Krone BA BiG M 420 Operating instructions

Original operating instructions

Self-propelled High-Performance

Mower-Conditioner

BiG M 420

(from serial no.: 935 157)

Order no.: 150 000 301 02 us

21.10.2015

Table of Contents

2

Pos: 1 /Layout M odule /Inhalts verzeichnis @ 0\mod_1196861 555655_78.doc x @ 15165 @ 1 @ 1

1 Table of Contents

1 Table of Contents ................................................................................................................................... 2

1.1 Validity .............................................................................................................................................. 13

1.2 Re-Ordering ...................................................................................................................................... 13

1.3 Information on Direction ................................................................................................................... 13

1.4 Representation and Utilization of Warning Notes ............................................................................ 13

1.5 Identification of the hazard warnings................................................................................................ 13

2 Safety ..................................................................................................................................................... 14

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

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

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

2.3.1 Personnel Qualification and Training ........................................................................................ 15

2.3.2 Dangers in Case of Non-compliance with the Safety Instructions ............................................ 15

2.3.3 Safety-conscious work practices ............................................................................................... 15

2.4 Safety and Accident Prevention Regulations ................................................................................... 16

2.5 Conveying persons, guides, operating personnel ............................................................................ 17

2.6 Self-propelled working machine ....................................................................................................... 17

2.7 Autopilot ........................................................................................................................................... 18

2.8 Implements ....................................................................................................................................... 19

2.9 Hydraulic system .............................................................................................................................. 19

2.10 Battery .............................................................................................................................................. 20

2.11 Cooling system ................................................................................................................................. 20

2.12 Tyres................................................................................................................................................. 20

2.13 Emergency exit ................................................................................................................................. 20

2.14 Working in the vicinity of power transmission lines .......................................................................... 21

2.15 Fire preventions ................................................................................................................................ 21

2.16 Maintenance ..................................................................................................................................... 22

2.17 Telephone and radio sets ................................................................................................................. 22

2.17.1 Wheel chocks ............................................................................................................................ 22

2.17.2 Main battery switch ................................................................................................................... 23

3 Machine Description ............................................................................................................................ 24

3.1 Variants for Machine Equipment ...................................................................................................... 24

3.2 Machine overview ............................................................................................................................. 24

3.3 Identification Plate ............................................................................................................................ 25

3.4 Information Required for Questions and Orders .............................................................................. 25

3.4.1 Contact ...................................................................................................................................... 26

4 Safety ..................................................................................................................................................... 27

4.1 Introduction ....................................................................................................................................... 27

4.2 Position of the Adhesive Safety Stickers on the Machine ................................................................ 28

4.2.1 Basic machine „front -/ rear view“ ............................................................................................. 28

4.2.2 Basic machine „left and right side hand of machine” ................................................................ 30

4.2.3 Lateral mowing unit left / right ................................................................................................... 32

4.2.4 Front mowing unit ...................................................................................................................... 36

5 Technical Data of the Machine ............................................................................................................ 40

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

5.1.1 Technical Data Air Conditioning System................................................................................... 42

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5.1.2 Refrigerant data sheet R 134a (excerpt) ................................................................................... 42

5.2 Technical Data of Electrical System ................................................................................................. 42

5.3 Consumables ................................................................................................................................... 43

5.4 Lubricants ......................................................................................................................................... 43

5.4.1 Central Lubrication System, NLGI Class 2 ............................................................................... 44

6 Cabin ...................................................................................................................................................... 45

6.1 Ladder to driver's cabin .................................................................................................................... 45

6.2 Opening the cabin door .................................................................................................................... 46

6.3 Operators controls ............................................................................................................................ 47

6.3.1 Overview ................................................................................................................................... 47

6.4 Air comfort seat ................................................................................................................................ 48

6.4.1 Setting the left armrest .............................................................................................................. 50

6.4.2 Right armrest ............................................................................................................................. 50

6.4.3 Drawer for first-aid kit/operating instructions............................................................................. 51

6.5 Guide's seat...................................................................................................................................... 52

6.5.1 Cooler ........................................................................................................................................ 52

6.5.2 Emergency Exit ......................................................................................................................... 53

6.5.3 Engine diagnostics plug (Service Tool Connector) ................................................................... 54

6.6 Steering Column and Foot Pedals ................................................................................................... 55

6.6.1 Steering Column Adjustment .................................................................................................... 56

6.6.2 Horn........................................................................................................................................... 57

6.6.3 Flashing Light Switch ................................................................................................................ 57

6.6.4 Full Beam .................................................................................................................................. 58

6.6.5 Headlamp Flasher ..................................................................................................................... 58

6.6.6 Using the operating brake ......................................................................................................... 59

6.7 Switch Group Roof Panel ................................................................................................................. 60

6.8 Lighting ............................................................................................................................................. 61

6.8.1 Overview ................................................................................................................................... 61

