Krone BA EasyCollect 450-2 / 600-2 / 750-2 FP Operating Instructions


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

EasyCollect 450-2 FP

EasyCollect 600-2 FP

EasyCollect 750-2 FP

(from serial no.: 1136331)

Order no.: 150 000 797 07 us

Maize header

05.10.2023

Table of Contents

1 Table of Contents

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

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

2.1

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

2.2

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

2.3

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

2.4

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

2.5

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

2.5.1

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

2.5.2

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

2.5.3

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

2.5.4

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

2.5.5

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

2.5.6

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

2.5.7

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

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

3.1

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

3.2

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

3.3

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

3.4

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

3.5

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

3.5.1

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

3.5.2

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

3.5.3

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

3.5.4

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

3.5.5

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

3.5.6

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

3.5.7

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

3.5.8

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

3.5.9

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

3.5.10

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

3.5.11

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

3.5.12

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

3.5.13

Safety sign on the machine ....................................................................................................... 23

3.5.14

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

3.5.15

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

3.5.16

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

3.5.17

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

3.5.18

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

3.5.19

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

3.5.20

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

3.6

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

3.6.1

Shutting down and safeguarding the machine .......................................................................... 29

3.6.2

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

3.6.3

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

3.7

Location of the safety signs on the machine .................................................................................... 32

3.8

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

3

Table of Contents

3.8.1

Ordering additional warning signs and information signs ......................................................... 42

3.8.2

Attaching the safety signs and information signs ...................................................................... 42

3.8.3

Contact for KRONE NORTHAMERICA .................................................................................... 42

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

4.1

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

4.2

Identification Plate ............................................................................................................................ 48

4.2.1

Contact for KRONE NORTHAMERICA .................................................................................... 49

4.3

Overload protection .......................................................................................................................... 50

4.4

Approved adaptations ...................................................................................................................... 51

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

5.1

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

5.1.1

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

5.1.2

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

5.2

Ballasting of forage harvester .......................................................................................................... 55

6 Initial operation - Claas ........................................................................................................................ 56

6.1

Checks before starting up the machine for the first time .................................................................. 56

6.2

Adapting the machine to the CLAAS forage harvester, type 493 and up ........................................ 57

6.2.1

Aligning the coupling disc ......................................................................................................... 59

7 Initial operation – John Deere ............................................................................................................. 64

7.1

Checks before starting up the machine for the first time .................................................................. 64

7.2

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ............... 66

7.3

Adjusting the machine to the John Deere forage harvester of the series 8000 and 9000 with universal shaft ............................................................................................................................................... 68

7.4

Adapting the machine to the John Deere forage harvester of the 8000 series and 9000 series with header quick coupling ................................................................................................................................... 71

7.4.1

Aligning the coupling disc ......................................................................................................... 72

8 Initial operation – New Holland ........................................................................................................... 78

8.1

Checks before starting up the machine for the first time .................................................................. 78

8.2

Adapting the machine to the New Holland forage harvester ........................................................... 79

9 Initial commissioning of transport chassis (for "transport chassis" version) .............................. 83

9.1

Preparing the header for mounting the transport chassis ................................................................ 83

9.2

Connecting operation panel ............................................................................................................. 84

10 Start-up - CLAAS .................................................................................................................................. 85

10.1

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

10.2

Attachment to the CLAAS forage harvester ..................................................................................... 87

10.3

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

10.3.1

Connecting Drive Type 491, Type 492 ..................................................................................... 88

10.3.2

Connecting the drive, type 493 and up ..................................................................................... 89

10.3.3

Connecting hydraulics and electrics ......................................................................................... 90

11 Start-up – John Deere .......................................................................................................................... 92

11.1

Checking and observing before start-up .......................................................................................... 93

11.2

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ............... 94

11.3

Coupling ........................................................................................................................................... 94

11.3.1

Connecting drive ....................................................................................................................... 96

11.3.2

Connecting hydraulics and electrics ......................................................................................... 97

11.4

Mounting on John Deere forage harvester of 8000 series and 9000 series .................................... 99

11.4.1

Connecting drive ....................................................................................................................... 99

11.4.2

Connecting hydraulics and electrics ....................................................................................... 101

4

Table of Contents

12 Start-up - New Holland Start-up - New Holland ............................................................................... 102

12.1

Checking and observing before start-up ........................................................................................ 103

12.2

Mounting on New Holland forage harvesters ................................................................................. 104

12.3

Coupling ......................................................................................................................................... 104

12.3.1

Connecting drive ..................................................................................................................... 106

12.3.2

Connecting hydraulics and electrics ....................................................................................... 107

13 Driving and Transport ........................................................................................................................ 109

13.1

Preparing the machine for road travel ............................................................................................ 110

13.2

Using the transport chassis (for the version with "transport chassis") ........................................... 111

13.2.1

Attaching the transport chassis ............................................................................................... 112

13.2.2

Connecting road travel lighting ............................................................................................... 115

13.2.3

Using the transport chassis ..................................................................................................... 116

13.2.4

Activating bearing pressure control of FP machines .............................................................. 117

13.2.5

Removing the transport chassis .............................................................................................. 118

13.3

Switching off the machine .............................................................................................................. 120

13.4

Lifting the machine ......................................................................................................................... 121

14 Operation ............................................................................................................................................. 122

14.1

From transport into working position .............................................................................................. 122

14.1.1

Removing the protective cover ............................................................................................... 123

14.1.2

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

14.1.3

Swinging the right-hand / left-hand side parts into working position ....................................... 125

14.2

Using the Machine for Work ........................................................................................................... 127

14.2.1

Field mode on slopes .............................................................................................................. 127

14.2.2

Insert the maize header .......................................................................................................... 128

14.2.3

Operating the main gearbox (Claas, John Deere series 6000 and 7000) .............................. 129

14.2.4

Operating input gearbox (Claas) ............................................................................................. 130

14.2.5

Setting the rotational speed of the maize header (Claas)....................................................... 131

14.2.6

Setting rotational speed of the maize header (John Deere series 6000 and 7000) ............... 132

14.2.7

Setting rotational speed of the maize header (John Deere series 8000 and 9000) ............... 133

14.2.8

Setting rotational speed of the maize header (New Holland) ................................................. 133

14.2.9

Operating row detection (for the version with “row detection”) ............................................... 134

14.2.10

Operating active ground contour (for the version with “active ground contour”) .................... 137

14.3

Switching from working position to transport position .................................................................... 141

14.3.1

Swinging the right hand / left hand side parts upward into transport position ........................ 141

14.3.2

Installing guard on the right/left ............................................................................................... 143

14.3.3

Installing the front guard ......................................................................................................... 143

14.3.4

Connecting indicators and position lights on the right/left....................................................... 144

14.4

Detaching the machine .................................................................................................................. 145

14.4.1

Moving the right hand / left hand parking supports into parking position ................................ 145

14.4.2

Swinging the right-hand / left-hand side parts into working position ....................................... 146

14.5

Dismantling the machine in case of adaptation to Claas forage harvester .................................... 147

14.5.1

Disconnecting hydraulics and electrics ................................................................................... 147

14.5.2

Connecting .............................................................................................................................. 148

14.5.3

For version with universal shaft (e.g. type 491 und 492) ........................................................ 149

14.5.4

Version with header quick coupling (type 493 and up) ........................................................... 149

14.6

Dismantling the machine in case of adaptation to John Deere forage harvester of 6000 and 7000 series 150

14.6.1

Disconnecting hydraulics and electrics ................................................................................... 150

14.6.2

Connecting .............................................................................................................................. 151

5

Table of Contents

14.7

Removing the machine with adaptation to John Deere forage harvesters of the series 8000 and

9000 153

14.7.1

Disconnecting hydraulics and electrics ................................................................................... 153

14.7.2

Disconnecting header ............................................................................................................. 154

14.8

Dismantling the machine in case of adaptation to Claas forage harvester .................................... 155

14.8.1

Disconnecting hydraulics and electrics ................................................................................... 155

14.8.2

Connecting .............................................................................................................................. 156

14.9

Removing the machine and storing it with supports (for the version with supports) ...................... 157

14.9.1

Support jacks right/left in transport position ............................................................................ 158

14.9.2

Relocating the support jack bracket ........................................................................................ 158

14.9.3

Mounting console support ....................................................................................................... 159

14.9.4

Mounting side guards .............................................................................................................. 160

14.9.5

Setting the lateral supports at rear .......................................................................................... 161

14.9.6

Putting header down ............................................................................................................... 162

15 Settings ............................................................................................................................................... 163

15.1

Setting the Tubular Bars ................................................................................................................ 164

15.1.1

Setting the tubular bar in terms of its inclination (EasyCollect 600-2 FP, 750-2 FP) .............. 165

15.1.2

Setting the tubular bar in terms of its inclination (EasyCollect 450-2 FP, 750-2 FP) .............. 167

15.2

Adjusting the crop press roller (for version without transport chassis) .......................................... 168

15.3

Setting Holding-Down Device Roller .............................................................................................. 168

15.4

Adjusting skids ............................................................................................................................... 168

15.5

Adjusting the plant dividers ............................................................................................................ 169

15.6

Adapting Star-shaped Conveyor Height to Maize Crop ................................................................. 170

15.7

Adjusting the oscillation of the header ........................................................................................... 171

16 Maintenance ........................................................................................................................................ 173

16.1

Special Safety Instructions ............................................................................................................. 174

16.1.1

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

16.2

Spare Parts .................................................................................................................................... 174

16.3

Maintenance table .......................................................................................................................... 175

16.4

Tightening torques .......................................................................................................................... 177

16.4.1

Metric Thread Screws with Control Thread ............................................................................ 177

16.4.2

Metric Thread Screws with Fine Thread ................................................................................. 178

16.4.3

Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................. 178

16.4.4

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes ...................... 179

16.5

Hydraulics ....................................................................................................................................... 180

16.6

Input gearbox ................................................................................................................................. 181

16.7

Main gearbox .................................................................................................................................. 183

16.8

Collector Gearbox .......................................................................................................................... 184

16.9

Intermediate gearbox ..................................................................................................................... 186

16.10

Roller Gearbox ............................................................................................................................... 187

16.11

Checking and adjusting the collector tension ................................................................................. 188

16.11.1

Checking the collector pre-tension .......................................................................................... 188

16.11.2

Adjusting the collector pretension ........................................................................................... 188

16.11.3

Checking the collector pre-tension .......................................................................................... 189

16.11.4

Adjusting the collector pretension ........................................................................................... 189

16.11.5

Checking the Collector Tensioning Function .......................................................................... 190

16.11.6

Setting the collector tensioning function ................................................................................. 190

16.12

Adjusting the Scraper ..................................................................................................................... 191

16.13

Setting Infeed Sheets ..................................................................................................................... 192

6

Table of Contents

16.14

Changing the tips ........................................................................................................................... 193

16.15

Adjusting the tips ............................................................................................................................ 193

16.15.1

Adjusting the side tips ............................................................................................................. 194

16.15.2

Adjusting the row tips .............................................................................................................. 194

16.15.3

Adjusting the central tip ........................................................................................................... 194

16.16

Removing and Installing Guide Bracket at Tip Retainer ................................................................ 195

16.17

Converting Tip Retainer for Special Row Distances ...................................................................... 196

16.18

Releasing star ratchet clutch at the universal shaft ....................................................................... 197

16.19

Blade Changing .............................................................................................................................. 198

16.19.1

Changing bow and step blades ............................................................................................... 198

16.19.2

Changing the cutting blades ................................................................................................... 200

16.19.3

Changing the scraper blade .................................................................................................... 202

16.20

Replacing the wear plates .............................................................................................................. 202

16.21

Checking/adjusting the distance between bottom guide roller and guide rail ................................ 203

16.22

Check hydraulic hoses ................................................................................................................... 205

16.23

Maintaining and checking the tyres (for the version with "transport chassis") ............................... 205

16.24

Adjusting the tip retainer EC 600-2, 750-2 for 38" row spacing ..................................................... 206

17 Maintenance – lubrication ................................................................................................................. 206

17.1

Special Safety Instructions ............................................................................................................. 207

17.2

Lubrication Chart ............................................................................................................................ 209

18 Placing in Storage .............................................................................................................................. 214

19 Before the Start of the New Season ................................................................................................. 215

19.1

Special Safety Instructions ............................................................................................................. 215

19.2

Test run. ......................................................................................................................................... 216

20 Disposal of the machine .................................................................................................................... 217

20.1

Disposal of the machine ................................................................................................................. 217

21 Index .................................................................................................................................................... 218

7

To this Document

2 To this Document

2.1

2.2

2.3

2.4

Validity

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

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

Re-Ordering

.

You can request a replacement document if this document became completely or partly unusable, or if you need it in a different language. Please specify the document number shown on the cover page in your order. Contact data can be found in the chapter “Contact persons”.

The document can additionally be downloaded via KRONE MEDIA https://media.mykrone.green

Further applicable documents

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

– Operating instructions of universal shaft(s)

– Forage harvester operating instructions

Target group of this document

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

8

2.5

2.5.1

2.5.2

2.5.3

2.5.4

To this Document

How to use this document

Directories and References

Table of contents/headers:

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

Index directory:

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

Cross references:

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

Example:

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

Torques”.

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

Direction Information

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

Term “Machine”

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

Figures

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

9

To this Document

2.5.5

2.5.6

Scope of Document

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

Means of representation

Icons in the text

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

Action step

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

• Set the left outside mirror.

Sequence of actions

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

• Loosen counter nut.

• Set the screw.

• Tighten counter nut.

List

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

– Brakes

– Steering

– Lighting

10

To this Document

Symbols in figures

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

Icon Explanation

1 Reference sign for part

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

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

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

Direction of motion

Direction of travel opened closed enlargement of display detail

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

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

Laying routes

Left-hand machine side

LH

RH

Right-hand machine side

11

To this Document

Warning signs

Warning

WARNING! - Type and source of hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention.

Caution

CAUTION! - Type and source of hazard!

Effect: Damage to property.

• Measures for risk prevention.

Notes with information and recommendations

Note

Note

Effect: Economic benefit of the machine.

• Measures to be performed.

12

2.5.7

To this Document

Conversion table

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

Quantity

Area

Flow

Force

Length

Power

Pressure

Torque

SI Units (Metric)

Unit Name hectare liters per minute

Abbreviation ha

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

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

Factor

2.47105

0.2642

4.4029

0.2248

0.03937

3.2808

1.3410

0.1450

145.0377

14.5038

0.7376

Inch-Pound Units

Unit Name acre

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

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

8.8507 pound-inch or inch-pound in∙lbf

Temperature degree

Celsius

Velocity meter per minute

Volume

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

°C m/min m/s km/h

L ml cm³ kg

°Cx1.8+32 degree

Fahrenheit

3.2808 foot per minute

3.2808

0.6215

0.2642

0.0338

0.0610 foot per second miles per hour

US gallon

US ounce cubic inch

2.2046 pound

°F ft/min ft/s mph

US gal.

US oz. in³ lbs

13

Safety

3

3.1

Ver

3.2

Safety

Purpose of Use

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

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

Intended use

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

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

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

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

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

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

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

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

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

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

14

3.3

3.4

Safety

Reasonably foreseeable misuse

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

Such misuse is for example:

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

“Intended use”

– Transportation of people

– Transportation of goods

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

– Non-compliance with the safety signs on the machine and safety notices in the operating instructions

– Performing fault clearance, 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 release the manufacturer from any liability for consequential damage.

