forage harvester terminal, refer to the operating instructions of the forage harvester, chapter Terminal menus, “Season setting menu”.

• Set the parameter “Header profile” to “Maize 2-part”.

55

Commissioning

6.4 Adjusting the machine to the forage harvester BiG X 600-1100

6.4.1 Adjusting the adapter frame

Note

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

Note

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

1

2

Fig. 23

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

1

2

3

3

EC500096_1

Fig. 24

Check the axle base "a" between the holding bolt (1,3) of the adapter frame on the machine and, if necessary, adapt it to the size of the pendulum frame (forage harvester).

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

• Tighten the screw connections (2).

56

6.4.2

6.4.3

Commissioning

Pendulum frame

Note

For more information on the pendulum frame, see operating instructions of the forage harvester.

Connecting the hydraulic lines

Warning! - Connection of the hydraulic line

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

• Before 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 because of the risk of injury and wear safety goggles.

• 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 the hydraulic hose lines at regular intervals and replace them if damaged or worn!

The replacement hoses must fulfil 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.

57

Commissioning

4

6.4.4

EC500105_1

Fig. 25

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

• Connect the sensor connector cable (2).

• Open the stop cock (4) on the header.

Note

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

Setting in the operating terminal

Warning! – Machine damage caused by wrongly configured header type.

If the header type is wrongly configured, the incorrect on-off switching behaviour may increase the stress on the overload protection devices.

Effect: Increased stress on the drive chain.

• Insert the correct header type into the forage harvester terminal.

To ensure the maize header can be operated with the forage harvester, the season settings for the forage harvester terminal must be checked.

Procedure:

• From the forage harvester terminal, call up the “General machine settings” menu, see the operating instructions of the forage harvester, info centre “EasyTouch”, information area,

General machine settings, maize header.

• Select the operating mode “two-part EasyCollect” .

58

6.5

6.5.1

Commissioning

Spout: Mounting Conical End Flap

BiG X 480-630 and BiG X 680-880

WARNING

Risk of injury due to suspended load!

There is a danger for persons due to falling load.

• Pay attention to sufficient carrying load of the hoist.

• Do not stay under the suspended load.

• If work has to be performed under the load, securely support the load.

The forage harvester is delivered ex works with a “spout end piece eight rows” and straight spout flap. To optimise the crop flow, a straight spout flap is used for grass mode and a conical spout flap is used for maize mode. A conical spout flap is included in the scope of delivery of the

EasyCollect 450-2 and EasyCollect 600-2 for the eight-row spout extension.

Notice

The conical spout flap must not be used in grass mode. Due to the conical shape and different flow properties of grass compared to maize, there is increased risk of crop blockage in the spout.

Removing Spout Flap

4 5

3 6

4

2 5

1 3

8 7

2

EC500133

Fig. 26

Prerequisites:

- The spout is located on right-hand machine side and is fully lowered.

- The spout flap is fully open.

- The hydraulic circuits are depressurised.

- The machine is shut down and safeguarded, refer to the operating instructions of the forage harvester.

• Dismount the cotter pin (8) and the bolt (7) and remove the hydraulic cylinder (6) from the support.

• Unscrew the screws (3) of the guidance (5).

• Detach the springs (4).

• Unscrew the screws (2) and remove the flap (1).

59

Commissioning

6.5.2 Mounting Spout Flap

4 5

3 6

4

2 5

1 3

8 7

2

EC500133

Fig. 27

• Insert the flap (1) and mount the screws (2).

• Hook in the springs (4).

• Mount the guidance (5) with the screws (3).

• Insert the hydraulic cylinder (6) into the support, mount the bolt (7) and the cotter pin (8).

60

7

7.1

7.2

Start-up

Start-up

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 highways and roads, EasyCollect 450-2, EasyCollect 600-2 and EasyCollect 750-

2 maize header must basically be brought into transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

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.

Mounting Machine on Forage Harvester

For the "spherical roller adaptation" design

• To fit the front attachment to the BiG X 480-630 forage harvester, see the operating instructions of the BiG X 480-630 forage harvester.