6.8.2 Indicator, hazard warning flasher and brake light ..................................................................... 62

6.8.2.1 Switching on the indicator .................................................................................................. 62

6.8.2.2 Brake light .......................................................................................................................... 62

6.8.2.3 Switching on the hazard warning flasher ........................................................................... 62

6.8.3 Side light/dipped beam.............................................................................................................. 63

6.8.3.1 Switching on the parking light ............................................................................................ 63

6.8.3.2 Switching on the dipped beam ........................................................................................... 63

6.8.4 Working floodlights .................................................................................................................... 64

6.8.4.1 Working floodlights Cab ..................................................................................................... 65

6.8.4.2 Working floodlight Bottom front .......................................................................................... 65

6.8.4.3 Working floodlights "down the side and at the right/left mowing units" ............................. 66

6.8.4.4 Working floodlight rear ....................................................................................................... 66

6.8.5 Allround lights (optional)............................................................................................................ 67

6.8.6 Interior Lighting / Spotlight ........................................................................................................ 68

6.8.7 Additional Spotlight ................................................................................................................... 69

6.9 Outside mirrors ................................................................................................................................. 70

6.9.1 Left Outside Mirror .................................................................................................................... 70

6.9.2 Right outside mirror and anti-collision mirror ............................................................................ 71

6.9.2.1 Setting the right outside mirror ........................................................................................... 71

6.9.2.2 Setting the anti-collision mirror .......................................................................................... 71

6.10 Inside mirror ..................................................................................................................................... 72

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6.11 Sun blind .......................................................................................................................................... 72

6.12 Windshield wipers ............................................................................................................................ 73

6.13 Washer system – windshield ............................................................................................................ 73

6.14 Switch Panel ..................................................................................................................................... 74

6.15 Panel Switch ..................................................................................................................................... 74

6.15.1 Actuating release switches ....................................................................................................... 75

6.15.2 Release switch – road/field ....................................................................................................... 76

6.15.3 Autopilot release switch / - optional .......................................................................................... 77

6.15.4 Release switch - holding brake ................................................................................................. 78

6.15.5 Release switch travelling gear .................................................................................................. 79

6.15.6 Axle separation key ................................................................................................................... 80

6.16 Indicator Lamps ................................................................................................................................ 82

6.16.1 Charge Indicator Lamp.............................................................................................................. 82

6.16.2 Ignition lock ............................................................................................................................... 84

6.16.3 Cigarette lighter / 12-V socket ................................................................................................... 85

6.17 Diagnostics Socket (ISO-Bus) .......................................................................................................... 85

6.17.1 Diagnostics Socket / USB Connection ...................................................................................... 86

6.18 Multi-Function Lever ......................................................................................................................... 88

6.18.1 Multi-Function Lever (Continued) .............................................................................................. 90

6.18.1.1 Driving ................................................................................................................................ 90

6.19 Klimatronik / heating ......................................................................................................................... 91

6.19.1 Control and display elements .................................................................................................... 91

6.19.2 Operation .................................................................................................................................. 93

6.19.3 Switching on the System ........................................................................................................... 93

6.19.4 Setting the Desired Cab Temperature ...................................................................................... 93

6.19.5 Switch air conditioning On / Off ................................................................................................. 94

6.19.6 Switching REHEAT Mode On/Off ............................................................................................. 95

6.19.7 Manual setting of evaporator fan speed .................................................................................... 96

6.19.8 Switching the Temperature Display to ° Fahrenheit ................................................................. 97

6.19.9 Showing Faults in the Display ................................................................................................... 97

6.20 Adjustable Fan Nozzles ................................................................................................................... 99

6.21 Radio ................................................................................................................................................ 99

7 Info centre "EasyTouch" ................................................................................................................... 100

7.1.1 Overview ................................................................................................................................. 100

7.2 Information Section ........................................................................................................................ 102

7.2.1 Motor Data (II) Information Section ......................................................................................... 104

7.2.2 Information section of the travelling gear data (III) ................................................................. 105

7.2.3 Information section of settings (IV and V) ............................................................................... 106

7.2.4 Information Section Drive Information (VI) .............................................................................. 106

7.3 Quick Access Keys in the Basic Screen ........................................................................................ 107

7.3.1 Quick Access “Hydraulically Adjustable Cutting Height” (optional)......................................... 107

7.3.2 Quick access "Hydraulically adjustable lateral spring compensation" (ground pressure)

(optional) 109

7.3.3 Quick Access “Regenerating Diesel Particulate Filter” ........................................................... 111

7.3.4 Quick Access „Customer Data Counter“ ................................................................................. 112

7.3.5 Changing a customer record (1) or creating a new one ......................................................... 113

7.3.5.1 Switching the counter on or off ........................................................................................ 114

7.3.5.2 Selecting / Deleting the Area(s) of a Customer Counter ................................................. 115

7.3.5.3 Switching to General Counters (Machine Data Counters)............................................... 116

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7.3.6 Quick access "Hydraulic axle suspension" ............................................................................. 117