Service life of the machine

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

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

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

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

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

15

Safety

3.5

3.5.1

3.5.2

Basic safety instructions

Non-compliance with the safety instructions and warnings

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

Importance of the operating instructions

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

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

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

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

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

• Hand over the operating instructions to subsequent users.

Personnel qualification

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

– He is physically capable of controlling the machine.

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

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

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

– He is familiar with driving vehicles safely.

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

16

3.5.3

3.5.4

3.5.5

Safety

Personnel qualification of the technicians

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

• Qualified professional, with relevant training.

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

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

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

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

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

Children in danger

Children cannot assess danger and behave unpredictably.

As a result, children are especially at risk.

• Keep children away from the machine.

• Keep children away from consumables.

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

Coupling the machine safely

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

• Observe all operating instructions when connecting:

– The operating instructions of the machine

– The operating instructions of the forage harvester

– The operating instructions of universal shaft

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

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

• Observe the changed driving behaviour of the combination.

17

Safety

3.5.6

3.5.7

3.5.8

Structural changes to the machine

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

Structural changes and enhancements are not permitted.

Additional equipment and spare parts

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

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

Workstations on the Machine

Passengers

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

Ejected objects may strike and injure passengers.

• Never let people ride on the machine.

18

3.5.9

Safety

Operational safety: Technically perfect condition

Operation only when the machine has been started up correctly

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

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

Technically perfect condition of the machine

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

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

Adjustment.

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

Danger resulting from damage to the machine

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

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

– Safety devices

– Connecting devices

– Hydraulic system

– Universal shafts

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

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

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

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

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

Technical limit values

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

– Maximum permitted operating pressure of hydraulics

– Maximum permitted drive speed

– Maximum permitted axle loads of forage harvester

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

19

Safety

3.5.10 Danger zones

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

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

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

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

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

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

The safety clearance is:

For machine in shunting operation and field mode

In front of the machine

Behind the machine

Laterally to the machine

30 m

5 m

3 m

For machine switched on without driving motion

In front of the machine 3 m

Behind the machine

Laterally to the machine

5 m

3 m

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

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

• Consider the information in all relevant operating instructions:

– The operating instructions of the machine

– The operating instructions of the universal shaft

– The operating instructions of the forage harvester

– The operating instructions of the transport wagon

20

Safety

Danger zone universal shaft

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

• Observe operating instructions for the universal shaft.

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

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

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

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

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

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

Danger zone PTO shaft

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

Before switching on the PTO shaft:

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

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

• Switch off the drives if they are not necessary.

Danger zone between precision forage harvester and header

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

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

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

Danger zone because objects may shoot out

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

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

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

21

Safety

3.5.11

Danger zone when drive is switched on

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

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

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

Danger zone due to coasting machine parts

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

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

– Universal shafts or quick coupler

– Collector

– Rotating towers

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

Keeping safety devices functional

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

• Replace damaged safety devices.

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

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

22

3.5.12

3.5.13

Safety

Personal Protective Equipment

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

Personal protective equipment is for example:

– Suitable protective gloves

– Safety boots

– Tight-fitting protective clothing

– Hearing protection

– Protective goggles

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

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

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

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

Wear suitable clothing

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

• Wear tight-fitting clothing.

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

• Cover long hair with a hairnet.

• Wear sturdy shoes or protective work boots.

Safety sign on the machine

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

• Clean dirty safety signs.

• Each time after cleaning, check to ensure that the safety signs are complete and legible.

• Immediately replace missing, damaged and unrecognisable safety signs.

• Attach the appropriate safety signs to spare parts.

For descriptions, explanations and order numbers of the safety signs, see the operating instructions for the machine, chapter Safety, "Safety signs on the machine".

23

Safety

3.5.14

3.5.15

Traffic safety

Dangers in road traffic

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

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

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

Danger when driving on road and field

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

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

Transport”.

Dangers if machine is not prepared properly for road travel

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

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

Transport, “Preparations for Road Travel”.

Parking the machine safely

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

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

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

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

• Before parking: Shut down and safeguard the machine.

Unattended parking

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

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

“Shutting Down and Safeguarding the Machine“.

24

3.5.16

3.5.17

Safety

Consumables

Unsuitable consumables

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

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

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

Environmental protection and disposal

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

• Do not release consumables into the environment.

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

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

Dangers associated with the operational environment

Fire hazard

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

In case of dry usage conditions, dust, impurities and crop residue may ignite on hot parts and the resulting fire may seriously injure or kill people.

• Check and clean the machine daily before using it for the first time.

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

25

Safety

3.5.18 Sources of danger on the machine

Noise may damage your health

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

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

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

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

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

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

• Remove hearing protection for road travel.

Liquids under high pressure

The following liquids are under high pressure:

– Hydraulic oil

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

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

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

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

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

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

Hot liquids

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

• When draining hot consumables, wear personal protective equipment.

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

Damaged hydraulic hoses

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

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

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

26

3.5.19

Safety

Dangers associated with certain activities: Work on the machine

Work on the machine only when it has been shut down

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

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

Machine”.

Maintenance and repair work

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

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

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

Raised machines and machine parts

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

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

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

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

27

Safety

3.5.20

Danger associated with welding work

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

• Never weld on the following components:

– Gearbox

– Components of the hydraulic system

– Components of the electronics

– Frame or bearing component groups

– Running gear

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

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

• Have welding work performed by experienced technicians only.

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

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

Behaviour in hazardous situations and when accidents occur

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

• In principle: Switch off the machine.

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

• Safeguard the accident location.

• Rescue people from the danger zone.

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

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

• Take immediate life-saving measures.

28

3.6

3.6.1

3.6.2

Safety

Safety routines

Shutting down and safeguarding the machine

WARNING!

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

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

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

To park the machine securely:

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

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

• Apply the parking brake.

• Place the front attachment on the ground.

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

• Switch off the main battery switch.

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

Supporting lifted machine and machine parts securely

WARNING!

Crushing hazard by movement of machine or machine parts!

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

Thus there is a risk of crushing or death.

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

In order to firmly support the machine or machine parts:

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

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

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

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

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

29

Safety

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

WARNING!

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

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

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

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

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

“Securely Supporting Raised Machine and Machine Parts”.

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

Safeguarding the Machine”.

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

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

Technical Data, “Consumables”.

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

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

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

30

This page has been left blank deliberately.

Safety

31

Safety

GL

3.7 Location of the safety signs on the machine

Fig. 1

32

L

L

L

L

L

Safety

1) Ord. no. 942 019 2 (1x)

2) Ord. no. 27 008 200 1 (1x)

WARNING!

- Read and understand operator´s manual before operating or servicing machine.

- Do not allow unqualified personnel to operate the machine.

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

WARNING!

To avoid possible injury:

Use only authentic KRONE spare parts and accessories authorised by KRONE. The use of spare parts, accessories or additional equipment not manufactured, tested or approved by

KRONE will exclude any liability for consequential damage.

CAUTION

27 002 059 0

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

CAUTION

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

– Do not use finger or skin to check leaks.

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

CAUTION

CAUTION

Max. PTO speed 750 RPM.

Max. PTO speed

750 RPM

27 002 701 0

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

Warning

To avoid personal injury.

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

WARNING

To avoid personal injury.

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

27 002 057 0

33

GL

Safety

Fig. 2

34

L

L

L

Safety

6) Order No. 27 003 029 0 (2x)

Warning

To avoid Possible injury.

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

Keep your distance!

WARNING

To avoid possible injury.

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

Keep your distance!

27 003 029 0

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

DANGER

ROTATING DRIVELINE – CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT-

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

- Driveline securely attached at both ends.

- Driveline guards that turn freely on driveline.

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

Warning

To avoid Possible injury.

Do not stand between

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

WARNING

To avoid possible injury.

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

27 002 702 0

35

GL

Safety

Fig. 3

36

L

L

L

Safety

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

CAUTION

The operating pressure of the hydraulic system must not exceed

200 ba r.

CAUTION

The operating pressure of the hydraulic system must not exceed

200 bar.

27 004 598 0

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

Warning

To avoid personal injury.

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

WARNING

To avoid possible injury.

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

27 003 325 0

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

WARNING

WARNING

Avoid bodily injuries from rotating knives.

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

L

Avoid bodily injuries from rotating knives.

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

942 536 -0

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

Warning

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

WARNING

To avoid possible injury.

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

27 003 030 0

37

GL

Safety

Fig. 4

38

L

L

Safety

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

Warning

To avoid personal injury.

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

WARNING

To avoid personal injury.

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

27 002 057 0

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

DANGER

Blade can cause serious injury or death.

- S tay clear of machine while in operation.

- K eep discharge chute and shields in place.

DANGER

Blade can cause serious injury or death.

– Stay clear of machine while in operation.

– Keep discharge chute and shields in place.

15) Order No. 27 004 017 0 (1x) only with "pendulum frame adaptation" design

WARNING

Hydraulic accumulators store energy.

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

Failure to comply could result

WARNING!

Hydraulic accumulators store energy.

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

Failure to comply could result in death or serious injury.

27 004 017 0

39

Safety

3.8 Location and meaning of the information signs on the machine

40

Fig. 5

Safety

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

There are suspension points on the machine marked with this information sign, see chapter Driving and transport, "Lifting the machine".

942 012-1

2) Order no. 939 157 1 (4x)

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

10 hours; see chapters Maintenance "Maintenance table" and

"Tightening torques".

3) Order no. 942 522 0 (1x)

Operate the stop cock when connecting or disconnecting, see chapter "Initial commissioning", "Connecting hydraulic hoses".

L

942 522 0

• Order no. 27 021 260 0

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

"Lubrication".

Lubrication points which are not directly visible are additionally marked with this information sign.

41

Safety

3.8.1

3.8.2

3.8.3

Ordering additional warning signs and information signs

Notice

Each safety sign and information sign is provided with an order number and can be ordered directly from the manufacturer or KRONE dealer (see chapter "Contacts"). Immediately replace missing, damaged and unrecognisable safety signs and information signs.

Attaching the safety signs and information signs

Notice

When attaching safety signs and information signs, the contact surface on the machine must be clean and free of dirt, oil and grease to ensure optimum adhesion of the safety signs and information signs.

Contact for KRONE NORTHAMERICA

Mailing address

Krone North America, Inc.

P.O. Box 18880

Memphis, TN 38181-0880

USA

Phone

Fax

E-mail

Internet

Physical address

Krone North America, Inc.

3363 Miac Cove

Memphis, TN 38118

USA

+1 901 842-6011

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

42

4

4.1

Machine Description

Machine overview

3 4 5

1

13 14

12

15

11

8

10

9

16 15

Machine Description

2 6

7

17 18 19 11 20 21

EC500131_1

Fig. 6

1) Collector including blades, right

16) Document storage tube

19) Main gearbox

2) Plant divider 3) Crop press roller

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

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

10) Row tip

13) Tubular bar

11) Support jack

14) Lateral frame, left

12) Side tip

15) Folding cylinder

17) Coupling disc

20) Lateral frame, right

18) Input gearbox

21) Sliding skid

43

Machine Description

For adaptation Claas version

1 2 3 4

6 5

EC500158

Fig. 7: Example: EasyCollect 600-2 FP for Claas forage harvester, type 493 and up

1) Pendulum tension spring 2) Take-up pocket 3) Locking lever

4) Connecting rod 5) Lower holding fixture 6) Intermediate frame

44

For version adaptation John Deere of 6000 and 7000 series

1 2 3 2

Machine Description

4

EC500159

Fig. 8: Example: EasyCollect 600-2 FP for John Deere forage harvesters of 6000 and 7000 series

1) Intermediate frame 2) Connecting area 3) Pendulum tension spring

4) Locking boreholes

45

Machine Description

John Deere series 8000 and 9000 adaptation version

1 2 1

3

EC500174

Fig. 9: Example: EasyCollect 600-2 FP for John Deere forage harvester of the series 8000 and 9000

1) Locating bores 2) Intermediate frame 3) Lower holding fixtures

46

For adaptation New Holland version

1

Machine Description

3 2

Fig. 10: Example: EasyCollect 750-2 FP for New Holland forage harvester FR

1) Adapter frame 2) Locking 3) Cross beam

EC500160

47

Machine Description

4.2 Identification Plate

1

EC500001

Fig. 11

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

Information Required for Questions and Orders

The type plate shows data to identify the machine.

2

1

Fig. 12 Type plate

Example image

1) Type 2) Machine number

For inquiries about the machine and for ordering spare parts, please specify type (1) and machine number (2) of the particular machine.

Notice

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

Notice

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

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

48

4.2.1

Machine Description

Contact for KRONE NORTHAMERICA

Mailing address

Krone North America, Inc.

P.O. Box 18880

Memphis, TN 38181-0880

USA

Phone

Fax

E-mail

Internet

Physical address

Krone North America, Inc.

3363 Miac Cove

Memphis, TN 38118

USA

+1 901 842-6011

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

49

Machine Description

4.3 Overload protection

Notice

Machine damage due to load peaks

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

• Use only the overload protections installed in the machine.

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

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

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

1 2 1

EC500211

Fig. 13

To protect against overload, there are star ratchet clutches (1, 2) installed on the universal shafts in the lateral frame and on the main gearbox. These star ratchet clutches (1, 2) do not have to be disengaged.

If the star ratchet clutches (1, 2) release when the machine is overloaded, see chapter

Maintenance "Releasing star ratchet clutch at the universal shaft".

50

4.4

Machine Description

Approved adaptations

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

Notice

The combinations with forage harvesters from other manufacturers listed below are approved by KRONE and are technically possible.

Prior to driving on the road, check the national road traffic regulations in the respective country of use for the legality of the combinations.

• If necessary, contact KRONE customer service.

In order to adapt the forage harvester types Claas 491-502, a basic adaptation and the supplementary kit suitable for the forage harvester must be mounted.

Manufacturer/type Adaptation

Claas

491–502

Basic adaptation Claas Jaguar

Supplementary kit Claas 491/492

Supplementary kit Claas 493-502

Accessories kit

20 298 300 2

20 298 302 0

20 298 303 0

The adaptation of the forage harvester types John Deere 6000/7000 and 8000-9900 requires a basic adaptation and a supplementary kit matching the forage harvester to be mounted.

Manufacturer/type Adaptation Accessories kit

John Deere

6000/7000

John Deere

8000-8800 and

9500-9900

Basic adaptation

JD 6000/7000

Supplementary kit JD 6x–7x narrow -

2FP

JD 6610, 6710, 6810, 6910,

6650, 6750, 6850, 6950,

7200, 7300, 7400, 7500,

7250, 7350, 7450, 7550,

Supplementary kit JD 6x–7x wide -2FP

JD 7180, 7280, 7380, 7480, 7580,

7700, 7800,

7750, 7850, 7950,

7780, 7980

Basic adaptation

JD 8000/9000

Supplementary kit

JD 8100-8500 and

8600 (from model year 2019)

Supplementary kit

JD 8600 (up to model year 2018) -8800 and 9500-9900

20 298 200 1

20 298 201 0

20 298 202 0

20 298 100 1

20 298 101 0

20 298 102 0

In order to adapt the forage harvesters of New Holland, the accessories kit suitable for the forage harvester must have been mounted.

Manufacturer

New Holland

Model

FR 9040, 9050, 9060, 9080, 9090

Accessories kit

20 097 429 1

FR 450, 500, 600, 700, 850

FR 480, 550, 650, 780, 920

51

Machine Description

This page has been left blank deliberately.