• To fit the header to the BiG X 680-880 forage harvester, see the operating instructions for the BiG X 680-880 forage harvester.

With "pendulum frame adaptation" design

• To fit the front attachment to the BiG X 600-1100 forage harvester, see the operating instructions of the BiG X 600-1100 forage harvester.

61

Start-up

7.2.1 Support jacks right/left in transport position

Note

Stop the machine.

6

2

5 4

2

3

1

2

2

4

1

Fig. 28

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 collector 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 collector frame.

• Secure the position of the front support jacks (1) by means of the spring locking pins (2).

62

8

Driving and Transport

Driving and Transport

Danger! - Road travel, carrying passengers, driving conduct

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

• It is forbidden to carry passengers on the machine.

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

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

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

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

• On public highways and roads, EasyCollect 450-2, EasyCollect 600-2 and EasyCollect 750-

2 maize header must basically be brought into transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

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.

Note

If a combination of a working machine and a crop harvester is deployed for on-road use, this combination must be entered in the vehicle papers of the working machine. If the harvesting attachment has not yet been entered in the vehicle documents, the details in the vehicle papers must be supplemented accordingly.

• Please request the required sample report from your sales partner for this purpose.

• The conditions in the vehicle papers must be observed.

Note

If a forage harvester with a maize header is used, the forage harvester must be additionally weighed down by a rear weight For the number of intermediate plates for the rear weight, please refer to the technical data in the operating instructions of the forage harvester.

If no appropriate values for the number of intermediate plates are available in the operating instructions for the maize header, this information is taken from the forage harvester survey.

63

Driving and Transport

EC500007

Fig. 29:

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

EC500103

Fig. 30:

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.

64

9

9.1

9.1.1

Operation

Operation

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

Fig. 31:

• Stop the machine.

• Remove the lighting cable.

• Remove front guard (1).

• Remove the guards (2) right and left.

65

Operation

9.1.2 Support jacks right/left in transport position

Note

Stop the machine.

6

5 4

3

1

2

2

EC500084

Fig. 32

Support jacks at rear on right/left:

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).

66

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

7 3

4

7

Operation

1 2

EC500014_1

Fig. 33

On the machines of EasyCollect series 450-2, 600-2 and 750-2, 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.

The drive of the header may not be switched on until the lowered side parts are pushed towards the middle and thus cover a sensor.

Notice

If the header is in the 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 (4).

Lowering

Make sure that the side parts are only lowered when the forage harvester is at a standstill.

Lower the side parts via forage harvester hydraulics.

To do this:

• Press and hold down the actuation key (3) until the side parts (1, 2) are folded down and the tubular bars (7) are folded up.

After lowering

To ensure that the interlock ratchet mechanisms are engaged:

• After the tubular bars (7) are folded up, press and hold down the actuation key (3) for two seconds.

67

Operation

9.1.4 Swinging the plant divider into working position

Fig. 34

• Press the actuating keys (3) to swing the plant divider (1) into working position through the hydraulic cylinder (2).

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.

68

9.2

9.2.1

Operation

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 - 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.

69

Operation

9.2.2 Lifting gear distance control (optional)

1

EC500010

Fig. 35

Note

The lifting gear distance control is available only if distance sensors (1) have been fitted. When lifting gear distance control is active, the control of the forage harvester sets the stubble height

(max. stubble height about 50 cm.) constant relative to the ground (header contour).

Lifting gear distance control depending on stubble height is only guaranteed if the distance sensors (1) have sufficient contact with the ground.

70

9.2.3 Row detection

X

Operation

2

2

EC903091

Fig. 36

On forage harvesters of series (BiG X V 8, BiG X V 12, BiG X 650) fitted with a B/W display

(black/white display), the "AUTOPILOT" function for EasyCollect machines is only available if the steel row tracers (repair kit 20 085 241 0) are mounted instead of the plastic row tracers.