7.3.6.1 From the "Road travel" basic screen ............................................................................... 117

7.3.6.2 From the "Field mode" basic screen ................................................................................ 118

7.3.7 Quick access "Machine settings" ............................................................................................ 119

7.4 Menu level ...................................................................................................................................... 120

7.4.1 Bringing up a Menu Level ....................................................................................................... 124

7.5 Main menu 1 "Settings" .................................................................................................................. 125

7.6 Menu 1-1 "Parameters" .................................................................................................................. 126

7.6.1 Entering parameters ................................................................................................................ 127

7.7 Menu 1-2 „Machine Setting“ ........................................................................................................... 128

7.7.1 Menu 1-3 "Units" ..................................................................................................................... 133

7.7.2 Menu 1-4 "Language" ............................................................................................................. 134

7.7.3 Menu 1-5 "Display" .................................................................................................................. 135

7.7.4 Menu 1-5-1 "Contrast" ............................................................................................................. 136

7.7.5 Menu 1-5-2 Beeper ................................................................................................................. 137

7.7.6 Beeper limited by time ............................................................................................................. 138

7.7.7 Menu 1-5-4 Direction of Rotation ............................................................................................ 139

7.7.8 Menu 1-5-5 Configure status line ............................................................................................ 140

7.7.9 Menu 1-6 Date/time ................................................................................................................. 141

7.7.10 Menu 1-9 Owner's address ..................................................................................................... 142

7.8 Main Menu 2 Counters ................................................................................................................... 143

7.8.1 Machine Data Counter ............................................................................................................ 143

7.8.1.1 Deleting the Machine Data Counters (Sets 1 to 3) .......................................................... 144

7.8.2 Switching to Customer DataCounters ..................................................................................... 144

7.9 Main Menu 3 Maintenance ............................................................................................................. 145

7.9.1 Menu 3-1 "Calibration of cutting height" .................................................................................. 146

7.10 Calibrating Menu 3-3 ISOBUS Steering System ............................................................................ 148

7.10.1 Calibrating Steering Angle Sensor .......................................................................................... 149

7.11 Calibrating Steering (Valves) Automatically ................................................................................... 150

7.11.1 Calibrating Steering (Valves) Manually ................................................................................... 154

7.12 Setting the Steering Radius ........................................................................................................... 155

7.12.1 Menu 3-5 „Manual Mode“ ........................................................................................................ 156

7.12.2 Status display of general sensors (2) ...................................................................................... 158

7.12.3 Menu 3-6 Regenerating Diesel Particulate Filter .................................................................... 160

7.13 Main Menu 4 Service...................................................................................................................... 162

7.13.1 Menu 4-1 Diagnostics ............................................................................................................. 163

7.13.2 Display of Possible Faults for the Diagnostics ........................................................................ 166

7.13.3 Menu 4-1-1 Diagnostics of axle suspension ........................................................................... 167

7.13.4 Menu 4-1-3 Diagnostics of spring compensation .................................................................... 170

7.13.5 Menu 4-1-4 Diagnostics of cutting height................................................................................ 176

7.13.6 Menu 4-1-5 Diagnostics of hydraulic auger hood (optional) ................................................... 184

7.13.7 Menu 4-1-6 Sideshift diagnostics (optional) ............................................................................ 190

7.13.8 Menu 4-1-7 Diagnostics front guard flaps (optional) ............................................................... 195

7.13.9 Menu 4-1-9 ISOBUS Steering System .................................................................................... 200

7.13.10 Menu 4-1-10 Diagnostics Work ............................................................................................... 203

7.13.11 Menu 4-1-11 CAN-Bus ............................................................................................................ 214

7.13.12 Menu 4-1-12 Travelling gear ................................................................................................... 215

7.13.13 Menu 4-1-13 Electronics ......................................................................................................... 226

7.13.14 Menu 4-1-14 Diesel Engine .................................................................................................... 227

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7.13.15 Menu 4-1-15 Joystick .............................................................................................................. 230

7.13.16 Menu 4-1-16 Control Unit Console ......................................................................................... 232

7.13.17 Menu 4-1-17 Display ............................................................................................................... 235

7.14 Menu 4-2 Error list .......................................................................................................................... 236

7.15 Menu 4-3 "Service level" ................................................................................................................ 241

7.16 Menu 4-4 Information ..................................................................................................................... 242

7.16.1 Menu 4-4-1 Joystick ................................................................................................................ 243

7.16.2 Menu 4-4-2 Software ............................................................................................................... 244

7.16.3 Menu 4-4-3 Machine ............................................................................................................... 246

7.16.4 Menu 4-4-8 Display Software Packages ................................................................................. 247

7.17 Menu 5 Basic Screen ..................................................................................................................... 248

7.17.1 Error Messages ....................................................................................................................... 249