52

5

Technical data

Technical data

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

Indication

Length

Height in working position

Total width in working position

Working width

Height (folded in)

Width (folded in)

Weight

Drive speed

Maximum permitted operating pressure

Hydraulic connections

Electrical connection 12V

(lighting)

1 double-acting hydraulic connection

Indication

Length

Height in working position

Total width in working position

Working width

Height (folded in)

Width (folded in)

Weight

Drive speed

Maximum permitted operating pressure

Hydraulic connections

Electrical connection 12 V

(lighting)

1 double-acting hydraulic connection

EasyCollect 450-2 FP EasyCollect 600-2 FP

2190 mm 2190 mm

1500 mm

4650 mm

4500 mm

2560 mm

2900 mm

2600 kg

300 - 700 rpm

200 bar

1x DA

7-pole

EasyCollect 750-2 FP

2190 mm

1500 mm

7550 mm

7500 mm

4000 mm

2900 mm

3300 kg

300 - 700 rpm

200 bar

1x DA

7-pole

1

1

1500 mm

6150 mm

6000 mm

3310 mm

2900 mm

3000 kg

300 - 700 rpm

200 bar

1x DA

7-pole

1

Airborne noise emission

Emissions value (sound pressure level)

Measurement device

Accuracy class

74.9 dB(A) ¹

Bruel & Kjaer, Type 2236

2

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

¹ Value measured with EasyCollect 750-2 in combination with forage harvester BiG X 630

Ambient temperature

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

53

Technical data

Tyre table (for the version with "transport chassis")

Tyre designation Maximum permissible speed Air pressure

15.0/55-17 10PR TL AW705 40 km/h 1.8 bars

Axle load

Permitted axle load 1,400 kg

5.1

5.1.1

5.1.2

Consumables

Biodegradable consumables can be used on request.

Oils

Designation

Input gearbox adaptation Claas

Input gearbox adaptation John Deere

Input gearbox adaptation New Holland main gearbox collector gearbox

Filling quantity

0.85 L

1.3 L

1.3 L

Specification

SAE 90 GL 4,

e.g.:

- Esso Spartan EP 150

- Shell Omala OIL 150

- Fuchs- EP 85 W90

- Castrol EPX 90 intermediate gearbox roller gearbox

0.3 L

2 x 0.06 L

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

Note - Observe maintenance intervals

Effect: Long expected service life of machine

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

Lubricating grease

1.0 L

2 x 3.3 L

Designation

Manual lubrication points

Filling quantity as required

Specification

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

54

5.2

Technical data

Ballasting of forage harvester

Notice

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

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

Notice

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

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

Notice

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

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

55

Initial operation - Claas

6

6.1

Initial operation - Claas

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

Danger! - Incorrect assembly

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

• Only authorised service centres may assemble the machine.

• The machine must be assembled with special care.

• Always heed the applicable accident prevention regulations.

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

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

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

Checks before starting up the machine for the first time

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

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

• All hoses are routed properly.

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

• The hydraulic system was checked for leaks.

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

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

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

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

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

• The machine has been adjusted to the forage harvester; see chapter Initial commissioning.

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

56

Preparation for lighting (except Italy)

1

Initial operation - Claas

6.2

EC500206

Fig. 14

If the standard driving headlights of the forage harvester are covered when the side parts of the maize header are in road position, additional driving headlights (1) must be mounted on the cabin.

Adapting the machine to the CLAAS forage harvester, type 493 and up

Note

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

Note

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

57

Initial operation - Claas

Notice

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

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

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

Mounting coupling disc

4 3 2 1

EC400109

Fig. 15

To mount the coupling:

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

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

• Tighten the screw (2) to 100 Nm.

Cleaning the coupling disc

1 2

EC400093_2

Fig. 16

To prepare the coupling for the attachment of the header:

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

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

58

6.2.1

Initial operation - Claas

Aligning the coupling disc

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

2

1

EC400090

Fig. 17

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

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

II

I

EC400094_1

Fig. 18

Correct position of clutch disc

The clutch disc is correctly aligned when:

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

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

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

(I).

59

Initial operation - Claas

Mounting header on forage harvester

• Dismount the protective cap.

• Mount the header on the forage harvester.

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

Checking position of the coupling disc and input gearbox y

9

13

EC400095_2 EC400096

Fig. 19

• Check the position of the clutch disc.

If the clutch disc has been correctly aligned:

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

If the clutch disc has not been correctly aligned:

Inclination setting of the input gearbox:

• Loosen the 4 screws M16 (10).

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

• Retighten the 4 screws (10).

If the input gearbox has to be moved laterally:

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

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

60

Setting the input gearbox laterally

Initial operation - Claas

EC400095_2

Fig. 20

• Loosen the 4 screws M16 (10).

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

• Retighten the 4 screws M16 (10).

Checking the position of the coupling disc

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

If the coupling disc has been correctly aligned:

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

If the coupling disc has still not been correctly aligned:

• Repeat the adjustment process of the input gearbox.

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

61

Initial operation - Claas

Setting lower holder

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

2 4 3

5 6

7

9 10

11

12

8 13

1 15 14

EC500127_1

Fig. 21

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

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

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

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

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

• Shut down the machine.

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

62

Initial operation - Claas

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

• Remove the header and reverse the forage harvester.

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

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

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

• Remove the header and reverse the forage harvester.

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

• Mount the header on the forage harvester.

• Swivel the lever (6) inwards.

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

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

• Dismount the bolt (14).

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

• Tighten the lock nut and mount the bolt.

If the length of the connecting rod is adjusted:

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

Checking the gap dimension of the infeed sheets

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

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

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

63

Initial operation – John Deere

7

7.1

Initial operation – John Deere

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

Danger! - Incorrect assembly

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

• Only authorised service centres may assemble the machine.

• The machine must be assembled with special care.

• Always heed the applicable accident prevention regulations.

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

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

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

Checks before starting up the machine for the first time

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

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

• All hoses are routed properly.

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

• The hydraulic system was checked for leaks.

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

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

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

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

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

• The machine has been adjusted to the forage harvester; see chapter Initial commissioning.

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

64

Preparation for lighting (except Italy)

1 1

Initial operation – John Deere

EC500208

Fig. 22

If the standard driving headlights of the forage harvester are covered when the side parts of the maize header are in road position, additional driving headlights (1) must be mounted on the cabin.

Mounting the machine to a John Deere forage harvester of the series 8000 and 9000:

Notice

The header is not recognised automatically

If the electronics of the forage harvester do not automatically recognise the header:

• Enter the total width of the implement and the number of rows manually. See operating instructions for the forage harvester.

65

Initial operation – John Deere

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

Notice

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

Note

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

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

Setting the holder for the locking pins

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

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

I II

1 2 3

EC500138

Fig. 23

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

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

• Mount the linch pin (3).

66

Initial operation – John Deere

85

2

81 3

6

4

EC500110_1

Fig. 24

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

• Lower the intake housing until the holding brackets (6) are positioned under the cross tube (1) of the maize header support bracket.

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

• Ensure that the entire surface of the holding brackets (6) is positioned behind the cross tube (1) of the maize header support bracket.

• Lift the intake housing using the lifting hydraulics until the locking pins (2) are in front of the borehole in the adapter frame holding fixture (4).

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

• Secure the header against dropping, see operating instructions for the forage harvester.

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

If not:

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

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

• Lock the locking pins (2).

• Tighten the screws (3).

Checking the gap dimension of the infeed sheets

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

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

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

67

Initial operation – John Deere

7.3 Adjusting the machine to the John Deere forage harvester of the series 8000 and 9000 with universal shaft

Note

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

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

Dismounting the clutch disc

1

2

3

EC500162

Fig. 25

• Remove the screw (3) and pull the mounted unit of compression spring (1) and clutch disc (2) from the gear shaft.

68

Setting the holder for the catch hook

Initial operation – John Deere

1

EC500184

Fig. 26

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

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

2

1 3

4

5

6

EC500176

Fig. 27

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

• Lower the intake housing.

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

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

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

69

Initial operation – John Deere

3

4

1

2

EC500177

Fig. 28

• Move the holding fixture (2) so that the catch hook (1) of the forage harvester can penetrate correctly.

• Swivel the lever (4) upwards to secure the header with the catch hook (1) of the forage harvester.

• Ensure that the catch hook (1) is locked with pretension.

If this is not the case:

• Swivel the lever (4) downwards and adjust the linkage of the lever (4) until the catch hook (1) locks with pretension.

• Mount the linch pin (3).

1

EC500184

Fig. 29

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

• Mount the universal shaft of the forage harvester and check the length with the header up and down. Adjust or replace the universal shaft if necessary.

Checking the gap dimension of the infeed sheets

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

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

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

70

7.4

Initial operation – John Deere

Adapting the machine to the John Deere forage harvester of the 8000 series and 9000 series with header quick coupling

Note

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

Note

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

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

Cleaning the coupling disc

1 2

EC500185

Fig. 30

To prepare the coupling for the attachment of the header:

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

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

71

Initial operation – John Deere

7.4.1 Aligning the coupling disc

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

1 2

3

EC500163

Fig. 31

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

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

Correct position of the clutch disc at the header

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

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

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

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

72

Mounting header on forage harvester

2

Initial operation – John Deere

4

1

3

5

EC500175

Fig. 32

• Dismount the guard (1).

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

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

2

1 3

4

5

6

EC500176

Fig. 33

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

• Lower the intake housing.

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

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

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

73

Initial operation – John Deere

3

4

1

2

EC500177

Fig. 34

• Move the holding fixture (2) so that the catch hook (1) of the forage harvester can penetrate correctly.

• Swivel the lever (4) upwards to secure the header with the catch hook (1) of the forage harvester.

• Ensure that the catch hook (1) is locked with pretension.

If this is not the case:

• Swivel the lever (4) downwards and adjust the linkage of the lever (4) until the catch hook (1) locks with pretension.

• Mount the linch pin (3).

1

EC500178

Fig. 35

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

74

Checking the position of the clutch disc

1 2

Initial operation – John Deere

1

2

EC500179

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

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

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

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

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

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

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

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

75

Initial operation – John Deere

Checking the position of the input gearbox

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

4

2 Y

5

1

3

EC500180

Fig. 36

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

To do this:

• Loosen the screws (1, 2, 3, 4).

• Adjust the height of the input gearbox.

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

• Tighten the screws (1, 2, 3, 4).

• Check the position of the clutch disc.

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

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

76

Adjusting input gearbox towards the rear

Initial operation – John Deere

1

EC500181

Fig. 37

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

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

• Tighten screws (1).

• Reinstall the guard.

Checking the gap dimension of the infeed sheets

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

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

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

77

Initial operation – New Holland

8

8.1

Initial operation – New Holland

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

Danger! - Incorrect assembly

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

• Only authorised service centres may assemble the machine.

• The machine must be assembled with special care.

• Always heed the applicable accident prevention regulations.

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

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

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

Checks before starting up the machine for the first time

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

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

• All hoses are routed properly.

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

• The hydraulic system was checked for leaks.

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

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

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

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

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

• The machine has been adjusted to the forage harvester; see chapter Initial commissioning.

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

78

Preparation for lighting (except Italy)

1

Initial operation – New Holland

8.2

EC500209

Fig. 38 Illustration similar

If the standard driving headlights of the forage harvester are covered when the side parts of the maize header are in road position, additional driving headlights (1) must be mounted on the cabin.

Adapting the machine to the New Holland forage harvester

Notice

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

Note

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

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

79

Initial operation – New Holland

Setting the locking sleeves

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

2

1

Fig. 39

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

EC500114

80

4

Initial operation – New Holland

71

2

3

3

EC500112

Fig. 40

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

• Lower the intake housing until the holding fixture (3) is under the support pipe (1) of the maize header.

• Move the forage harvester forwards until the intake housing (2) of the forage harvester is positioned in front of the maize header adapter frame and the holding fixture (3) of the forage harvester is under the support pipe (1).

• Lift the intake housing using the lifting hydraulics until the adapter frame (4) of the maize header is positioned on the intake housing (2) of the forage harvester.

• Ensure that the support pipe (1) is correctly positioned in the holding fixture (3).

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

• Secure the header against dropping, see operating instructions for the forage harvester.

81

Initial operation – New Holland

1

6

1

2

7

5

4

2

3

EC500113

Fig. 41

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

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

If not:

• Loosen the screws (3).

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

• Tighten the screws (3).

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

If not:

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

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

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

Note

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

Checking the gap dimension of the infeed sheets

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

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

Removing header from forage harvester

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

• Remove the header from the forage harvester.

• Reverse the forage harvester.

82

9

9.1

Initial commissioning of transport chassis (for "transport chassis" version)

Initial commissioning of transport chassis (for "transport chassis" version)

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

Preparing the header for mounting the transport chassis

Before attaching the transport chassis to the EasyCollect for the first time, the guard sheet between the input and main gearbox must be cut.

• Separate the 5 bars (3) to remove the cutout (2) in the guard sheet (1) between the input and main gearbox.

• Burr the cut edges on the guard sheet (1) and protect against corrosion with anti-rust protection.

• Dispose of the cutout (2).

1

2

3

EC500190

Fig. 42:

83

Initial commissioning of transport chassis (for "transport chassis" version)

9.2 Connecting operation panel

Notice

Short circuit caused by contamination and moisture in the plug connection

A short circuit can damage the machine

• Ensure that the plugs and sockets are clean and dry.

• If necessary, check the fuse in the housing and replace it.

1

2 3

EC500202

Fig. 43

In connection with FP machines, the operation box (1) must be put on the cabin of the forage harvester.

Prerequisite:

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

• Connect the plug (2) with a 12 VDC socket of the forage harvester.

• Connect the plug (3) via the adapter cable with the solenoid valve on the header. Ensure that the cable is neither pinched nor chafing.

• Activate the transport chassis locking. See chapter Driving and transport, "Attaching the transport chassis".

84

10

Start-up - CLAAS

Start-up - CLAAS

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

WARNING!

Risk of injury or damage to the machine due to connection lines which have been incorrectly connected, interchanged or improperly installed

If the connection lines of the machine have been incorrectly connected to the tractor or have been improperly installed, they may pull off or be damaged. This may result in serious accidents. If connection lines are interchanged, functions may inadvertently be actuated which may also result in serious accidents.

• Correctly connect and secure the hoses and cables.

• Lay the hoses, cables and ropes so that they do not scrape, come under tension or become jammed or come into contact with other components (e.g. tyres), especially when cornering.

• Couple and connect the hoses and cables to the designated connections as described in the operating instructions.

85

Start-up - CLAAS

10.1

Warning! - Attaching / detaching and operating the machine

Effect: Danger to life or serious injuries.

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

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

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

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

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

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

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

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

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

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

• On public streets and highways, the maize header EasyCollect 450-2 FP, 600-2 FP,

750-2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting into the transport position, ensure that the EasyCollect 450-2 FP, 600

-

2 FP,

750

-

2 FP does not collide with the tractor cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

86

10.2

10.3

Start-up - CLAAS

Attachment to the CLAAS forage harvester

Coupling

2 4 3

5 6

7

9 10

11

12

13 8

1 15 14

EC500127_1

Fig. 44

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

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

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

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

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

• Shut down the machine.

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

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

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

If the cotter pin cannot be mounted:

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

• Ensure that the interlocking claw (15) contacts the shaft (7) under pretension without any gap.