To fit EasyCollect machines with plastic row tracers for forage harvesters of series (BiG X 500,

BiG X 650-1, BiG X 700-1, BiG X 850-1, BiG X 1100-1) with colour display, at least the following software versions:

• KMC2:

• KMC3:

• Terminal:

• Autopilot:

150200102-27

150200103-27

150200104-28

150200029-17 or higher must be imported.

If the software versions are lower, the latest software version must be imported before row detection can be used.

Notice

In order to use the row detection on the header, the forage harvester must be equipped with automatic steering. The automatic steering automatically controls the forage harvester so that the central tip of the header is guided centrally between two maize rows.

Notice

The prerequisite for proper functioning of the row detection in combination with the automatic steering of the forage harvester is that the row spacing of the maize plants or other stem-like forage crops is within a range from 50 cm to 85 cm.

71

Operation

9.3 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!

9.3.1 Swinging the plant divider into transport position

Note

If the plant divider is in the bottom position, it may collide with the tubular bar on the side part during the folding process.

Fig. 37

• If necessary, press the actuation key (3) to swing up the plant divider (1) with hydraulic cylinder (2).

72

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

Operation

3

9.3.3

1 2

EC500015

Fig. 38

• Swing up the side parts (1, 2) into transport position by pressing the actuation key (3).

Note

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 briefly pushed to the outside and then they are swivelled upwards.

Installing guard on the right/left

2 1

4

4

5

3

EC50044_1

Fig. 39

• 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).

73

Operation

9.3.4 Installing the front guard

9.3.5

Fig. 40

• Attach the front guard (1) on the right and left to the support on the guards and centrally on 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.

Connecting indicators and position lights on the right/left

BiG X 480-630 and BiG X 680-880

3

2 1

EC500045_1 EC500046_1

Fig. 41

• 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.

74

BiG X 600-1100

Operation

2 1

EC500045_1

Fig. 42

• 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.

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.

75

Operation

9.4

9.4.1

Detaching the machine

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

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

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

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

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

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

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

• Swing up the maize header into transport position.

Note

Stop the machine.

Moving support jacks on right/left into parking position

5

2

3

1

2

2 4

4 2

1

EC500027 EC500026

Fig. 43

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 on the lateral frames.

• Secure the position of the rear support jacks with the spring locking pins (2).

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).

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.

76

Operation

1

2

9.4.2

EC500088

Fig. 44

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 support jacks must be differently aligned depending on the tyre diameter.

• If the front axle tyres on the forage harvester are 34 inches or lower, insert the spring locking pin into the upper hole pattern (1).

• If the front axle tyres on the forage harvester are 38 inches or higher, insert the spring locking pin into the lower hole pattern (2).

Notice

Since the height of the holder elements on the forage harvester is also dependent on the tyre pressure of the front wheels of the forage harvester, the forage harvester may still be unable to accommodate the maize header despite the fact that the support jacks are correctly mounted on the forage harvester.

• Correct the tyre pressure in the front wheels.

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

3

1 2

EC500085

Fig. 45

• Swivel side parts (1, 2) into working position by pressing the actuation key (3).

• Keep actuation key (3) pressed until the interlock ratchet mechanisms are engaged.

• Stop the machine.

77

Operation

9.4.3 Disconnecting Hydraulic Hoses (for version with “pendulum frame adaption”)

BiG X 480-630

6 1

3

2

5

4

EC500047_2 EFL000092_2

Fig. 46

• Loosen the screw (4) and open the locking (5) of the hose support.

• Separate the hydraulic hoses (1) from the plug-in connectors and lay them in the hose support (2) on the intake of forage harvester.

• Pull the plug (3) out of the socket and lay it down in the hose support (2) with mounted protective cap (6).

• Close the locking (5) of the hose support and tighten the screw (4).

• Cover the socket on header with protective cap (7).

BiG X 680-880

2

1

3

4

EC500047_2 EFL000 113

Fig. 47

• Disconnect the hydraulic hoses (1) from the plug-in connections and place in the hose support (2) on the intake of the forage harvester.

• Pull the plug (3) out of the socket and insert with attached cover flap (4) into the hose support (2).