7.17.2 Information message ............................................................................................................... 250

8 Commissioning ................................................................................................................................... 251

8.1 Fitting the guard cloths ................................................................................................................... 251

8.2 Folding Down Lateral Mowing Units ............................................................................................... 251

8.2.1 Description of Installation ........................................................................................................ 253

8.2.2 Guard cloths (CRI with upper roller drive) ............................................................................... 254

8.2.3 Installing Rear Reflectors ........................................................................................................ 255

8.3 Installation of Cutter Blades ........................................................................................................... 255

8.4 Checking / Setting the Tyre Pressure ............................................................................................ 256

9 Start-up ................................................................................................................................................ 257

9.1 Check before Start-up .................................................................................................................... 257

9.2 Daily checks ................................................................................................................................... 257

9.2.1 On the Basic Machine ............................................................................................................. 258

9.2.2 On the Mowing Units ............................................................................................................... 258

10 Driving and Transport ........................................................................................................................ 259

10.1 Transport / Road Travel ................................................................................................................. 259

10.2 Preparation for transport/road travel .............................................................................................. 260

10.2.1 Folding Up the Guards ............................................................................................................ 260

10.2.2 Moving the Front Mowing Unit To Central Position (with Sideshift Option) ............................ 261

10.2.3 Error Message 1414 or 1415 .................................................................................................. 262

10.2.4 Disable the shut-off valve on the front outrigger ..................................................................... 263

10.2.5 Release switch – road/field ..................................................................................................... 263

10.2.6 Release switch travelling gear ................................................................................................ 264

10.3 Starting the engine ......................................................................................................................... 265

10.3.1 Killing the Engine .................................................................................................................... 267

10.3.2 Starting with an Auxiliary Battery ............................................................................................ 267

10.4 Starting to Drive .............................................................................................................................. 268

10.4.1 Setting the Acceleration Behaviour ......................................................................................... 269

10.4.2 General on Driving .................................................................................................................. 269

10.4.3 Overheating of Hydrostatic System ........................................................................................ 270

10.4.4 Driving Forwards ..................................................................................................................... 271

10.4.5 Reversing ................................................................................................................................ 272

10.5 Cruise Control ................................................................................................................................ 273

10.5.1 Saving the Speed for Cruise Control Mode ............................................................................ 273

10.5.2 Activating Cruise Control......................................................................................................... 274

10.5.3 Deactivating Cruise Control .................................................................................................... 274

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10.6 Stopping ......................................................................................................................................... 275

10.6.1 Stopping with the Multi-Function Lever ................................................................................... 275

10.6.2 Stopping with Foot Brakes ...................................................................................................... 276

10.7 Parking Brake ................................................................................................................................. 277

10.8 Switching Off the Engine ................................................................................................................ 278

10.9 Switch off the machine ................................................................................................................... 278

10.10 Towing ............................................................................................................................................ 279

10.10.1 Releasing the holding brake manually .................................................................................... 279

11 Operation – Mowing Units ................................................................................................................. 280

11.1 Intended use ................................................................................................................................... 280

11.2 Reasonably foreseeable misuse .................................................................................................... 280

11.3 Operation of Mowing Units ............................................................................................................. 281

11.4 Folding Down the Mowing Units ..................................................................................................... 282

11.4.1 Folding down Each Lateral Mowing Unit from Transport Position to Headland Position ....... 283

11.4.2 Folding down Lateral Mowing Units Simultaneously from Transport Position to Headland

Position 283

11.5 Lowering Mowing Units .................................................................................................................. 284

11.5.1 Lowering Front Mowing Unit from Headland Position to Working Position ............................ 284

11.5.2 Lowering Each Lateral Mowing Unit Individually from Headland Position to Working Position284

11.5.3 Lowering All Mowing Units from Headland Position to Working Position ............................... 285

11.6 Mowing Unit Drive .......................................................................................................................... 286

11.6.1 Switching On Or Switching Off Mowing Unit Drives ............................................................... 287

11.6.2 Switching On / Switching Off Mowing Unit Drive .................................................................... 287

11.6.3 Switching On / Switching Off Mowing Unit Drive .................................................................... 288

11.6.4 Switching On / Switching Off Mowing Unit Drive Front ........................................................... 289

11.6.5 Switching On / Switching Off All Mowing Unit Drives ............................................................. 290

11.7 Lifting the Mowing Units ................................................................................................................. 291

11.7.1 Lifting Front Mowing Unit from Working Position to Headland Position ................................. 291

11.7.2 Lifting Each Lateral Mowing Unit Individually from Working Position to Headland Position ... 292

11.7.3 Lifting All Mowing Units from Working Position to Headland Position .................................... 293

11.8 Folding up the Mowing Units .......................................................................................................... 294