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

If there is a gap or no pretension between interlocking claw and shaft:

• Adjust the length of the connecting rod. See Initial commissioning, "Adapting the machine to

CLAAS forage harvesters".

87

Start-up - CLAAS

10.3.1 Connecting Drive Type 491, Type 492

1 2

4 3

EC400085_1

Fig. 45

• Fold down the guard sheet (3).

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

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

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

• Close the guard sheet (3).

Note

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

88

10.3.2 Connecting the drive, type 493 and up

2

1

Start-up - CLAAS

EC400090

Fig. 46

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

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

Note

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

Notice

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

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

89

Start-up - CLAAS

10.3.3 Connecting hydraulics and electrics

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

90

Start-up - CLAAS

2 1

3

EC400147 EC500220

Fig. 47

A double-acting hydraulic connection on the forage harvester side is required for operation of the maize header.

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

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

• Open the stop cock (3) on the header.

"Row detection and ground contour" version

• Connect the electrical plug with the socket on the forage harvester.

"Transport chassis" version

• Connect the connection cable of the operation box with the header.

Note

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

91

Start-up – John Deere

11 Start-up – John Deere

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

WARNING!

Risk of injury or damage to the machine due to connection lines which have been incorrectly connected, interchanged or improperly installed

If the connection lines of the machine have been incorrectly connected to the tractor or have been improperly installed, they may pull off or be damaged. This may result in serious accidents. If connection lines are interchanged, functions may inadvertently be actuated which may also result in serious accidents.

• Correctly connect and secure the hoses and cables.

• Lay the hoses, cables and ropes so that they do not scrape, come under tension or become jammed or come into contact with other components (e.g. tyres), especially when cornering.

• Couple and connect the hoses and cables to the designated connections as described in the operating instructions.

92

11.1

Start-up – John Deere

Warning! - Attaching / detaching and operating the machine

Effect: Danger to life or serious injuries.

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

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

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

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

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

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

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

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

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

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

• On public streets and highways, the maize header EasyCollect 450-2 FP, 600-2 FP,

750-2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting into the transport position, ensure that the EasyCollect 450-2 FP, 600

-

2 FP,

750

-

2 FP does not collide with the tractor cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

93

Start-up – John Deere

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

11.3 Coupling

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

I II

1 2 3

EC500138

Fig. 48

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

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

• Mount the linch pin (3).

1 2

6 1

EC500111_1

Fig. 49

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

• Lower the intake housing until the holding brackets (6) are positioned under the cross tube (1) of the maize header support bracket.

94

Start-up – John Deere

2

81

6

4

EC500146

Fig. 50

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

• Ensure that the entire surface of the holding brackets (6) is positioned behind the cross tube (1) of the maize header support bracket.

• Lift the intake housing using the lifting hydraulics until the locking pins (2) are in front of the borehole in the adapter frame holding fixture (4).

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

• Secure the header against dropping, see operating instructions for the forage harvester.

I II

1 2 3

EC500139_1

Fig. 51

Lock the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

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

• Mount the linch pin (3).

95

Start-up – John Deere

11.3.1 Connecting drive

1 5

2

EC500136

Fig. 52

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

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

• Close the guard sheet (5).

96

11.3.2

Start-up – John Deere

Connecting hydraulics and electrics

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

97

Start-up – John Deere

3 4

2

1

5

EC500135_1 EC500222

Fig. 53

A double-acting hydraulic connection on the forage harvester side is required for operation of the maize header.

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

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

• Open the stop cock (5) on the header.

"Row detection and ground contour" version

• Connect the cable for the sensor system with the socket on the forage harvester.

• Connect hydraulic hose III with the plug-in coupling (3) or screw coupling of the forage harvester.

• Connect hydraulic hose IV with the corresponding plug-in coupling (4) or screw coupling of the forage harvester.

Note

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

98

11.4

11.4.1

Start-up – John Deere

Mounting on John Deere forage harvester of 8000 series and 9000 series

Warning! - Risk of injury due to unexpected movements of the machine.

When the electronics of the forage harvester detect a fault in the automatic header recognition, there can be unexpected movements of machine parts that pose a risk to persons.

• If the terminal of the forage harvester displays an error during automatic attachment recognition, please refer to the information in the operating instructions of the forage harvester for further action.

Connecting drive

2

1 3

4

5

6

EC500176

Fig. 54

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

• Lower the intake housing.

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

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

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

3

4

1

2

EC500177

Fig. 55

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

99

Start-up – John Deere

Forage harvester with quick coupler for header

1 2

1

2

EC500179

Fig. 56

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

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

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

Forage harvester with universal shaft

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

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

100

11.4.2

Start-up – John Deere

Connecting hydraulics and electrics

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

2 3

4

1

5

EC500167 EC500222

Fig. 57

Prerequisites:

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

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

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

• Open the stop cock (5) on the header.

"Transport chassis" version

• Connect the connection cable of the operation box with the header.

Note

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

101

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

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

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

WARNING!

Risk of injury or damage to the machine due to connection lines which have been incorrectly connected, interchanged or improperly installed

If the connection lines of the machine have been incorrectly connected to the tractor or have been improperly installed, they may pull off or be damaged. This may result in serious accidents. If connection lines are interchanged, functions may inadvertently be actuated which may also result in serious accidents.

• Correctly connect and secure the hoses and cables.

• Lay the hoses, cables and ropes so that they do not scrape, come under tension or become jammed or come into contact with other components (e.g. tyres), especially when cornering.

• Couple and connect the hoses and cables to the designated connections as described in the operating instructions.

102

12.1

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

Warning! - Attaching / detaching and operating the machine

Effect: Danger to life or serious injuries.

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

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

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

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

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

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

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

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

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

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

• On public streets and highways, the maize header EasyCollect 450-2 FP, 600-2 FP,

750-2 FP must always be in the transport position. In this process, the transport height must be set so that the max. permissible height of 4 m is not exceeded.

• When lifting into the transport position, ensure that the EasyCollect 450-2 FP, 600

-

2 FP,

750

-

2 FP does not collide with the tractor cabin of the forage harvester or other machine parts.

Checking and observing before start-up

• Check the oil level in the gearboxes.

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

• Check that the screws are tight.

• Mount and lock all protective devices.

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

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

• Never allow the machine to run unsupervised.

103

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

12.2 Mounting on New Holland forage harvesters

12.3 Coupling

Warning! - Connecting

Effect: Danger to life or serious injuries.

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

2

1

Fig. 58

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

EC500114

104

4

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

71

2

3

3

EC500112

Fig. 59

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

• Lower the intake housing until the holding fixture (3) is under the support pipe (1) of the maize header.

• Move the forage harvester forwards until the intake housing (2) of the forage harvester is positioned in front of the maize header adapter frame and the holding fixture (3) of the forage harvester is under the support pipe (1).

• Lift the intake housing using the lifting hydraulics until the adapter frame (4) of the maize header is positioned on the intake housing (2) of the forage harvester.

• Ensure that the support pipe (1) is correctly positioned in the holding fixture (3).

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

• Secure the header against dropping, see operating instructions for the forage harvester.

1

6

1

2

7

5

4

2

3

EC500113

Fig. 60

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

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

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

Note

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

105

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

12.3.1 Connecting drive

1 5

2

EC500136

Fig. 61

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

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

• Close the guard sheet (5).

106

12.3.2

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

Connecting hydraulics and electrics

Warning! - Connecting the hydraulic line

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

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

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

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

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

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

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

Effect: Injuries, serious damage to the machine

• Identify the hydraulic connections.

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

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

Caution! - Soiling of the hydraulic system

Effect: Damages to the machine

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

• Note chafing areas or points of contact.

107

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

1

2

5

ECFH0019

3

EC500220

Fig. 62

The maize header is equipped with a hydraulic quick coupler.

• Connect the hydraulic quick coupler (1) to the designated connection on the forage harvester.

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

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

• Open the stop cock (3) on the header.

"Row detection and ground contour" version

• Connect the connection cable with the operation box and connect the connection cable of the blinking and position lamps to the socket on the basic adaptation.

Notice

For further settings for maize header operation, see the operating instructions of the forage harvester

Notice

The oscillating movement of the EasyCollects during operation is achieved via the pendulum frame of the forage harvester.

108

13

Driving and Transport

Driving and Transport

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

Danger! - Road travel, carrying passengers, driving conduct

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

• It is forbidden to carry passengers on the machine.

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

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

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

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

• On public streets and highways, the maize header EasyCollect 450-2, FP, 600-2 FP,

750-2 FP must always be in the transport position.

Warning! – Unsafe driving behaviour due to low load on the rear axle of the forage harvester.

If a header is attached to a forage harvester, it can happen that the steering and braking behaviour is no longer safe due to the reduced load on the rear axle of the forage harvester.

A rear weight can be used to restore the necessary load on the rear axle, so that safe steering and braking is ensured during road travel and work.

• Dimension the rear weight such that the necessary load is achieved on the rear axle so that safe steering and braking behaviour is ensured.

• Ensure that the admissible axle loads and the admissible total weight of the forage harvester are 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.

Notice

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

109

Driving and Transport

13.1 Preparing the machine for road travel

EC500143

Fig. 63:

Prerequisite:

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

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

To do this:

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

• Switch off the engine and remove the ignition key.

• After having mounted the header to the forage harvester, push in the right/left support jacks in transport position; refer to chapter Operation, "Support jacks right/left in transport position".

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

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

• Ensure that the lighting functions perfectly.

EasyCollect 750-2 FP

EC500144

Fig. 64:

To ensure that the maximum permissible height of 4 m is not exceeded in the EasyCollect 750-

2:

• Using the lifting unit on the forage harvester, lower the header so that the dimension of

X = 250 mm is reached, see the operating instructions of the forage harvester.

110

13.2

Driving and Transport

Notice

When driving onto the field, there may be insufficient ground clearance. To ensure sufficient ground clearance when driving onto the field proceed as follows:

• Ensure that there are no overhead lines or other obstacles above the machine.

• Use the lifting unit of the forage harvester to raise the header and provide for sufficient ground clearance. Make sure that the header does not collide with the tractor cabin of the forage harvester.

• On the field, set the header to working position or lower it so far that a height of 4 m is not exceeded.

Using the transport chassis (for the version with "transport chassis")

1

EC500191

Fig. 65:

The transport chassis ensures that the maize headers are safely transported during road travel while complying with the total weights and axle loads of the forage harvester prescribed by law.

The transport chassis is only permitted on the headers listed in connection with the following forage harvesters:

• Claas type 494, 496, 497, 498, 502

• John Deere 8000, 9000

111

Driving and Transport

13.2.1 Attaching the transport chassis

2

1

I

II

EC500203

Fig. 66

Prior to attaching the transport chassis:

• Swing the header up to transport position.

• Move the switch (1) upwards to position (I). See chapter Initial commissioning and transport chassis, "Connecting the operation box".

– The LED (2) shines.

– The control of the transport chassis locking device is activated; the header folding mechanism is deactivated.

The locking device is controlled via the "Fold header" button of the harvester. (See original operating instructions of the related harvester).

112

Driving and Transport

1

2

EC500193

Fig. 67:

Prerequisites:

– The transport chassis (1) is located on a horizontal and even surface.

– The maize header is attached to the forage harvester and is in the transport position, refer to the operating instructions of the forage harvester.

– The transport chassis (1) is parallel in front of the forage harvester.

– The claws (2) of the transport chassis (1) grip into the ground.

– The main mode switch for the forage harvester is in the "field mode" position, refer to the operating instructions of the forage harvester.

– The lifting unit of the forage harvester is in the lower position.

3

EC500194

Fig. 68

• Before attaching the transport chassis, the plant divider (3) must be moved to the correct position.

If the plant divider is too low, it collides with the upper frame of the chassis.

If the plant divider is too high, it collides with the roller when the arm is moved up.

113

Driving and Transport

4 5 4 5

EC500195

Fig. 69

• Open the locking (8) completely (lower end position); see operating instructions for the forage harvester.

• Drive forward slowly with the forage harvester.

• Place the central tip (4) on the guard sheet (5).

7

7

6

6

Fig. 70

• Thread the lock bolt (6) into the collecting pockets (7) of the transport chassis.

EC500196

8 9

EC500197

Fig. 71

• With the lock (8) open lift up the transport chassis via the intake lifting unit until the wheel (9) lifts off the ground.

114

Driving and Transport

8

10

EC500198

Fig. 72

• Actuate the hydraulic system to close the locking (8); see operating instructions for the forage harvester.

• Ensure that the bolts (10) of the transport chassis are correctly inserted into the holes of the take-up pockets of the header.

• Lower the intake lifting unit.

12

13.2.2

11

EC500199

Fig. 73

• Shut down and safeguard the machine, refer to the Safety chapter in the operating instructions, "Shutting down and safeguarding the machine".

• Fasten the guard cloths (11) to the frame of the maize header with tension springs (12).

Connecting road travel lighting

Notice

Short circuit caused by impurities and moisture in the plug connection

The machine may be damaged by a short circuit.

• Make sure that the plugs and sockets are clean and dry.

115

Driving and Transport

1

13.2.3

2

EC500200

Fig. 74

The road travel lighting is connected by means of the enclosed 7-pin lighting cable (2).

Prerequisite:

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

• Connect the 7-pin plug of the lighting cable (2) to the 7-pin socket (1) of the machine.

• Lay the lighting cable (2) so that it does not touch the forage harvester wheels.

Using the transport chassis

Driving on pubic roads with the transport chassis attached:

• Move the main mode switch of the forage harvester to the "Road mode" position before driving. See operating instructions for the forage harvester.

116

13.2.4 Activating bearing pressure control of FP machines

John Deere version

3

Driving and Transport

EC500204

Fig. 75

Pressing the button (3) on the control lever activates bearing pressure control in road mode.

(Operation on John Deere 8000, year of manufacture 2015, as example. Please contact your authorized dealer for other equipment variants. With John Deere forage harvesters of the series

8000 and 9000, the buttons on the control lever can be configured individually. This means that a different button may have to be pressed to activate the bearing pressure.)

• During initial commissioning, set the bearing pressure as specified in the operating instructions for the forage harvester. Ensure that the admissible drawbar load on the transport chassis is not exceeded.

Claas version

4

EC500205

Fig. 76

Pressing the button (4) on the control lever activates bearing pressure control (oscillation suppression) in road mode. (Operation on Claas Jaguar type 497, year of manufacture 2016, as an example. Please contact your authorized dealer for other equipment variants.)

117

Driving and Transport

13.2.5 Removing the transport chassis

CAUTION!

Damage to the machine due to folding in working position when the transport chassis is attached

If the maize header is folded in working position with the transport chassis attached, this can result in damage to the machine.

• Before folding in the working position, remove the transport chassis.

Notice

With mounted and locked transport chassis and the switch at the operation box in position "II", the transport chassis is unlocked when the function "Fold side parts in working position" is actuated.

• Find a suitable, flat place to put the transport chassis.

• To activate the hydraulics, set the main mode switch of the forage harvester to the "Field mode" position, see the operating instructions for the forage harvester.

8 9

Fig. 77

• To remove the road travel lighting and the guard cloths, shut down and safeguard the machine, see chapter on Safety "Shutting down and safeguarding the machine".

• Pull off the lighting cable for the road travel lighting and place on the transport chassis.

• Disassemble the tension springs of the guard cloths from the frame of the maize header.

• Raise the maize header until the wheel (9) of the transport chassis is approx. X=0.4 m above ground.

• Open the lock (8) by actuating the hydraulics.