• Seal the socket on the header with the cover flap (7).

78

9.4.4

Operation

Disconnecting Hydraulic Hoses (for version with “pendulum frame adaption”)

BiG X 600-1100

1

EC500104

Fig. 48

Prepare the header for disconnecting the hydraulic hoses:

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

• Close the stop cock (1) on the header.

• Depressurise the forage harvester hydraulics, refer to the operating instructions of the forage harvester.

• Disconnect the hydraulic hoses (2) from the plug-in connectors and place them on the header.

• Pull the plugs (3, 4) out of the socket and place them on the header.

79

Operation

9.4.5 Placing the Machine on the Ground

BiG X 480-630 and BiG X 680-880

3

1

2

4

EC500029_1 XC000044

Fig. 49

With hydraulic comfort header locking:

• Unlock the locking pin (1).

• Lower the intake of the forage harvester until the roll guides (2) are free and can be moved back without touching the pendulum crossbar (3).

• Reverse the forage harvester.

With mechanical header locking:

• Pull out the locking pin (4).

• Lower the intake of the forage harvester until the roll guides (2) are free and can be moved back without touching the pendulum crossbar (3).

• Reverse the forage harvester.

• Put the maize header down on the ground by using the forage harvester hydraulics.

Notice

Make sure that the maize header is secured by all four support jacks after it has been lowered.

If this is not the case, raise the maize header by using forage harvester hydraulics and put it down at another place.

80

BiG X 600-1100

Operation

Fig. 50

• Remove the joint fork (5) from the drive journal (6) of the transfer gearbox and place it onto the support (7).

Note

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

• Put the maize header down on the ground by using the forage harvester hydraulics.

Notice

Make sure that the maize header is secured by all four support jacks after it has been lowered.

If this is not the case, raise the maize header by using forage harvester hydraulics and put it down at another place.

81

Operation

9.5 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.

• 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.

To save space, the header can be lowered into transport position. To do so, mount additional supports on the header.

• Swing up the maize header into transport position.

Note

Stop the machine.

• Move the support jacks right/left into transport position, refer to chapter Start-up “Support jacks right/left in transport position”.

82

9.5.1 Mounting console support

1 2

Operation

5 3 5 4

EC500153

Fig. 51

To save space, the header can be lowered into transport position. To do so, mount additional supports on the header.

83

Operation

9.5.2 Mounting side guards

6

3

2

5

4

1

EC500154

Fig. 52

• Insert the lower holder (2) of the side part (1) into the tip (3) on the collector 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).

84

9.5.3 Setting the lateral supports at rear

Operation

2

1

EC500155

Fig. 53

To ensure that the forage harvester can accommodate the maize header which is stored with the support, the height of the holder on the forage harvester must be matched to the height of the holder on the maize header. For this purpose, the rear support must be set differently depending on the tyre diameter when parking the machine.

• If the front axle tyres on the forage harvester are less than or equal to 34 inches, mount the support in the lower hole pattern (1).

• If the front axle tyres on the forage harvester are 38 inches or higher, mount the support into the upper hole pattern (2).

Notice

Since the height of the holders also depends on the tyre pressure of the front wheels of the forage harvester, the forage harvester may still be unable to accommodate the maize header despite the fact that the supports are correctly mounted on the forage harvester.

• Correct the tyre pressure in the front wheels or mount the rear support in another hole pattern.

85

Operation

9.5.4 Putting header down

• Disconnect the hydraulic hoses, refer to chapter Operation, “Disconnecting the hydraulic hoses”.

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.

• 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.

86

10

10.1

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. 54

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.

87

Settings

10.1.1 Setting the Inclination of Tubular Bars (EasyCollect 600-2, 750-2)

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. 55

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. 56

• 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).

88

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. 57

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.

89

Settings

10.1.2 Setting the Inclination of the Tubular Bars (EasyCollect 450-2)

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. 58

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. 59

• 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).

90

10.2 Setting Holding-Down Device Roller

1

Settings

I

II

2

10.3

III

2 2

EC500024

Fig. 60

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. 61:

• 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.