11.8.1 Folding up Each Lateral Mowing Unit Individually from Headland Position to Transport

Position 295

11.8.2 Folding up the Lateral Mowing Units Simultaneously from Headland Position to Transport

Position 295

11.9 Mowing ........................................................................................................................................... 296

11.10 Game animal protection ................................................................................................................. 297

11.10.1 Moving the guards into the working position ........................................................................... 298

11.10.2 Mowing with Individual Mowing Units ..................................................................................... 298

11.10.3 Quick Stop ............................................................................................................................... 299

11.10.4 Fast Direction Change (Fast Reversing) ................................................................................. 299

11.10.5 Switching On/Off Axle Separation ........................................................................................... 300

12 Adjusting the mowing units .............................................................................................................. 301

12.1 Special Safety Instructions ............................................................................................................. 301

12.2 Adjusting the cutting height ............................................................................................................ 302

12.2.1 Front mowing unit .................................................................................................................... 302

12.2.2 Adjusting the Lifting Height ..................................................................................................... 303

12.2.2.1 Front mowing unit ............................................................................................................ 303

12.2.3 Adjusting the cutting height ..................................................................................................... 304

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12.2.3.1 Lateral Mowing Unit ......................................................................................................... 304

12.3 Adjusting Skids ............................................................................................................................... 306

12.4 Adjusting the Compensation Springs ............................................................................................. 306

12.4.1 Front mowing unit .................................................................................................................... 307

12.4.2 Lateral Mowing Unit ................................................................................................................ 308

12.5 Adjusting the Tedder Speed ........................................................................................................... 309

12.5.1 Lateral Mowing Unit ................................................................................................................ 309

12.5.2 Front mowing unit (CV) ........................................................................................................... 310

12.6 Adjusting the conditioner plate ....................................................................................................... 311

12.7 Adjusting the roller conditioner (optional extra/BiG M CRI) ........................................................... 312

12.7.1 Adjusting the roller distance .................................................................................................... 312

12.7.2 Adjusting the roller pressure ................................................................................................... 313

12.8 Setting of the Scraper on the Cross Conveyor (Optional).............................................................. 314

12.9 Adjusting the swath width ............................................................................................................... 315

12.9.1 Front mowing unit .................................................................................................................... 315

12.9.2 Lateral Mowing Unit ................................................................................................................ 316

12.10 Mounting/Dismounting BSS Swath Width for BiG M CV ................................................................ 317

12.10.1 Removing Extension on Cross Conveyor Left/Right ............................................................... 317

12.10.2 Dismounting Additional Scraper on Left/Right ........................................................................ 318

12.10.3 Mounting Extension on Cross Conveyor Left/Right ................................................................ 319

12.10.4 Mounting Additional Scraper on Left/Right ............................................................................. 320

12.11 Setting the Transverse Links on the Side Mounted Mowers.......................................................... 321

12.12 Deflector Plates .............................................................................................................................. 321

12.12.1 Front mowing unit .................................................................................................................... 321

13 Special Equipment – Mowing Units .................................................................................................. 322

13.1 Converting the Tedder Deflector Plate to an Auger-Type Cross Conveyor ................................... 322

13.1.1 Hooking Conditioner Baffle Sheet into Hoist ........................................................................... 323

13.1.2 Releasing the tension jacks .................................................................................................... 323

13.1.3 Removing the tedder deflector plate ....................................................................................... 324

13.1.4 Checking the Tines ................................................................................................................. 324

13.1.5 Removing the guard ................................................................................................................ 325

13.1.6 Mounting Auger-type Cross Conveyor .................................................................................... 326

13.1.7 Locking the tension jacks ........................................................................................................ 327

13.1.8 Tensioning the V-belt .............................................................................................................. 327

13.1.9 Installing the guard .................................................................................................................. 328

13.1.10 Connecting Speed Sensor and Hydraulics ............................................................................. 328

13.1.11 Relaying the Lubrication Lines ................................................................................................ 329

13.1.12 Installation Instructions – Bulge Bags for BiG M 400 / BiG M 420 with BSS .......................... 329

13.1.13 Switching on the auger monitoring mode................................................................................ 330

13.1.14 Conversion Auger-type Cross Conveyor to “Conditioner Baffle Sheet Unit” .......................... 331

13.2 Additional Equipment – Mulching Device ....................................................................................... 332

13.3 Removing Mowing Units ................................................................................................................ 333

13.3.1 Front mowing unit .................................................................................................................... 333

13.3.2 Removing of the compensation springs .................................................................................. 334

13.3.3 To remove the PTO shaft: ....................................................................................................... 335

13.3.4 Remove the Weiste Triangle ................................................................................................... 336

13.3.5 Attaching the Front Mowing Unit ............................................................................................. 337

13.3.6 Removing the Side Mowing Unit ............................................................................................. 338

13.3.7 Attaching the Lateral Mowing Unit .......................................................................................... 343

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13.3.8 The remainder of the installation is in reverse order to the removal procedure. .................... 344