• With the lock fully open (8) lower the intake lifting unit until the locking pins are free and the transport chassis is on the ground.

• Drive away from the transport chassis.

• Close the locking (8). The crop press roller swivels to the top working position.

118

Driving and Transport

1

I

II

2

EC500203

Fig. 78

After the transport chassis has been removed:

• Move the switch (1) downwards to position (II). See chapter Initial commissioning and transport chassis, "Connecting the operation box".

– The LED (2) does not shine.

– The control of the header folding mechanism is activated; transport chassis locking is deactivated.

119

Driving and Transport

13.3 Switching off the machine

Notice

Damage to the machine from removing the machine from forage harvester with the transport chassis attached

The machine may be damaged when the maize header is disassembled from the forage harvester with the transport chassis attached.

• Before disassembling the machine from the forage harvester, remove the transport chassis.

1

2

EC500004

Fig. 79:

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

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

Storage with supports (for the version with supports)

1

2 3

EC500152

Fig. 80:

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

120

13.4

Driving and Transport

Lifting the machine

Warning! - Stop and transportation equipment inadequately dimensioned.

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

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

Fig. 81:

• For internal transport (e.g. loading), attach the hoist to the suspension points shown.

Note

Check the chain length!

121

Operation

14

14.1

Operation

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

From transport into working position

Warning! - Lowering the machine into working position

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

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

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

• Never allow the machine to run unsupervised.

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

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

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

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

122

14.1.1 Removing the protective cover

2 2

Fig. 82:

• Stop the machine.

• Remove the lighting cable.

• Remove front guard (1).

• Remove the guards (2) right and left.

1

Operation

123

Operation

14.1.2 Support jacks right/left in transport position

Prerequisite:

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

There are markings in the contact surfaces of the support jacks which indicate the mounting locations of the individual support jacks: "V" for mounting at the front of the machine and "H" for mounting at the rear of the machine.

6

3

5

1

2

2

4

Fig. 83

Support jacks at rear on right/left:

EC500125_1

Notice

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

Support jacks at front on right/left:

Notice

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

124

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

7 7

Operation

1 2

EC500121

Fig. 84

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

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

Notice

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

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

Transport chassis version:

2

1

I

II

EC500203

Fig. 85

• Move the switch (1) of the operation box to the lower position (II).

– The LED (2) does not shine.

– The control of the header folding mechanism is activated.

125

Operation

Swivelling side parts

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

Swivel the side parts via forage harvester hydraulics.

To do this:

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

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

After swivelling

To ensure that the interlock ratchet mechanisms are engaged:

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

Notice

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

126

14.2

14.2.1

Operation

Using the Machine for Work

Warning! - Lowering the machine into working position

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

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

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

• Never allow the machine to run unsupervised.

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

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

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

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

Field mode on slopes

EC400135

Fig. 86

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

127

Operation

14.2.2 Insert the maize header

Note - clean cut

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

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

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

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

• Drive into the crop with the forage harvester.

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

Note

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

Note regarding resonance vibrations

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

Note - Reversing

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

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

128

14.2.3 Operating the main gearbox (Claas, John Deere series 6000 and 7000)

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

– Position L = low speed

– Position H = high speed

Operation

1

2

3

H L

EC500108_1

Fig. 87

Prerequisite:

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

To switch the main gearbox:

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

• Dismount the linch pin (3).

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

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

129

Operation

14.2.4 Operating input gearbox (Claas)

Different speeds can be selected when switching the input gearbox.

– Position I = lower speed

– Position II = higher speed

2

1

EC400071

Fig. 88

Prerequisite:

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

To switch the input gearbox:

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

3

II

3

4 I

EC400072_3

Fig. 89

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

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

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

EC400073_2

130

14.2.5

Operation

Setting the rotational speed of the maize header (Claas)

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

4 rotational speed values can be set for the Claas forage harvester type 493 and up.

8 rotational speed values can be set for the Claas forage harvester Types 491 and 492 by using the 2-gear gearbox of the forage harvester.

Actuating lever of input gearbox

Actuating lever of main gearbox

Speed ratio

Item

II

II

I

I

Item

H

L

H

L

Speed

120 %

100 %

83 %

70 %

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

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

Notice

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

Notice

On Claas forage harvesters with adjustable drive speed (e.g. Claas forage harvester type

498), a constant rotational speed is provided by the harvester, as the speed sensors required for variable speed adjustment are not installed on the header.

• Adjust the rotational speed of the header as described above.

131

Operation

14.2.6 Setting rotational speed of the maize header (John Deere series 6000 and 7000)

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

4 rotational speed values can be set by using the 2-gear gearbox of the forage harvester.

Actuating lever of main gearbox

Speed ratio

Pos.

H

L

Speed

120 %

100 %

• The actuating lever position of the main gearbox for the desired range can be found in the table.

• Switch the actuating lever of the main gearbox to the indicated position. See chapter

Operation, "Operating main gearbox".

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

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

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

132

14.2.7

14.2.8

Operation

Setting rotational speed of the maize header (John Deere series 8000 and 9000)

Notice

The admissible rotational speed for the drive of the John Deere forage harvesters of the series 8000 and 9000 is 300 ...700 rpm.

The rotational speed of the maize header can be set to different values by the rotational speed of the forage harvester

• Adjust the rotational speed of the header to the harvesting conditions.

Setting rotational speed of the maize header (New Holland)

The rotational speed of the maize header can be set to different values by the rotational speed of the forage harvester

• Adjust the rotational speed of the header to the harvesting conditions.

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

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

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

133

Operation

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

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

1 1

2 2

EC903098

Fig. 90 notice

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

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

For Claas forage harvesters from type 494.

1 2

Fig. 91

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

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

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

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

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

134

Operation

For John Deere forage harvesters of 6000 and 7000 series

The "John Deere Automatic Steering Row-Trak II" takes over automatic guidance of the forage harvester between 2 rows of thin-stemmed plants using the row tracers on the maize header.

2 1

EC500166

Fig. 92

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

– The forage harvester is fitted with the "John Deere Automatic Steering Row-Trak II" system for using the row detection.

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

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

• Follow the operating instructions for the forage harvester, in particular the chapter on operation of the "John Deere Automatic Steering Row-Trak II".

John Deere forage harvesters of the series 8000 and 9000.

Using the row tracers on the maize header, the "John Deere automatic steering system

AutoTrac™ RowSense™" automatically guides the forage harvester between two rows of stalktype plants.

1 2

EC500170

Fig. 93

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

– The forage harvester is equipped with the "John Deere automatic steering system

AutoTrac™ RowSense™" to use row detection.

– The accessories kit B367 "Row detection and ground contour JD 8000 and 9000" is mounted.

– The connections (1) of the header are connected to the connections (2) of the forage harvester.

• Observe the operating instructions for the forage harvester, in particular the chapter on operation of "John Deere automatic steering system AutoTrac™ RowSense™".

135

Operation

For New Holland forage harvesters

The "New Holland Automatic Row Guidance System for Maize Header" takes over automatic guidance of the forage harvester between 2 rows of thin-stemmed plants using the row tracers on the maize header.

1 2

EC500171

Fig. 94

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

– The forage harvester is fitted with the "New Holland Automatic Row Guidance System for

Maize Header" system for using the row detection.

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

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

• Follow the operating instructions for the forage harvester, in particular the chapter on operation of "New Holland automatic row guidance for maize headers".

136

14.2.10

Operation

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

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

2

1

EC500010

Fig. 95

For Claas forage harvesters from type 494.

When ground contour is active, the ground tracers (1) scan the ground below the header. The unevenness of the ground is compensated for by the forage harvester in the direction of travel, and at right angles to the direction of travel by the hydraulic cylinder (2) on the intermediate frame of the header.

Notice

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

1 2 3 4

6 5

Fig. 96

Prerequisite for using active ground contour tracing with the forage harvester:

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

– The accessories kit B338 "Row detection CL" and the accessories kit B341 "Active ground contour CL494-502" are mounted.

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

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

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

• Observe the operating instructions for the forage harvester, in particular the chapter on operating the cutting height control.

137

Operation

For John Deere forage harvesters of the series 7000.

During active ground contour, the ground tracers scan the ground below the header. The unevenness of the ground is compensated for by the forage harvester in the direction of travel and by the hydraulic cylinder on the intermediate frame of the header transversely to the direction of travel.

Notice

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

1 2

3 4

EC500172_1

Fig. 97

Prerequisite for using active ground contour tracing with the forage harvester:

– The forage harvester is equipped with the "John Deere Automatic Header Control AHC" system.

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

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

– Hydraulic hose III is connected to the plug-in coupling (3), or to the screw coupling of the forage harvester.

– Hydraulic hose IV is connected to the plug-in coupling (4) or to the screw coupling of the forage harvester.

• Observe the operating instructions of the forage harvester, in particular the chapter about the operation of the "Automatic header control AHC" system.

138

Operation

John Deere forage harvesters of the series 8000 and 9000.

During active ground contour, the ground tracers scan the ground below the header. The forage harvester compensates for the unevenness of the ground.

Notice

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

1 2

EC500170

Fig. 98

Prerequisite for using active ground contour tracing with the forage harvester:

– The forage harvester is equipped with the "John Deere Automatic Header Control AHC" system.

– The accessories kit B367 "Row detection and active ground contour JD8000" is mounted.

– The connections (1) of the header are connected to the connections (2) of the forage harvester.

• Observe the operating instructions of the forage harvester, in particular the chapter about the operation of the "Automatic header control AHC" system.

139

Operation

For New Holland forage harvesters

During active ground contour, the ground tracers scan the ground below the header. The forage harvester compensates for the unevenness of the ground.

Notice

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

1 2

5

EC500168

Fig. 99

Prerequisite for using active ground contour tracing with the forage harvester:

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

– The accessories kit B340 "Row detection and active ground contour NH FR" is mounted.

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

– The connections (1) of the header are connected at the forage harvester connections, and are secured with the lever (5).

• Observe the operating instructions of the forage harvester, in particular the chapter about the operation of "AutoFloat™".

140

14.3

14.3.1

Operation

Switching from working position to transport position

Notice

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

Note

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

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

Transport chassis version:

2

1

I

II

EC500203

Fig. 100

• Move the switch (1) of the operation box to the lower position (II).

– The LED (2) does not shine.

– The control of the header folding mechanism is activated.

1 2

EC500141

Fig. 101

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

Notice

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

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

• Lift the maize header with the forage harvester hydraulics high enough to ensure adequate ground clearance for travel on the road. Make sure that the header does not collide with the tractor cabin of the forage harvester.

141

Operation

EasyCollect 750-2 FP

EC500144

Fig. 102:

To ensure that the maximum permissible height of 4 m is not exceeded in the EasyCollect 750-

2:

• Using the lifting unit on the forage harvester, lower the header so that the dimension of

X = 250 mm is reached, see the operating instructions of the forage harvester.

142

14.3.2 Installing guard on the right/left

2 1

4

4

Operation

5

14.3.3

3

EC50044_1

Fig. 103

• Insert both hexagon head screws (1) to the contact sheets (2) of the side parts into the bore holes of the tips (3).

• Fasten the guard cloths (4) to the frame with tension springs (5).

Installing the front guard

5

3

2 1

4

Fig. 104

• Attach the front guard (1) on the right and left to the support on the guards as well as on the centre of the central tip. Pay attention to the stipulated position of the warning stripes (2)

(the hatching must point downwards and outwards).

• Secure front guard (1) on the right and left with spring cotter pin (3) and hook tension spring

(4) on the central tip.

Note

If the central tip has been re-adjusted due to reasons concerning the harvest, it may be necessary to move the holding plates (5) in the side part within the arrangement of holes.

143

Operation

14.3.4 Connecting indicators and position lights on the right/left

Claas adaptation version (without "Row detection" version)

3

2 1

EC500045_1 EC500124

Fig. 105

• 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.

Claas adaptation version (with "Row detection" version), John Deere adaptation and New

Holland adaptation

3

2 1

EC500045_1 EC500123_2

Fig. 106

• Connect the connection cable (2) of the indicators and position lights (1) in the socket (3) on the maize header.

• Check the lighting for proper 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.

144

14.4

14.4.1

Operation

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 the maize header up to transport position.

Note

Stop the machine.

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

3

1

2

5

2

6

4

2

2 1

4

EC500026 EC500116_1

Fig. 107

Support jacks at front on right/left:

• Dismount the spring locking pins (2) and pull the front support jacks (1) down from the guide pins (3) and remove them from the holders on the lateral frames.

• Push the front support jacks (1) into the front guidances on the lateral frames.

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

Support jacks at rear on right/left:

• Dismount the spring locking pins (2) and pull the rear support jacks (4) out of the holders (5) on the lateral frames.

• Push the rear support jacks into the rear guidances (6) on the lateral frame.

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

Notice

Push the support jacks into the guidances on the lateral frames so that the bottom plates of the support jacks are parallel to the ground when parking the machine.

Notice

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

145

Operation

1

2

14.4.2

EC500165

Fig. 108

To ensure that the forage harvester can accommodate the maize header, the height of the holder elements on the forage harvester must be matched to the height of the holder elements on the maize header.

For this purpose, the rear parking supports can be differently aligned when parking by means of spring locking pins (1) in the hole pattern (2) depending on the tyre diameter.

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

7 7

1 2

EC500121

Fig. 109

• Swivel side parts (1, 2) into working position, see operating instructions of the forage harvester.

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

• Shut down and safeguard the machine, refer to chapter Safety, “Shutting down and safeguarding the machine”.

146

14.5

14.5.1

Operation

Dismantling the machine in case of adaptation to Claas forage harvester

Disconnecting hydraulics and electrics

Caution! - Danger of accident and damage!

Lay the hydraulic hoses and the electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

Prerequisites:

– The forage harvester is shut down and secured; see operating instructions for the forage harvester.

– The forage harvester hydraulics are depressurised; see operating instructions for the forage harvester.

2 1

3

EC500221 EC400147

Fig. 110

• Close the stop cock (3) on the header.

• Disconnect the hydraulic hoses (1) from the plug-in connections, close them with dust caps and put them down on the header.

• Disconnect the lighting cable (2) from the socket and put it down on the header.

"Transport chassis" version

• Disconnect the connection cable from the operation box.

147

Operation

14.5.2 Connecting

Prerequisites:

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

– The support jacks are in the support position.

2 4 3

5 6

7

1

8

Fig. 111

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

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

EC500128

148

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

1 2 5 6

Operation

14.5.4

4 3

EC400085_1

Fig. 112

• Open the guard sheet (3).

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

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

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

• Put the universal shaft aside for re-assembly.

• Move the forage harvester back.

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

EC400141

Version with header quick coupling (type 493 and up)

2

1

EC400090

Fig. 113

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

• Reverse the forage harvester.

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

149

Operation

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

14.6.1 Disconnecting hydraulics and electrics

Caution! - Danger of accident and damage!

Lay the hydraulic hoses and the electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

Prerequisites:

– The forage harvester is shut down and secured; see operating instructions for the forage harvester.

– The forage harvester hydraulics are depressurised; see operating instructions for the forage harvester.

4

2

1

EC500223

3

EC500207

Fig. 114

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

• Disconnect the hydraulic hoses (1) from the plug-in connections, close them with dust caps and put them down on the header.

• Disconnect the lighting cable (2) from the socket and put it down on the header.

"Ground contour" version:

• Disconnect the hydraulic lines (3) for ground contour from the hydraulic couplings and close them with dust caps.