91

Settings

10.4 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 3

2

1

EC500018

Fig. 62

• Press the actuation keys (3) to adjust the height of the plant divider (1) via hydraulic cylinder

(2).

92

10.5

Settings

Adapting Star-shaped Conveyor Height to Maize Crop

The star-shaped conveyors help convey the crops thereby improving the crop flow to the intake rollers of the forage harvester.

In short maize fields, it may be advantageous to replace the cover of the star-shaped conveyor on both sides by the star-shaped conveyor segment provided. This improves the crop flow.

Replacing cover by star-shaped conveyor segment

3 4

1

2

EC500089

3 5

EC500091

Fig. 63

• Move the header into the transport position/position for road travel.

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

Safeguarding the Machine”.

• Unscrew the screws (1) and remove the scraper edge (2) including support.

• To enable the star-shaped conveyors to be rotated by hand, bring the roller gearbox to the

“neutral” position, see chapter Settings, “Setting the Rotational Speed of Star-shaped

Conveyors”.

• Unscrew the screws (3) and remove the cover (4).

• Install the provided star-shaped conveyor segment (5) instead of the cover and mount it with the screws (3).

• Insert the scraper edge (2) including holder and mount with the screws (1). The gap dimension between the scraper edge and the star-shaped conveyor is 1 - 3 mm and must increase to the rear in the direction of flow.

• Move the roller gearbox into the desired position “H” or “L”.

93

Settings

10.6 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. 64

• 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).

94

This page has been left blank deliberately.

Settings

95

Maintenance

11 Maintenance

11.1

11.2

Special Safety Instructions

Danger! - When performing repair, maintenance or cleaning work or when making technical modifications to the machine, drive elements may start moving (caution, cutters continue to run).

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

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

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

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

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

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. 65

• 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!

96

Maintenance

11.2.1

11.3

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.

97

Maintenance

11.4 Maintenance table

Maintenance work 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.

98

Maintenance

11.5 Tightening torques

11.5.1 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.

A = thread size

Tightening torque in Nm (unless otherwise stated)

(stability class can be seen on screw head)

A

29

42

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

3.0 4.4 5.1

5.9

10

25

8.7

15

36

10

18

43

49

85

135 200 235

210

425 610 710

571 832 972

730

72

125 145

310

84

365

1050 1220

1100 1550 1800

1450 2100 2450

M4

M5

M6

M8

M10

M12

M14

M16

M20

M22

M24

M27

M30

Note

Regularly check that nuts and bolts are tightly in place (approx. every 50 hours) and tighten them if necessary.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

99

Maintenance

11.5.2

11.5.3

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.

100

Maintenance

11.5.4 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.

101

Maintenance

11.6 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.

102

11.7 Hydraulic circuit diagram

1) Pflanzenteiler

2) Verriegelung

links

3) Seitenteil links

schieben

Maintenance

4) Seitenteil rechts

schieben

5) Verriegelung

rechts

6) Steuerblock

Ein-/Ausklappen E-Col xxx-2

7) Seitenteil links

ein-/ausklappen

8) Seitenteil rechts

ein-/ausklappen

9) Nur bei Variante 750 mm

Pendelrahmenadaption

10) 2x doppeltwirkendes

Steuergerät am Feldhäcksler

Fig.66: The working position is represented.

1) Plant divider 2) Locking left

4) Push side part right 5) Locking right

7) Fold in/out side part left

10) 2x double-acting control unit on the forage harvester

8) Fold in/out side part right

3) Push side part left

6) Fold in/out control block E-

Col xxx-2

9) Only for version 750 mm

Pendulum frame adaptation

103

Maintenance

11.8 Input gearbox

Note

Check oil level and top up oil when the header is in horizontal position.

Drain oil when the gearbox in horizontal position.

1

2

EC500049

Fig. 67

1) Inspection screw / control hole 2) Drain plug

Interval for oil level check and oil change: refer to chapter Maintenance “Maintenance Table”

For information regarding oil quality / amount of oil, refer to chapter Technical Data “Lubricants”

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”.