14 Maintenance – Engine ........................................................................................................................ 345

14.1.1 Engine Overview ..................................................................................................................... 345

14.2 Maintenance Intervals .................................................................................................................... 345

14.3 Maintenance Table – Engine ......................................................................................................... 347

14.4 Contamination in the engine compartment .................................................................................... 349

14.5 Cleaning the Engine Compartment with Compressed Air.............................................................. 349

14.6 Engine oil level ............................................................................................................................... 350

14.6.1 Checking Engine Oil Level ...................................................................................................... 350

14.6.2 Topping up Engine Oil............................................................................................................. 350

14.6.3 Engine oil and filter replacement ............................................................................................. 350

14.7 Fuel filter/water separator .............................................................................................................. 351

14.7.1 Replacing the Fuel Pre-Filter .................................................................................................. 351

14.7.2 Emptying the Water Separator ................................................................................................ 351

14.8 Replacing the fuel filter insert ......................................................................................................... 352

14.9 Fuel................................................................................................................................................. 353

14.10 Tanks .............................................................................................................................................. 354

14.11 Venting the fuel system .................................................................................................................. 355

14.12 Engine Coolant ............................................................................................................................... 355

14.13 Engine coolant – checks and controls ............................................................................................ 356

14.14 Air filter ........................................................................................................................................... 357

14.14.1 Safety cartridge ....................................................................................................................... 358

15 Maintenance – Mowing Units ............................................................................................................ 359

15.1 Special Safety Instructions ............................................................................................................. 359

15.1.1 Test run ................................................................................................................................... 360

15.2 Spare Parts .................................................................................................................................... 360

15.3 Tool box .......................................................................................................................................... 360

15.4 Maintenance Table – Mowing Units ............................................................................................... 361

15.5 Tightening torques .......................................................................................................................... 362

15.5.1 Metric Thread Screws with Control Thread............................................................................. 362

15.5.2 Metric Thread Screws with Fine Thread ................................................................................. 363

15.5.3 Metric Thread Screws with Countersunk Head and Hexagonal Socket ................................. 363

15.5.4 Deviating Tightening Torques ................................................................................................. 364

15.6 Opening the Front Guard ............................................................................................................... 364

15.6.1 Lateral mowing unit left / right ................................................................................................. 364

15.6.2 Front mowing unit .................................................................................................................... 365

15.7 Cleaning the Tedder Housing ........................................................................................................ 366

15.8 Eliminating Blockages on the Cross Conveyor .............................................................................. 367

15.9 Shear pins on the conditioner ........................................................................................................ 368

15.10 Filling Quantities and Lubrication Designations for Gearboxes ..................................................... 369

15.10.1 Oil Level Check and Oil Change Intervals (Gearboxes) ......................................................... 369

15.11 Main gearbox .................................................................................................................................. 370

15.11.1 Lateral Mowing Unit ................................................................................................................ 370

15.12 Angular gearbox ............................................................................................................................. 372

15.12.1 Front Mowing Unit (CV+CRI) .................................................................................................. 372

15.13 Input gearbox ................................................................................................................................. 373

15.13.1 Front Mowing Unit (CV+CRI) .................................................................................................. 373

15.14 Speed gearbox ............................................................................................................................... 374

15.14.1 Front mowing unit (CV) ........................................................................................................... 374

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15.15 Angular gearbox ............................................................................................................................. 375

15.15.1 Bottom part .............................................................................................................................. 375

15.16 Gearbox for Top Roller Drive ......................................................................................................... 376

15.17 Oil level check and oil change on the cutter bar ............................................................................ 377

15.17.1 Front mowing unit .................................................................................................................... 377

15.17.2 Aligning the Cutter Bar ............................................................................................................ 377

15.17.3 Checking the oil level .............................................................................................................. 378

15.17.4 Oil change ............................................................................................................................... 379

15.18 Oil level check and oil change on the cutter bar ............................................................................ 380

15.18.1 Lateral Mowing Unit ................................................................................................................ 380

15.18.2 Checking the oil level .............................................................................................................. 380

15.18.3 Oil change ............................................................................................................................... 381

15.19 Checking the Cutter Blades and Blade Holder .............................................................................. 382

15.19.1 Cutter Blades .......................................................................................................................... 382

15.19.2 Blade screw connection .......................................................................................................... 383

15.19.3 Blade Quick-Fit Device............................................................................................................ 384

15.19.4 Checking the Material Thickness of the Retaining Bolts ......................................................... 384

15.19.4.1 Checking the material thickness of the retaining bolts .................................................... 385

15.19.5 Periodical Inspection of the Leaf Springs................................................................................ 386

15.19.6 Checking the Material Thickness of the Leaf Springs ............................................................. 386

15.19.6.1 Checking the material thickness of the leaf springs ........................................................ 387

15.19.7 Periodical Inspection of the Cutting Discs / Blade Drums ....................................................... 388