150

14.6.2

Operation

Connecting

Prerequisites:

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

– The support jacks are in the support position.

2 10

1

EC500137

Fig. 115:

• Open the guard sheet (10).

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

• Pull the universal joint (1) down from the gearbox of the maize header.

• Put the universal shaft aside for re-mounting later.

151

Operation

I II

1 2 3

EC500138

Fig. 116

Release the locking pins (1).

To do this, on both sides of the machine:

• Dismount the linch pin (3).

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

• Mount the linch pin (3).

6 1

EC500140

Fig. 117

• Lower the intake housing until the holding brackets (6) are positioned under the cross tube (1) of the maize header support bracket.

• Move the forage harvester back.

152

14.7

14.7.1

Operation

Removing the machine with adaptation to John Deere forage harvesters of the series

8000 and 9000

Disconnecting hydraulics and electrics

Caution! - Danger of accident and damage!

Lay the hydraulic hoses and the electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

Prerequisites:

– The forage harvester is shut down and secured; see operating instructions for the forage harvester.

– The forage harvester hydraulics are depressurised; see operating instructions for the forage harvester.

2 3

4

5

1

EC500224 EC500167

Fig. 118

• Close the stop cock (5) on the header.

• To disconnect the connections (2) of the header from the connections (4) of the forage harvester, press down the safety button (3) and swivel the lever (1).

"Transport chassis" version

• Disconnect the connection cable from the operation box.

153

Operation

14.7.2 Disconnecting header

Prerequisites:

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

– The support jacks are in the support position.

For a forage harvester with universal shaft version:

– The universal joint has been disconnected from the gearbox of the header.

2

4

1 3

EC500182

Fig. 119

• To release the catch hook, dismount the linch pin (1) and swivel the lever (2) downwards.

• Lower the intake housing until the locating bolts (3) are under the cross tube (4) of the header support panel.

• Move the forage harvester backwards.

154

14.8

14.8.1

Operation

Dismantling the machine in case of adaptation to Claas forage harvester

Disconnecting hydraulics and electrics

Caution! - Danger of accident and damage!

Lay the hydraulic hoses and the electrical connection line on the maize header.

Notice

The system should be without pressure on both sides when disconnecting the hydraulic hoses.

Prerequisites:

– The forage harvester is shut down and secured; see operating instructions for the forage harvester.

– The forage harvester hydraulics are depressurised; see operating instructions for the forage harvester.

3

1

EC500221

2

5

Fig. 120

• Close the stop cock (3) on the header.

• Disconnect the coupler for hydraulic systems (1) from the connection at the forage harvester.

• Disconnect the lighting cable (2).

ECFH0019

155

Operation

14.8.2 Connecting

Prerequisites:

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

– The support jacks are in the support position.

1

ECFH0004_1

Fig. 121

• Pull the PTO shaft (1) down from the drive journal of the forage harvester gearbox.

1 3

5

4

EC500119

Fig. 122

• Open the locking hooks (5) with the locking lever (1).

• Lower the intake housing (3) with the lifting hydraulics until the holder (4) is positioned under the support pipe (2).

• Move the forage harvester backwards.

156

14.9

Operation

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

Danger! - Unexpected movement of the machine

Effect: Danger to life, serious injuries

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

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

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

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

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

Notice

Damage to the machine from removing the machine from forage harvester with the transport chassis attached

The machine may be damaged when the maize header is disassembled from the forage harvester with the transport chassis attached.

• Before disassembling the machine from the forage harvester, remove the transport chassis.

EC500164

Fig. 123

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

Prerequisite: The header is mounted on the forage harvester.

• Move the maize header into transport position.

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

157

Operation

14.9.1 Support jacks right/left in transport position

14.9.2

2

5

6

4

2 3

1

2

2

4 1

Fig. 124

Support jacks at rear on right/left:

EC500017_1 EC500016

• Unscrew the spring locking pins (2) and pull the rear support jacks (4) out of the guidance.

• Push the rear support jacks (4) into the holders (5) of the lateral frame frames so that no plant residues can collect in the area (6) above the support jacks.

• Secure the position of the support jacks at rear (4) by means of spring locking pins (2).

Support jacks at front on right/left:

• Dismount the spring locking pins (2) and pull the front support jacks (1) out of the guidance.

• Push the base of the front support jacks onto the guide pins (3) in the holders on the lateral frame.

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

Relocating the support jack bracket

1 2

3 4

2

1

EC500169 EC500173

Fig. 125

• Dismount the screws (2) and remove the support jack bracket (1) from the lateral frame.

• Put the support jack bracket (2) from below on the support jack (3) and secure it by means of the spring locking pin (4).

• Mount the screws (2) in the boreholes of the support jack bracket (1).

158

14.9.3 Mounting console support

5 3 5 4

Operation

1 2

EC500153_1

Fig. 126

• Push the rear console of the support jack (1) into the rear support jack holder (3) and secure it with the socket pin (5).

• Push the front console of the support jack (2) into the front support jack holder (4) and secure it with the socket pin (5).

159

Operation

14.9.4 Mounting side guards

6

3

2

5

4

1

EC500154

Fig. 127

• Insert the lower holder (2) of the side support (1) into the tip (3) on the lateral frame (on both sides of the machine).

• Raise the lateral support (1), push the upper profile (4) over the front and rear console (5) and secure it with the socket pin (6) (on both sides of the machine).

160

14.9.5 Setting the lateral supports at rear

Operation

2

1

EC500155

Fig. 128

To ensure that the forage harvester can pick up the maize header which is held by the support jacks, the height of the holder on the forage harvester and the height on the maize header need to be adjusted.

For this purpose, the support jacks can be set differently in terms of height and inclination.

• If required, mount the support jacks in both hole patterns (1, 2).

Notice

After being reinstalled on the forage harvester the support jack brackets must be mounted on their former lateral frame position so that they can be connected with the support jacks.

161

Operation

14.9.6 Putting header down

CAUTION! - Risk of tipping over

The parked header may tip over. As a result, accidents may occur and people may be seriously injured or killed.

• Park the machine in transport position with the supports on level and firm ground

(concrete/paving) only.

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

• Close the stop cock of the header.

• Depressurise the forage harvester hydraulics, see the operating instructions of the forage harvester.

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

• Lower the header to the ground by using the supports.

• Move the forage harvester back and shut it down.

• Make sure that the maize header is supported by the two supports after it has been lowered.

If this is not the case:

• Raise the maize header by using the forage harvester hydraulics and put it down at another place.

162

15

Settings

Settings

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

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.

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

163

Settings

15.1 Setting the Tubular Bars

1

1

2

EC500048

Fig. 129

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.

164

15.1.1

Settings

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

Depending on harvesting conditions, the inclination of the tubular bars can be set. Due to this, the tubular bar can be inclined somewhat to the front in order to press the plants to be cut slightly into the crop.

If the inclination of the tubular bar is changed, the contact pressure of the tubular bars in transport position changes, as well. An indicator for this is a rattling noise e.g. when driving on the road. The contact pressure must be set, if necessary; refer to “Setting the Contact Pressure of the Tubular Bars”.

1

4

5

3

2

6

7

EC500070_2

Fig. 130

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. 131

• 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).

165

X

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

11

12

10

EC500072_2

Fig. 132

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.

166

15.1.2

Settings

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

Depending on harvesting conditions, the inclination of the tubular bars can be set. Due to this, the tubular bar can be inclined somewhat to the front in order to press the plants to be cut slightly into the crop.

If the inclination of the tubular bars is changed, the contact pressure of the tubular bars in transport position changes, as well. An indicator for this is a rattling noise e.g. when driving on the road. The inclination and the contact pressure must be checked after each setting.

1

3

2

EC500082

Abb. 133

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. 134

• 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).

167

Settings

15.2 Adjusting the crop press roller (for version without transport chassis)

15.3 Setting Holding-Down Device Roller

1

I

15.4

II

2

2 2

III

EC500024

Fig. 135

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. 136:

• 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.

168

15.5

Settings

Adjusting the plant dividers

CAUTION

Risk of damaging the machine from plant divider movements!

When the transport chassis is mounted, there is a risk of interference of the plant divider with parts of the machine. If the plant divider is too low, it collides with the upper frame of the chassis. If the plant divider is too high, it collides with the crop press roller during the upwards movement.

• With the transport chassis attached, move the plant divider to a position where interference with the machine is avoided.

Notice

Adapt the height of the plant divider (1) to the respective crops so that the plants are guided at

60-70% of their plant height by the tubular bars when being drawn into the chopper unit.

1

2 3

2

Fig. 137

• The height of the plant divider (1) can be adjusted by relocating the bolt (2).

• Secure the bolt (2) in the desired borehole by means of a spring cotter pin (3).

EC500120_1

169

Settings

15.6 Adapting Star-shaped Conveyor Height to Maize Crop

The star-shaped conveyors additionally drive the crop and thus improve the crop flow to the intake rollers of the forage harvester, especially with short maize plants.

For extremely high maize plants, however, it can be advantageous to replace the upper starshaped conveyor segment on both sides with the cover provided. This improves the crop flow, and excess lengths in the chopped material can be avoided.

Replacing the star-shaped conveyor segment

2

4 5

1

3

EC500080_1

4 6

EC500219

Fig. 138

• Move the header to transport position/road travel.

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

• Dismount the screws (1) and remove the infeed sheet (2) and the scraper edge (3) including the support.

• Dismount the screws (4) and remove the star-shaped conveyor segment (5).

• Insert the cover (6) provided instead of the star-shaped conveyor segment (5), and mount it with the screws (4).

• Insert the infeed sheet (2) and the scraper edge (3) including the support, and mount them with the screws (1). The gap between scraper edge (3) and star-shaped conveyor is

1 ... 3 mm.

170

15.7

Settings

Version with pendulum frame on the header and without "active ground contour"

Adjusting the oscillation of the header

The header is able to adapt to the ground contour of the field due to the oscillating movement.

The height of the header is permanently aligned relative to the ground via the sliding skids.

The pendulum springs (1) counteract the oscillating movement of the header and thus dampen the oscillating movement.

The design of the pendulum spring case with an inner and an outer pipe ensures that during oscillation, the movement takes place in the respective opposite oblong hole (9).

1 Z 2 3 4 5 6

7

9

8

EC400110_2

Fig. 139

Move the pendulum compensation to its initial position:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Remove the screw connection (8).

• Tighten the feed shaft (7) hand-tight.

• Tighten the feed shaft (7) by 4 further rotations and then ensure that the feed shaft (7) can be secured against turning using the screw (8).

• Secure the feed shaft (7) against turning using the screw (8) and mount the screw connection (8).

• Tighten the nut (5) on the bar (6) hand-tight.

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Loosen the counter nut (4).

• Loosen the counter nut (3).

171

Settings

1 Z 2 3 4 5 6

7

9

8

EC400110_2

Fig. 140

If the oscillation movement of the header is too smooth or too hard, the force of the pendulum springs (1) which counteract the oscillation of the header can be adjusted.

To do this, perform the following on both sides of the machine:

• Loosen the counter nut (3).

• Loosen the counter nut (4).

• Remove the screw connection (8).

To reduce the force for the pendulum compensation:

• Loosen the feed shaft (7). At the same time, ensure that the nut (2) connected with the inner spring casing does not twist.

To increase the force for the pendulum compensation:

• Tighten the feed shaft (7) further. At the same time, ensure that the nut (2) connected with the inner spring casing does not twist.

When the pendulum springs have been adjusted:

• Secure the feed shaft (7) against twisting using the screw (8) and mount the screw connection (8).

• Check the dimension Z.

• If the dimension is Z=1–3 mm, the setting is correct.

• If the dimension is not Z=1–3 mm, turn the nut (2) which is connected to the inner spring housing until the dimension is Z=1–3 mm.

• Loosen the counter nut (4).

• Loosen the counter nut (3).

172

16

Maintenance

Maintenance

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

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

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

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

"Safety routines".

NOTE!

Damage to the machine due to incorrectly performed or unfinished maintenance work

There is a risk of machine damage if maintenance work is not carried out by qualified personnel. A qualified specialist workshop has the required technical knowledge, qualification and tools to perform the required work on the machine properly. This applies in particular to safety-relevant work.

• Always have specially designated work performed by a qualified service centre.

173

Maintenance

16.1

16.1.1

16.2

Special Safety Instructions

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

Effect: Danger to life or serious injuries

• Switch off the drive and disengage PTO.

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

• Secure the forage harvester against accidental start-up and against rolling away.

• When working under or with the machine raised, always secure it with suitable supporting elements.

• Close shut-off valve on lifting cylinder of forage harvester!

• After all repair, maintenance and cleaning tasks are complete, all protective covers and safety devices must be put in place again.

Test run

Danger! - Testing the machine after repair, maintenance or cleaning work and after technical intervention.

Effect: Danger to life or serious injuries

• The machine must be in working position

• Do not switch on the drives until the machine is in cutting height and you are absolutely sure that neither persons, animals nor objects are in the danger zone.

• Start a trial run of the machine from the driver’s seat only.

Spare Parts

Warning! - Using non-approved spare parts.

Effect: Danger to life, serious injuries or loss of warranty claims as well as exclusion of liability

• Use only authentic KRONE spare parts and accessories authorised by the manufacturer.

The use of spare parts, accessories or additional equipment not manufactured, tested or approved by KRONE will exclude any liability for consequential damage.

174

16.3 Maintenance table

Maintenance work

Maintenance

Maintenance interval

Blade

Check fixed blades (bow blade, stepped blade, tip blade) and replace damaged or bent blades.

Check cutting blades (collector blades), replace damaged or bent blades.

Collector

Check collector tension.

Check whether the collector rests on the fixed blades. 1

Checking/adjusting the distance between bottom guide roller and guide rail

Check insertion fingers, replace damaged or bent insertion fingers.

Tighten screws/nuts

Check if the screws on the swivel-joint of the side parts

(left and right) are seated firmly.

Check all other screws. gearbox

Leakage check

Oil level check

Oil change

Cleaning the machine

Check the soiling in the collector compartment (inside) and clean it, if necessary.

Coupling

Check coupling for wear.

Hydraulic system

Check the hydraulic hoses for leaks and, if necessary, have them replaced by a KRONE service partner.

Lubricate machine according to lubrication chart

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

175

Maintenance

Maintenance work Maintenance interval

"Transport chassis" version:

Retighten the wheel nuts, see the chapter on Maintenance

"Retightening the wheel nuts"

X X

Visually inspect tyres for cuts and breaks, see the chapter on

Maintenance "Checking the tyres visually"

X

Check the tyre pressure, see the chapter on Maintenance

"Checking/adapting the tyre pressure"

X

1 To do this, move the machine to the working position and let it run forwards for approx. 1 minute.

X

176

16.4

16.4.1

Maintenance

Tightening torques

Deviating tightening torques

All screw connections must in general be tightened with the listed tightening torques following.

Deviations from the tables are marked accordingly.

Metric Thread Screws with Control Thread

NOTICE

The table does not apply to countersunk screws with hexagonal socket in case the countersunk screw is tightened via hexagonal socket.

Tightening torque in Nm (unless otherwise stated)

A = thread size

(stability class can be seen on screw head)

A

M4

M5

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

3.0 4.4 5.1

5.9 8.7 10

M6

M8

M10 29

10

25

49

15

36

72

18

43

84

M12

M14

M16

M20

M22

M24

M27

M30

42 85 125 145

135 200 235

210 310 365

425 610 710

571 832 972

730 1050 1220

1100 1550 1800

1450 2100 2450

NOTICE

Before the start of the season and at regular intervals (approx. every 50 hours), check all nuts and bolts for tightness and retighten 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.