Note

The used oil must be disposed of correctly

104

11.9

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. 68

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”.

105

Maintenance

11.10 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. 69

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”.

106

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.

107

Maintenance

11.11 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

Fig. 70

1) Filler screw / filling hole

EC500053_1

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.

108

11.12

Maintenance

Roller Gearbox

Note

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

1

2

EC500054

Fig. 71

1) Inspection screw / control 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”.

109

Maintenance

11.13 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

11.13.1

Fig. 72

Checking the collector pre-tension

11.13.2

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).

110

EasyCollect 450-2

1

Maintenance

4 5 6

9

10

2

7

Fig. 73

Checking the collector pre-tension

8

EC500077_1

11.13.3

11.13.4

Note

Check the collector pretension after the first 10 operating hours, then every 50 operating hours.

• Remove the cover plate (1).

• Check whether the pressure disc (4) is flush with the outer edge of the setting sheet (5).

If the deviation is less than ± 1 mm:

The collector pre-tension is OK.

• Mount the cover sheet (1).

Adjusting the collector pretension

If the deviation is greater than ± 1 mm:

The collector pre-tension must be re-adjusted.

• Loosen the counter nut (2)

To increase the collector pre-tension:

• Tighten the nut (3) until the deviation < 1 mm is reached.

To reduce the collector pre-tension:

• Loosen the nut (3) until the deviation is < 1 mm.

• Tighten the counter nut (2).

• Mount the cover sheet (1).

111

Maintenance

11.13.5

11.13.6

Checking the Collector Tensioning Function

• The edge (6) of the spring guide must be between the markings (7, 8).

• If this is not the case, set the collector tensioning function

Setting the collector tensioning function

• Loosen the counter nut (9) and, by turning the hexagon nut (10), adjust the spring guide so that the edge (6) is a distance of 8±1 mm from the marking (7).

• Tighten the counter nut (9).

• Check the collector pre-tension, see the chapter Maintenance, "Check collector pretension".

• Mount the cover (1).

112

11.14

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. 74

• 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. 75

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).

113

Maintenance

Gap dimensions (c) and (d):

3 d

1

4

2

2

EC500092_1

Fig. 76

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).

114

11.15

Maintenance

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

1

EC500061_2

Fig. 77

• 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.

115

Maintenance

11.16 Adjusting the tips

Fig. 78:

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.

4

11.16.1

11.16.2 b a

2

1

Fig. 79

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).

EC500078

3

116

11.16.3 Adjusting the central tip

1

2

Maintenance

EC500019

Fig. 80

• Loosen the screw connections (2) a little.

• Adjust the central tip (1) so that the lower edge of the central tip is approx. x = 30 –50 mm below the lower edges of the other tips.

• Tighten screw connections (2).

117

Maintenance

11.17 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. 81

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.

118

11.18

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 on the EasyCollect 450-2, 600-2 and

750-2 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. 82

To adjust the row tip from the original position (1) to the position for special row spacings (2):

• Remove the cover plate (3).

• Dismount the outer row tip (4).

• Dismount the cutter blades (5, 6, 7, 8).

• Mount the three outer cutter blades (5, 6, 7) respectively by 125 mm towards the middle of the machine.

• Mount the cutter 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 spacings.

• Mount the cover sheet (3) on the screwing points vacated at the 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.

119

Maintenance

11.19

11.19.1

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. 83:

• 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).

120

Changing the outer bow blade

1

Maintenance

2

EC500066_1

Fig. 84

• 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. 85

• 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).

121

Maintenance

11.19.2 Changing the cutting blades

Note

When replacing, observe the right/left cutting direction!

6

2

1

5

4

1

1

3

EC500068_3

Fig. 86

• 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.

122

11.19.3 Changing the scraper blade

1

Maintenance

11.20

2

Fig. 87:

• 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. 88

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.

123

Maintenance

This page has been left blank deliberately.

124

12

12.1

Maintenance – lubrication

Maintenance

– lubrication

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.