15.19.8 Abrasion Limit ......................................................................................................................... 389

15.20 Blade Changing on Cutting Discs .................................................................................................. 390

15.20.1 Blade Screw Connection ......................................................................................................... 391

15.20.2 Blade Quick-Fit Device............................................................................................................ 392

15.21 Replacing the linings ...................................................................................................................... 393

15.22 Rotary hub with shear protection ................................................................................................... 394

15.22.1 After Shearing Off ................................................................................................................... 395

15.22.2 Repairing the Sheared off Bearing Unit .................................................................................. 396

16 Maintenance – Basic Machine ........................................................................................................... 397

16.1 Brakes ............................................................................................................................................ 397

16.2 Hydraulic system ............................................................................................................................ 398

16.3 Maintenance - hydraulic system ..................................................................................................... 401

16.3.1 System Description Operating and Brake Hydraulics ............................................................. 401

16.3.2 Pumps ..................................................................................................................................... 401

16.3.3 Main block ............................................................................................................................... 402

16.3.4 Over-Pressure Valves ............................................................................................................. 403

16.3.5 Adjustable Throttles ................................................................................................................ 403

16.4 Hydraulic oil .................................................................................................................................... 404

16.5 Hydraulic oil level ........................................................................................................................... 405

16.6 Replacing the hydraulic oil filter ..................................................................................................... 406

16.7 High-pressure filter ......................................................................................................................... 407

16.8 Transfer gearbox ............................................................................................................................ 408

16.9 Air intake and distribution ............................................................................................................... 409

16.9.1 Changing / cleaning the fresh air filter .................................................................................... 410

16.9.2 Circulation filter ....................................................................................................................... 411

16.10 Windscreen washer system ........................................................................................................... 412

16.11 Cleaning the adjustment plate on the pre-separator ...................................................................... 413

Table of Contents

11

16.12 Position of the Sensors (Left Machine Side) .................................................................................. 414

16.13 Position of the Sensors (Right Machine Side) ............................................................................... 416

16.13.1 Adjusting the Sensors ............................................................................................................. 418

16.13.1.1 Namur sensor d = 12 mm ................................................................................................ 418

16.13.1.2 Namur Sensor d = 30 mm ................................................................................................ 418

16.14 Maintenance - air conditioning system and heating ....................................................................... 419

16.15 Special Safety Instructions ............................................................................................................. 419

16.15.1 Air conditioning components ................................................................................................... 419

16.15.2 Refrigerant .............................................................................................................................. 420

16.15.3 Manometric Switch .................................................................................................................. 420

16.15.4 Collector/drier .......................................................................................................................... 421

16.15.5 Checking Refrigerant Condition and Filling Quantity .............................................................. 422

16.16 Cleaning the Radiator and the Radiator Compartment .................................................................. 423

16.17 Belt drives ....................................................................................................................................... 424

16.17.1 Fan wheel drive ....................................................................................................................... 425

16.17.2 Outrigger arms ........................................................................................................................ 426

16.17.3 Drive of mowing unit ................................................................................................................ 428

16.17.4 Cross Conveyor Drive ............................................................................................................. 429

16.18 Tyres............................................................................................................................................... 430

16.19 Changing the Tyre Size .................................................................................................................. 430

16.19.1 Checking and maintaining tyres .............................................................................................. 431

16.19.2 Wheel mounting ...................................................................................................................... 432

16.19.3 Retightening the Attachment Bolts on the Outrigger .............................................................. 432

17 Maintenance – lubrication chart ....................................................................................................... 433

17.1 Lubricating the PTO shaft .............................................................................................................. 433

17.2 Lubricating the double joints on the main gearbox ........................................................................ 433

17.3 Lubrication Chart ............................................................................................................................ 434

18 Maintenance – electrical system ....................................................................................................... 435

18.1.1 Main battery switch ................................................................................................................. 435

18.2 Battery ............................................................................................................................................ 436

18.2.1 Servicing the battery ............................................................................................................... 436

18.2.2 Charging Batteries .................................................................................................................. 437

18.2.3 Removing and Installing Battery ............................................................................................. 439

18.3 Three-phase generator................................................................................................................... 441

18.4 Starter ............................................................................................................................................. 442

18.5 Control Units and Fuses ................................................................................................................. 443

18.5.1 Electronic-Control-Module (ECM) ........................................................................................... 444

18.5.2 Cabin relay circuit board ......................................................................................................... 444

18.5.3 Circuit Board Console ............................................................................................................. 446

18.5.4 Cab Circuit Board .................................................................................................................... 453

18.5.5 Circuit Board KRONE Machine Controller (KMC1) ................................................................. 457

19 Maintenance – Central Lubrication................................................................................................... 459

19.1 Overview ........................................................................................................................................ 460

19.2 Lubricant filling ............................................................................................................................... 464

19.3 Fill coupling .................................................................................................................................... 464