177

Maintenance

16.4.2

16.4.3

Metric Thread Screws with Fine Thread

Tightening torque in Nm (unless otherwise stated)

A

Stability class

5.6 8.8 10.9 12.9

A = thread size

(stability class can be seen on screw head)

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M24 x 2

M27 x 2

M30 x 1.5

Tightening torque (Nm)

88 130 152

145 213 249

222 327 382

368 525 614

465 662 775

787 1121 1312

1148 1635 1914

800 2100 2650

Metric Thread Screws with Countersunk Head and Hexagonal Socket

M4

M5

M6

M8

M10

M12

M14

M16

M20

NOTICE

The table applies only to countersunk screws with hexagonal socket and metric thread which are tightened via hexagonal socket.

Tightening torque in Nm (unless otherwise stated)

A = thread size

(stability class can be seen on screw head)

A

Stability class

5.6 8.8 10.9 12.9

Tightening torque (Nm)

2.5 3.5 4.1

4.7

8

7

12

8

15

23

34

20

39

68

29

58

100

35

67

116

108 160 188

168 248 292

340 488 568

A

BM 400 0234

NOTICE

Before the start of the season and at regular intervals (approx. every 50 hours), check all nuts and bolts for tightness and retighten 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.

178

16.4.4

Maintenance

Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes

This table applies only to locking screws with external hex in connection with copper seal ring for bleed valves made of brass with shaped seal ring.

Thread Locking screw and viewing glass with copper ring*)

Ventilation/breather filter made of steel

Bleed valve made of brass

Ventilation and breather filter made of brass

Aluminium

M10x1

M12 x 1.5

Steel and cast Aluminium Steel and cast

Maximum tightening torque (Nm) (±10%)

8

14

G1/4“

M14 x 1.5

M16 x 1.5 45

M18 x 1.5 50

M20 x 1.5

G1/2“

M22X1.5

M24x1.5

40

45

14

16

24

30

32

32

35

60

G3/4“

M33x2

G1“

M42x1.5

G1 1/4“

*) Always replace copper rings

60

80

80

100

100

24

30

NOTE

The tightening torques only apply to assembly of locking screws, viewing glasses, ventilation and breather filters and bleed valves in gearboxes with cast housings or aluminium or steel housings. The term “locking screw” includes the drain plug, the inspection screw as well as the ventilation and breather filters.

179

Maintenance

16.5 Hydraulics

WARNING!

Risk of injury from incorrect handling of liquids under high pressure. Escaping highpressure liquids may penetrate the skin and cause serious injury.

• Repair work on the hydraulic system may only be performed by authorised KRONE professional workshops.

• Depressurise the system before disconnecting lines.

• When working on the hydraulic system, wear personal protective equipment (protective goggles and protective gloves).

• High-pressure liquid that is escaping from a small opening is virtually invisible. Therefore, use suitable aids when searching for leaks (for example a piece of cardboard).

• If liquid penetrates the skin, consult a doctor immediately. The liquid must be removed from the body as quickly as possible. Danger of infection! Physicians who are not familiar with this area must consult appropriate information from a competent medical source.

• Check the hydraulic hoses at regular intervals and replace them if damaged or worn! Only original KRONE spare parts are permitted to be used as replacement lines as they correspond to the technical requirements of the manufacturer.

• Before the pressure in the system builds up again, ensure that all line connections are tight.

180

16.6

Maintenance

Input gearbox

For adaptation Claas version

Note

Check the oil level, top up oil and drain oil when the gearbox is in the horizontal position.

1

3

4

2

EC400099_1

Fig. 141

1) Filler plug / filling hole 2) Drain plug

3) Inspection screw / inspection hole 4) Guard sheet

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw with the specified tightening torque, refer to chapter

Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes".

If the oil does not reach the inspection hole:

• Unscrew the filler plug.

• Top up oil via the filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug with the specified tightening torque, refer to chapter Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheet.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheet.

181

Maintenance

For adaptation Claas version and adaptation New Holland version

Note

Check the oil level, top up oil and drain oil when the gearbox is in the horizontal position.

1

2

EC500109_1

Fig. 142

1) Inspection screw/inspection hole 2) Drain plug

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

182

16.7

Maintenance

Main gearbox

Notice

For oil level check and oil change, the header (collector) must be in horizontal position!

1

3

2

EC500050_1

Fig. 143

1) Filler plug/filling hole

3) Inspection screw/inspection hole

2) Drain plug

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

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”.

183

Maintenance

16.8 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. 144

1) Guard plate

3) Drain plug/drain hole

2) Inspection- and drain plug/

Inspection- and 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”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

184

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.

185

Maintenance

16.9 Intermediate gearbox

Notice

For oil level check and oil change, the header (collector) must be in horizontal position!

4

3

1 2

EC500053_2

Fig. 145

1) Filler plug / filling hole

3) Inspection screw / inspection hole

2) Drain plug

4) Guard sheet

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Oil level check:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw with the specified tightening torque, refer to chapter

Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the Gearboxes".

If the oil does not reach the inspection hole:

• Unscrew the filler plug.

• Top up oil via the filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug with the specified tightening torque, refer to chapter Maintenance "Tightening Torques for Locking Screws and Bleed Valves on the

Gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Dismount the guard sheet.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw and the filler plug.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Top up new oil via the oil filling hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, top up new oil via the oil filling hole up to the inspection hole.

• Mount the inspection screw and the filler plug, tightening torque see chapter Maintenance,

“Tightening Torques for Locking Screws and Bleed Valves on Gearboxes”.

• Mount the guard sheet.

186

16.10

Maintenance

Roller Gearbox

Notice

For oil level check and oil change, the header (collector) must be in horizontal position!

1

2

EC500054_1

Fig. 146

1) Inspection screw / inspection hole 2) Drain plug

• Observe the safety routine “Safely Performing Oil level Check, Oil Change and Filter

Element Change”, see chapter Safety, “Safely Performing Oil Level Check, Oil Change and

Filter Element Change”.

Checking the oil level:

• Unscrew the inspection screw.

The oil level must reach up to the inspection hole.

If the oil reaches the inspection hole:

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

If the oil does not reach the inspection hole:

• Top up oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, "Tightening torques for locking screws and bleed valves on gearboxes".

Oil change:

Collect escaping oil in a suitable container.

• Unscrew the drain plug and drain the oil.

• Unscrew the inspection screw.

• Mount the drain plug, tightening torque see chapter Maintenance, “Tightening Torques for

Locking Screws and Bleed Valves on the Gearboxes”.

• Refill new oil via the inspection hole up to the inspection hole.

• Wait for 2 minutes and check whether oil is still leaking out of the inspection hole.

• If necessary, refill oil up to the inspection hole via the inspection hole.

• Mount the inspection screw, tightening torque see chapter Maintenance, “Tightening

Torques for Locking Screws and Bleed Valves on Gearboxes”.

187

Maintenance

16.11 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

3 2

1 a 5 4

EC500060_1

16.11.1

Fig. 147

Checking the collector pre-tension

16.11.2

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).

188

EasyCollect 450-2

1

Maintenance

4 5 6

9

10

2 23

7 8

Fig. 148

Checking the collector pre-tension

EC500077_1

16.11.3

16.11.4

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).

189

Maintenance

16.11.5

16.11.6

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).

190

16.12

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. 149

• 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):

5 x y

1

7 b

EC500065

Fig. 150

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).

191

Maintenance

Clearances of the scrapers at the star-shaped conveyor:

3 c 5

4

16.13

2

2

1

Fig. 151

The scrapers (2) must be centrally aligned with the star-shaped conveyors (1).

The distance of the top scraper to the cover of the star-shaped conveyor (5) must be b=2.5 mm.

EC500092_2

The distance of the scrapers (2) to the star-shaped conveyor rotor (3) must be c = 0.5-2.0 mm.

To adjust the scrapers (2):

• Loosen the screws (4) a little.

• Move the scraper (2) so that the gap dimensions are observed.

• Tighten the screws (4).

Setting Infeed Sheets

1

2

4

3

EC500186

Fig. 152

The distance of the infeed sheet (2) to the cover sheet (1) must be a=0–4 mm.

Ensure that the gap is parallel and gets larger in the conveyance direction.

The distance of the infeed sheet (2) to the cover of the star configuration conveyor (3) must be b=0–2 mm.

To adjust the infeed sheet (2):

• Mount the header on the forage harvester and raise it by means of the forage harvester's lifting hydraulics.

• Shut down and safeguard the machine, see chapter Safety, "Shutting down and safeguarding the machine".

• Loosen the screws (4).

• Set the infeed sheet (2).

• Tighten the screws (4).

192

16.14

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

16.15

1

EC500061_2

Fig. 153

• Detach the row registration sensor (on central tip only) from the cable harness.

• Unscrew the cylinder screws (2) and remove the tip (1).

• Remove the bearing rings (3) from the tip (1) and insert them into the new tip. If necessary, renew worn bearing rings (3).

• Mount the new tip (1) with the cylinder screw (2) and secure with the locknut.

Note

If screw connections with self-locking nuts are loosened, the self-locking nuts must always be replaced before they are screwed.

Adjusting the tips

Fig. 154:

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.

193

Maintenance

4

16.15.1

16.15.2

16.15.3 a b

2

1

Fig. 155

Adjusting the side tips

The height of the side tips (a) can be adjusted with the screw (1).

To do this:

• Unscrew the counter nut (2)

• Adjust the height of the tips with the screw (1)

• Tighten the counter nut (2)

Adjusting the row tips

The height of the row tips (b) can be adjusted by moving the sliding piece (3)

To do this:

• Loosen the screw (4).

• Adjust the height of the row tip by moving the sliding piece (3).

• Tighten the screw (4).

Adjusting the central tip

1

2

3

EC500078

EC500107

Fig. 156

• Loosen the screw connections (2) slightly.

• Adjust the central tip (1) so that the lower edge of the central tip is approximately x = 30...50 mm below the lower edges of the other tips.

• Tighten the screw connections (2).

194

16.16

Maintenance

Removing and Installing Guide Bracket at Tip Retainer

For use in lodged maize, it may be helpful to dismount the guide brackets (1, 2, 3, 4). This improves the crop flow to the forage harvester.

The guide bracket (4) is supplied loose and can be attached if necessary.

1 2 3 4 2 4

3

5

EC500156_2

Fig. 157

The two inner row tips of each lateral frame are fitted with split guide brackets (2, 3, 4), the other rows feature single guide brackets (1).

Removing upper guide bracket (2)

• Unscrew the screws (5) and remove the upper guide bracket (2) and the lower guide bracket (3) upwards.

• Reinstall the lower guide bracket (3) by using screws which are 15 mm shorter.

Removing upper guide bracket (2) and lower guide bracket (3)

• Unscrew the screws (5) and remove the upper guide bracket (2) and the lower guide bracket (3) upwards.

Installing guide bracket

Installation is in reverse order to removal.

195

Maintenance

16.17 Converting Tip Retainer for Special Row Distances

To ensure that the maize header achieves an optimum collection result even with special row spacings (e.g. 70 cm row spacing), the outer row tips can be mounted 125 mm closer to the centre of the machine. The altered position of the row tip means that the cutter blades in this area must also be adjusted.

3 4

2

5 6 7

1

8

EC500094 EC500093

8 5 6 7

EC500095

Fig. 158

To convert the row tip from the original position (1) to the position for special row spacings (2):

• Remove the cover sheet (3).

• Dismount the outer row tip (4).

• Dismount the blades (5, 6, 7, 8).

• Mount the three outer blades (5, 6, 7) respectively by 125 mm towards the middle of the machine.

• Mount the blade (8) onto the space vacated by blade (5).

• When mounting the blades, make sure that no abutting edges are formed; if necessary, use distance sheets to compensate.

• Mount the outer row tip (4) in the position for special row spacing.

• Mount the cover sheet (3) on the screwing points vacated at the original position.

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.

196

16.18

Maintenance

Releasing star ratchet clutch at the universal shaft

Use the following procedure if a star ratchet clutch on the double joint is actuated at overload during the work process:

• Immediately switch off the header drive of the forage harvester; see operating instructions of the forage harvester.

• Shut down and safeguard the machine, see Safety chapter, "Shutting down and safeguarding the machine".

• Remove the crop blockage.

• When you switch on the header drive of the forage harvester, ensure that the star ratchet clutch is not actuated again.

197

Maintenance

16.19

16.19.1

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

1

2

EC500063

Fig. 159:

• 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).

198

Changing the outer bow blade

1

Maintenance

2

EC500066_1

Fig. 160

• 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

Fig. 161

• 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).

EC500067_1

Note

Use a “high-strength” screw locking agent (for example Loctite).

199

Maintenance

16.19.2 Changing the cutting blades

Note

When replacing, observe the right/left cutting direction!

1

3 4

2

6

4

4

5

EC500068_4

Fig. 162

• Reverse the machine to move the cutting blade (4) to be changed into the straight section at the front.

• Remove the screws (2) and take off the cover (1) of the cutting blade (4) you intend to change.

• To remove the cutting blade (4), dismount the inner screw (3).

• Reverse the machine to turn the collector (6) until the cutting blade (4) you intend to change is in section (5).

200

1

Maintenance

1

2

3

4

EC500187

Fig. 163

• Drive the cutting blade (1) downwards out of the collar bushing and remove it towards downwards.

• Insert the new cutting blade from behind and drive it from below into the collar bushing.

• Reverse the machine to move the new cutting blade into the straight section at the front on the machine.

• Mount the inner screw (2).

• Mount the cover (3) using the screws (4).

Notice

Tightening torque of hexagon head screws M12 (2) with a strength of 10.9 = 110 Nm.

Tightening torque of hexagon head screws M8 (4) = 45 Nm.

201

Maintenance

16.19.3 Changing the scraper blade

1

16.20

2

Fig. 164:

• 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 the wear plates

For an overview of the tightening torques, see chapter Maintenance "Tightening Torques".

1

EC500097

Fig. 165

Notice

Check wear plates (1) on the right / left side sections every 100 operating hours or at latest after the season for correct fit and wear and, if required, correct or replace.

• Loosen the corresponding screw connection.

• Replace the wear plate.

• Tighten screws.

202

16.21

Maintenance

Checking/adjusting the distance between bottom guide roller and guide rail

The distance between the bottom guide roller and the guide rail can be used to adjust the contact pressure of the collector on the stepped blades.

Preparing checking bottom guide roller

1 4 2 1 3

4

Fig. 166:

• Loosen the quarter turn fasteners (2) and open the flap (1).

• Dismount the collector covers (4) to the left and right of the screw (3).

Checking the distance between bottom guide roller and guide rail

EC500212

1 2

3

5

4

EC500213_1

Fig. 167:

• Move the collector (1) such that the rear screw (2) of a collector element is level with the screw (3).

• Check the distance "X" between bottom guide roll (5) and guide rail (4).

The setting is correct if the dimension is X=1±0.5 mm.

• Mount the collector cover back on and close the cover flap.

Adjust the distance if the dimension X is not 1±0.5 mm.

• Adjust the distance between bottom guide roll and guide rail.

203

Maintenance

Adjusting the distance between bottom guide roller and guide rail

1 2 1

3

2

3

3

Fig. 168:

• Loosen the screws (1).

• Insert a distance sheet (2) between wear rail (3) and upper frame.