125

Maintenance – lubrication

12.2 Lubrication Chart

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

25h

25h 25h

25h

250 h

250 h

25 h 250 h

25 h

250 h

25 h

Fig. 89:

250 h

EC500023_1

126

50 h

250 h

Maintenance – lubrication

50 h

50 h

Fig. 90:

50 h

25 h

50 h

EC500022_2

127

Placing in Storage

13 Placing in Storage

• Park the machine in a dry location, but not in the vicinity of artificial fertilisers or livestock buildings.

• Before placing the machine in winter storage, clean inside and outside thoroughly. If you use a high-pressure cleaner to do this. do not keep a stream of water directed at bearing points. After cleaning is completed, lubricate all lubrication points. Do not wipe off any grease that comes out of bearing points. The hardened grease will provide additional protection against moisture.

• Disassemble the PTO shaft. Lubricate the inner tubes and the guard tube with grease.

Grease the lubrication points on the cross joint and on the bearing rings of the guard tubes.

• Oil all joint points!

• Touch up damaged paint and preserve all uncoated areas thoroughly with rust protection agent.

• Check all movable components such as deflector rollers, joints, tension rollers, etc. to make certain they move easily. If necessary remove, clean, grease and remount. If necessary, replace with new parts.

• Use only original KRONE replacement parts.

Perform the necessary repair tasks during the time immediately after the harvest season. Draw up a list of all replacement parts you will need. This will make it easier for your KRONE dealer to process your orders and you will be certain that your machine will be ready for use at the beginning of the next season.

128

14

14.1

Before the Start of the New Season

Before the Start of the New Season

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.

129

Before the Start of the New Season

14.2 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.

130

15

15.1

Disposal of the machine

Disposal of the machine

Disposal of the machine

After the service life of the machine has expired, the individual components of the machine must be disposed of properly. The applicable country-specific, current waste disposal guidelines and the legal laws must be observed.

Metal parts

All metal parts must be brought to a metal recycling centre.

The components must be freed from operating fluids and lubricants (gear oil, oil from hydraulic system, ...) before being scrapped.

The operating fluids and lubricants must be brought separately to an environmentally friendly disposal point or recycling centre.

Operating fluids and lubricants

Operating fluids and lubricants (diesel fuel, coolant, gear oil, oil from hydraulic system, ...) must be brought to a disposal point for waste oil.

Synthetic materials

All synthetic materials must be brought to a recycling centre for synthetic materials.

Rubber

Rubber parts (hoses, tyres, …) must be brought to a rubber recycling centre.

Electronic scrap

Electronic parts must be brought to a disposal point for electronic scrap.

131

16 Index

A

Adapting Star-shaped Conveyor Height to Maize

Crop ................................................................ 93

Additional equipment and spare parts ................ 17

Adjusting machine to the forage harvester BiG X

480/530/580/630 and BiG X 680/780/880 ...... 45

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

Adjusting the collector pretension ............. 110, 111

Adjusting the locking plates ................................ 46

Adjusting the machine to the forage harvester

BiG X 600-1100 .............................................. 56

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

Align input gearbox ............................................. 51

Aligning the coupling disc ................................... 49

Attaching Safety Labels and Information Labels 34

B

Basic safety instructions ..................................... 15

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

Behaviour in hazardous situations and when accidents occur ............................................... 27

Blade Changing ................................................ 120

C

Changing the cutting blades ............................. 122

Changing the tips .............................................. 115

Check orientation of the clutch disc .................... 49

Children in danger .............................................. 16

Collector Gearbox ............................................. 106

Commissioning ................................................... 42

Connecting the hydraulic lines ...................... 54, 57

Consumables ................................................ 24, 41

Contact.......................................................... 34, 38

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

Converting Tip Retainer for Special Row

Distances ...................................................... 119

Coupling the machine safely .............................. 16

D

Danger zones ..................................................... 19

Dangers associated with certain activities

Work on the machine ...................................... 26

Dangers associated with the operational environment .................................................... 24

Detaching the machine ....................................... 76

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

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

Disconnecting Hydraulic Hoses (for version ....... 79

Disconnecting Hydraulic Hoses (for version ....... 78

132

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

Driving and Transport ........................................ 63

F

From transport into working position .................. 65

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

H

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

Hydraulic circuit diagram.................................. 103

Hydraulic hose line(s) ........................................ 96

Hydraulics ........................................................ 102

I

Identification Plate .............................................. 38

Importance of the operating instructions............ 15

Information Required for Questions and Orders 38

Input gearbox ................................................... 104

Intended use ...................................................... 13

K

Keeping safety devices functional ..................... 21

L

Lubricating grease ............................................. 41

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

M

Machine overview .............................................. 35

Main gearbox ................................................... 105

Maintenance ...................................................... 96

Maintenance - lubrication ................................. 125

Maintenance table .............................................. 98

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

Notes with information and recommendations 11

Warning signs ................................................. 11

Means of Representation

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

Metric Thread Screws with Control Thread ....... 99

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................. 100

Metric Thread Screws with Fine Thread .......... 100

Mounting console support .................................. 83

Mounting Machine on Forage Harvester ........... 61

Mounting side guards......................................... 84

Mounting Spout Flap .......................................... 60

O

Oils ..................................................................... 41

Operation ........................................................... 65

Operational safety: Technically perfect condition

........................................................................ 18

Overview of the different adaptation types ......... 37

P

Parking the machine safely ................................ 23

Personal protective equipment ........................... 22

Personnel qualification........................................ 15

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

Placing the Machine on the Ground ................... 80

Position of the Adhesive Safety and Information

Labels on the Machine.................................... 30

Purpose of Use ................................................... 13

Putting header down ........................................... 86

R

Reasonably foreseeable misuse ........................ 14

Removing and Installing Guide Bracke at Tip

Retainer ........................................................ 118

Removing Spout Flap ......................................... 59

Removing the machine and storing it with supports .......................................................... 82

Re-Ordering Safety Labels and Information Labels

........................................................................ 34

Re-Ordering this Document .................................. 7

Replacing wear plates ...................................... 123

Roller Gearbox .................................................. 109

Roller Manual Gearbox ..................................... 108

Row detection ..................................................... 71

S

Safely checking the oil level and changing the oil and filter element ............................................ 29

Safety .................................................................. 13

Safety routines .................................................... 28

Safety signs on the machine .............................. 22

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

Service life of the machine.................................. 14

Setting Holding-Down Device Roller .................. 91

Setting the collector tensioning function .......... 112

Setting the Inclination of the Tubular Bars

(EasyCollect 450-2) ....................................... 90

Setting the Inclination of Tubular Bars

(EasyCollect 600-2, 750-2) ............................ 88

Setting the lateral supports at rear ..................... 85

Setting the Star-shaped Conveyor Speed ......... 94

Setting the Tubular Bars .................................... 87

Settings .............................................................. 87

Sources of danger on the machine .................... 25

Spare Parts ........................................................ 97

Spout

Mounting Conical End Flap ............................ 59

Start-up .............................................................. 61

Stop points ......................................................... 43

Stopping and securing the machine .................. 28

Structural changes to the machine .................... 17

Supporting lifted machine and machine parts securely .......................................................... 28

Switching from working position to transport position ........................................................... 72

T

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

Technical data .................................................... 40

Term ..................................................................... 8

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

Test run .............................................................. 97

Tightening torques ............................................. 99

Tightening Torques for Locking Screws and Bleed

Valves on the Gearboxes ............................ 101

Traffic safety ...................................................... 23

U

Using the Machine for Work .............................. 69

W

Workstations on the Machine ............................ 17

133

Maschinenfabrik

Bernard Krone GmbH & Co. KG

Heinrich-Krone-Straße 10, D-48480 Spelle

Postfach 11 63, D-48478 Spelle

Phone +49 (0) 59 77/935-0

Fax +49 (0) 59 77/935-339

Internet: http://www.krone.de

eMail: [email protected]

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

advertisement

Table of contents