• Tighten the screws (1).

EC500214

1

2

EC500217_1

Fig. 169

• Check the distance "X" between bottom guide roll (1) and guide rail (2).

The setting is correct if the dimension is X=1±0.5 mm.

• Mount the collector cover back on and close the cover flap.

Adjust the distance if the dimension X is not 1±0.5 mm.

• Adjust the distance between bottom guide roll and guide rail again.

204

16.22 Check hydraulic hoses

250 BAR 43/2010

Maintenance

16.23

EFL000026

250 BAR 43/2010

Fig. 170

Hydraulic hoses are subject to natural ageing. This limits their service life. The recommended service life is 6 years, including a maximum storage time of 2 years. The date of manufacture is printed on the hydraulic hoses. When checking hydraulic hoses, the state-specific conditions

(e.g., BGVU) must be observed.

Perform a visual inspection

• Visually inspect all hydraulic hoses for damage and leaks and have them replaced by an authorised specialist if necessary.

Maintaining and checking the tyres (for the version with "transport chassis")

Checking tyres visually

• Check tyres for cuts and breaks visually.

If there are cuts or breaks in the tyres, have the tyres repaired or replaced by a KRONE service partner.

The maintenance intervals for visual inspection of the tyres can be found in the chapter on

Maintenance "Maintenance table".

Retightening wheel nuts

• Tighten the wheel nuts crosswise with a torque wrench, tightening torque=245 Nm.

Maintenance intervals for retightening the wheel nuts, see chapter on Maintenance

"Maintenance table"

Checking/adapting the tyre pressure

• Check the tyre pressure, see the chapter on Technical Data "Tyre table".

If the tyre pressure is too high, deflate air.

If the tyre pressure is too low, increase the tyre pressure.

Check the maintenance intervals for tyre pressure, see the chapter on Maintenance

"Maintenance table"

205

Maintenance – lubrication

16.24 Adjusting the tip retainer EC 600-2, 750-2 for 38" row spacing

To ensure that the maize header also achieves an optimum collection result at row spacings of

38", the second row tip from the inside on the EasyCollect 600-2 and 750-2 can be mounted

270 mm closer to the centre of the machine.

2 1

EC500098

Fig. 171

To convert the row tip, the wear plate in this area must be separated and the guide bracket for the row tip must be shortened.

5 8 6 9

4

X

3

10

EC500099

12 11

7

EC500100

X

17

206

EC500101 EC500102

Fig. 172

To convert the row tip from the original position (1) to the position for the 38" row spacing (2):

• Remove the cover sheet (3).

• Dismount the second row tip (4) from the inside.

• Dismount the wear plate (5) and separate the points (6) identified by notches.

• Dispose of the waste piece (7).

• Re-mount the wear plate, which now consists of two parts (8, 9).

• Shorten the guide bracket (10) of the dismounted row tip by the dimension X = 270 mm.

• Mount the dismounted row tips (11) in the position for 38" row spacings.

• Mount the cover sheet (12) on the screwing points vacated at the original position.

Maintenance – lubrication

17.1

Maintenance – lubrication

WARNING!

Risk of injury due to non-compliance with relevant safety notices

If the relevant safety notices are not observed, persons may get seriously injured or killed.

• To avoid accidents, the basic safety notices must have been read and followed, see chapter Safety, "Basic safety notices".

WARNING!

Risk of injury due to non-observance of the safety routines

Non-observance of the safety routines bears the risk of serious or fatal injuries.

• To avoid accidents, the safety routines must be read and followed, see chapter Safety,

"Safety routines".

Special Safety Instructions

Warning!

– When performing repair, maintenance or cleaning work on the machine, or in the case of technical intervention, drive elements may start moving.

As a result, people may be seriously or fatally injured.

• Switch the drive off and wait until all machine parts have come to a standstill and completely cooled down.

• Switch off the engine of forage harvester, pull off the ignition key and take it with you.

• Secure the forage harvester against unexpected start-up and rolling away.

• Switch off the PTO shaft and disconnect it.

• When working under the machine or on the raised machine, always make sure that it is securely supported. Close the stop cock at the forage harvester!

• Do not perform any work on the hydraulic system unless it is depressurised. Hydraulic liquid escaping under high pressure can penetrate through the skin and cause severe injuries.

• Avoid skin contact with oils, greases, cleaning agents and solvents.

• In the event of injuries or burns caused by oils, cleaning agents or solvents, contact a physician immediately.

• All other safety notices must also be followed to avoid injuries and accidents.

• After the repair, maintenance, cleaning work or technical modifications are completed, mount all protective covers and safety devices properly again.

207

Maintenance – lubrication

The information on maintenance intervals is based on average load of the machine. In case of an increased load and under extreme working conditions, the time periods must be reduced.

The types of lubrication are marked by means of icons in the lubrication chart, refer to table.

Type of lubrication

Lubricant Note

Greasing Multi-purpose grease – Apply two strokes of lubricating grease from the grease gun per grease nipple.

– Remove excess lubricating grease at the grease nipple.

Lubrication Multi-purpose grease

Oiling

– Remove old lubricating grease.

– Apply a thin layer of new lubricating grease by means of a brush or spray can.

– Remove excess lubricating grease.

– Distribute the oil evenly. Unless otherwise prescribed, use oils based on vegetable matter.

208

17.2

Maintenance – lubrication

Lubrication Chart

• The lubrication points mentioned below must be lubricated according to the operating hours indicated.

50 h

50 h 50 h

50 h

250 h

250 h

50 h 250 h

50 h

250 h

50 h

Fig. 173:

250 h

EC500023_3

209

Maintenance – lubrication

50 h

250 h 50 h

Fig. 174:

50 h

50 h

50 h

EC500022_5

210

Claas and John Deere

250 h

Maintenance – lubrication

250 h

Fig. 175

EC500130_1

211

Maintenance – lubrication

John Deere series 8000 and 9000

50 h

EC500225

212

"Transport chassis" version

Maintenance – lubrication

50 h

EC500189

Fig. 176

213

Placing in Storage

18 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.

214

19

19.1

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.

215

Before the Start of the New Season

19.2 Test run.

Danger! - Testing the machine after repair, maintenance or cleaning work or after technical intervention.

Effect: Danger to life or serious injuries

• Machine must be in the working position

• Do not switch on the drives until the machine is at cutting height and you are sure that there are no people, animals or objects in the danger zone.

• Start a test run of the machine from the driver’s seat only.

• Lubricate the machine completely. This will remove any condensation water which may have collected in the bearings.

• Check the oil level in the gearboxes; top up if necessary.

• Check all screws for tight seat; retighten if necessary.

• Check all electrical connection cables and the lighting; repair or replace if necessary.

• Check the entire setting of the machine and correct if required.

• Re-read the operating instructions thoroughly.

216

20

20.1

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.

217

21 Index

A

Activating bearing pressure control of FP machines ...................................................... 120

Adapting Star-shaped Conveyor Height to Maize

Crop .............................................................. 178 adapting the machine to the claas forage harvester, type 493 and up ............................. 59

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ........... 68

Adapting the machine to the John Deere forage harvester of the 6000 and 7000 series ........... 96

Adapting the machine to the John Deere forage harvester of the 8000 series and 9000 series with header quick coupling ............................. 73

Adapting the machine to the New Holland forage harvester ......................................................... 81

Additional equipment and spare parts ................ 18

Adjusting the central tip .................................... 205

Adjusting the collector pretension ............. 199, 200

Adjusting the crop press roller .......................... 176 adjusting the machine to the john deere forage harvester of the series 8000 and 9000 with universal shaft ................................................. 70 adjusting the oscillation of the header .............. 179

Adjusting the tip retainer EC 600-2, 750-2 for 38

...................................................................... 217

Adjusting the tips .............................................. 204

Aligning the coupling disc ............................. 61, 74

Approved adaptations ......................................... 51

Attaching the safety signs and information signs42

Attaching the transport chassis ........................ 115

B

Ballasting of forage harvester ............................. 57

Basic safety instructions ..................................... 16

Before the Start of the New Season ................. 226

Behaviour in hazardous situations and when accidents occur ............................................... 28

Blade Changing ................................................ 209

C

Changing the cutting blades ............................. 211

Changing the tips .............................................. 204

Check hydraulic hoses...................................... 216

Checking/adjusting the distance between bottom guide roller and guide rail ............................. 214

Checks before starting up the machine for the first time ..................................................... 58, 66, 80

Children in danger .............................................. 17

Collector Gearbox ............................................. 194

218

Connecting ....................................... 155, 158, 163

Connecting drive ................................ 98, 101, 108

Connecting Drive Type 491, Type 492 .............. 90

Connecting hydraulics and electrics ... 92, 99, 103,

109

Connecting operation panel ............................... 86

Connecting road travel lighting ........................ 118

Connecting the drive, type 493 and up .............. 91

Consumables ............................................... 25, 56

Contact for KRONE NORTHAMERICA ....... 42, 49

Conversion table ................................................ 13

Converting Tip Retainer for Special Row

Distances ..................................................... 207

Coupling the machine safely .............................. 17

D

Danger zones ..................................................... 20

Dangers associated with certain activities

Work on the machine ..................................... 27

Dangers associated with the operational environment ................................................... 25

Detaching the machine .................................... 151

Direction Information ............................................ 9

Directories and References ................................. 9

Disconnecting header ...................................... 161

Disconnecting hydraulics and electrics ... 154, 157,

160, 162

Dismantling the machine in case of adaptation to

Claas forage harvester......................... 154, 162

Dismantling the machine in case of adaptation to

John Deere forage harvester of 6000 and 7000 series ........................................................... 157

Disposal of the machine .................................. 228

Driving and Transport ...................................... 111

F

Field mode on slopes ....................................... 131

From transport into working position ................ 126

Further applicable documents ............................. 8

H

How to use this document ................................... 9

Hydraulics ........................................................ 189

I

Identification Plate .............................................. 48

Importance of the operating instructions............ 16

Information Required for Questions and Orders 48

Initial commissioning of transport chassis (for

"transport chassis" version) ........................... 85

Initial operation - Claas ...................................... 58

Initial operation – John Deere ............................. 66

Initial operation – New Holland ........................... 80

Input gearbox .................................................... 190

Intended use ....................................................... 14

Intermediate gearbox ........................................ 196

K

Keeping safety devices functional ...................... 22

L

Lifting the machine ............................................ 125

Location and meaning of the information signs on the machine .................................................... 40

Location of the safety signs on the machine ...... 32

Lubricating grease .............................................. 56

Lubrication Chart .............................................. 220

M

Machine overview ............................................... 43

Main gearbox .................................................... 193

Maintenance ..................................................... 181

Maintenance - lubrication ................................. 218

Maintenance table ............................................ 183

Means of representation ..................................... 10

Notes with information and recommendations 12

Warning signs ................................................. 12

Means of Representation

Figures .............................................................. 9

Metric Thread Screws with Control Thread ...... 185

Metric Thread Screws with Countersunk Head and Hexagonal Socket .................................. 186

Metric Thread Screws with Fine Thread ........... 186

Mounting console support ................................ 166

Mounting on John Deere forage harvester of 8000 series and 9000 series .................................. 101

Mounting side guards ....................................... 167

O

Oils ...................................................................... 56

Operating active ground contour ...................... 141

Operating input gearbox (Claas) ...................... 134

Operating row detection.................................... 138

Operating the main gearbox (Claas, John Deere series 6000 and 7000) .................................. 133

Operation .......................................................... 126

Operational safety: Technically perfect condition

........................................................................ 19

Ordering additional safety signs and information signs ................................................................ 42

Overload protection ............................................ 50

P

Parking the machine safely ................................ 24

Personal protective equipment .......................... 23

Personnel qualification ....................................... 16

Placing in Storage ............................................ 225

Preparing the header for mounting the transport chassis ........................................................... 85

Preparing the machine for road travel ............. 113

Purpose of Use .................................................. 14

Putting header down ........................................ 169

R

Reasonably foreseeable misuse ........................ 15

Releasing star ratchet clutch at the universal shaft

..................................................................... 208

Removing and Installing Guide Bracke at Tip

Retainer ....................................................... 206

Removing the machine and storing it with supports ....................................................... 164 removing the machine with adaptation to john deere forage harvesters of the series 8000 and 9000 ...................................................... 160

Removing the transport chassis ...................... 121

Re-Ordering this Document ................................. 8

Replacing the wear plates ............................... 213

Road travel

Preparing machine ....................................... 113

Roller Gearbox ................................................. 198

S

Safely checking the oil level and changing the oil and filter element ........................................... 30

Safety ................................................................. 14

Safety routines ................................................... 29 safety sign on the machine ................................ 23

Scope of Document ........................................... 10

Service life of the machine ................................. 15

Setting Holding-Down Device Roller ................ 176

Setting Infeed Sheets ...................................... 203

Setting rotational speed of the maize header

(John Deere series 6000 and 7000) ............ 136

Setting rotational speed of the maize header

(John Deere series 8000 and 9000) ............ 137

Setting rotational speed of the maize header

(New Holland) .............................................. 137

Setting the collector tensioning function .......... 201

Setting the holder for the catch hook ................. 71

Setting the holder for the locking pins................ 68

Setting the lateral supports at rear ................... 168

Setting the rotational speed of the maize header

(Claas) ......................................................... 135

Setting the tubular bar in terms of its inclination

(EasyCollect 600-2 FP, 450-2 FP) ............... 174

Setting the tubular bar in terms of its inclination

(EasyCollect 600-2 FP, 750-2 FP) ............... 172

219

Setting the Tubular Bars ................................... 171

Settings ............................................................. 170

Shutting down and safeguarding the machine ... 29

Sources of danger on the machine ..................... 26

Spare Parts ....................................................... 182

Start-up - CLAAS ................................................ 87

Start-up – John Deere ........................................ 94

Structural changes to the machine ..................... 18

Supporting lifted machine and machine parts securely .......................................................... 29

Switching from working position to transport position.......................................................... 146

Switching off the machine ................................. 123

T

Target group of this document .............................. 8

Technical data .................................................... 54

Term ..................................................................... 9

Test run ............................................................ 227

Test run ............................................................ 182

Tightening torques ........................................... 185

Tightening Torques for Locking Screws and Bleed

Valves on the Gearboxes ............................ 188

Traffic safety ...................................................... 24

U

Using the Machine for Work ............................ 131

Using the transport chassis ............................. 119

Using the transport chassis (for the version .... 114

W

Workstations on the Machine ............................ 18

220

Maschinenfabrik

Bernard Krone GmbH & Co. KG

Heinrich-Krone-Straße 10, D-48480 Spelle

Postfach 11 63, D-48478 Spelle

Phone +49 (0) 59 77/935-0

Fax +49 (0) 59 77/935-339

Internet: http://www.krone.de

eMail: [email protected]

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Key Features

  • Working widths: 4.5m, 6m, 7.5m
  • Floating cutter bar for ground contour following
  • Stalk guides for precise guidance
  • Hydraulic header lift and tilt
  • Integrated knife sharpener
  • Grain saving system to minimize grain loss
  • Optional row-independent header drive for harvesting lodged crops

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Frequently Answers and Questions

What are the working widths available for the Krone BA EasyCollect?
4.5m, 6m, and 7.5m
Does the header have a floating cutter bar?
Yes, for optimal ground contour following
Is an integrated knife sharpener included?
Yes, for convenient on-the-go sharpening
Can the header handle lodged crops?
Yes, with the optional row-independent header drive

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