19.4 Lubricant ......................................................................................................................................... 465

19.5 Checking the fill level...................................................................................................................... 466

19.6 Change the Times of the Lubrication Interval ................................................................................ 467

Table of Contents

12

19.7 Troubleshooting .............................................................................................................................. 467

20 Placing in Storage .............................................................................................................................. 469

20.1 At the End of the Harvest Season .................................................................................................. 469

20.2 Engine area .................................................................................................................................... 469

20.3 Before the Start of the New Season ............................................................................................... 470

20.4 Friction clutch –ByPy ...................................................................................................................... 471

20.4.1 Venting the Friction Clutch on the PTO Shaft ......................................................................... 471

21 Disposal of the machine .................................................................................................................... 472

21.1 Disposal of the machine ................................................................................................................. 472

22 Appendix ............................................................................................................................................. 473

22.1 Error Messages .............................................................................................................................. 473

23 Index .................................................................................................................................................... 474

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Table of Contents

13

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1.1 Validity

The Operating Instructions apply to all Self-Propelled High Performance Mowing Conditioners

BiG M 420.

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1.2 Re-Ordering

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If this document should become wholly or partially unusable, you can request a replacement

document by stating the order number mentioned on the cover sheet.

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1.3 Information on Direction

Information on direction in this document such as front, rear, right and left always applies in the

direction of travel.

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1.4 Representation and Utilization of Warning Notes

Warning of dangers are highlighted in this document as warning notes and they are marked with

danger signs and signal words.

The warnings must be read completely and the measurements must be strictly adhered to in

order to avoid personal injury.

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1.5 Identification of the hazard warnings

Danger!

DANGER! - Type and source of the hazard!

Effect: Danger to life or serious injuries.

• Measures for hazard prevention

Warning !

WARNING! - Type and source of the hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention

Caution!

CAUTION! - Type and source of the hazard!

Effect: Property damage

• Measures for risk prevention.

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General function instructions are indicated as follows:

Note!

Note

Effect: Economic advantage of the machine

• Actions to be taken

Instructions which are attached to the machine need to be followed and kept fully legible.

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Safety

14

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2 Safety

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Ver

2.1 Intended use

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The self-propelled high-performance mower conditioner is a self-propelled work machine with

three disc mowers and integrated mower conditioners. The self-propelled high-performance

mower conditioner is intended for use in agriculture. The self-propelled high-performance

mower conditioner is used to mow various living grasses and legumes (from the initial stage to

the end of the photosynthetic process).

The three mowing units can be used individually or together, thereby making it possible to

adjust the working width as required. The integrated mower conditioners accelerate the drying

process of the mowed crop.

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Intended use also includes compliance with the operating, cleaning, maintenance and repair

conditions set by the manufacturer.

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2.2 Reasonably foreseeable misuse

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Any usage outside of intended use (as described above) constitutes non-intended use and

therefore represents misuse as defined by the Machinery Directive. The manufacturer shall not

be held liable for any resulting damages. The user alone shall be liable.

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Examples of such misuse are:

• Mowing undergrowth and bushes

• Mowing non-living plants such as straw or maize stalks

• Mowing woody or highly fibrous plants such as trees, cotton stalks or sugar cane

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Unauthorised modifications to the machine may have a negative effect on the machine

characteristics or safe and reliable use of the machine or may interfere with proper operation.

Unauthorised modifications shall therefore release the manufacturer of any liability for

consequential damage.

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2.3 Service life of the machine

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

the operating conditions.

– Permanent operational readiness as well as long service life of the machine can be

achieved by observing the instructions and notes of these operating instructions.

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

damage.

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

– After the machine has been used for five years, carry out full technical inspection of the

machine. According to the results of this inspection, a decision concerning the possibility of

reuse of the machine should be taken.

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

be replaced.

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Safety

15

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2.3.1 Personnel Qualification and Training

The machine may be used, maintained and repaired only by persons who are familiar with it

and have been instructed about the dangers connected with it. The operator must define areas

of responsibility and monitoring of personnel. Should personnel lack the required knowledge,

they must receive the required training and instruction. The operator must ensure that the

contents of these operating instructions have been fully understood by personnel.

Repair work not described in these operating instructions should only be performed by

authorised service centres.

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2.3.2 Dangers in Case of Non-compliance with the Safety Instructions

Failure to follow the safety instructions could result in personal injury and environmental

hazards as well as damage to the machine. If the safety instructions are not respected, this

could result in the forfeiture of any claims for damages.

Failure to follow the safety instructions could result, for example, in the following hazards:

• Endangering of persons due to not protected working areas.

• Breakdown of important machine functions

• Failure of prescribed methods for repair and maintenance

• Endangering of persons due to mechanical and chemical effects

• Damage to the environment due to leaking hydraulic oil

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2.3.3 Safety-conscious work practices

Always observe the safety instructions set out in these operating instructions, all existing

accident prevention rules and any internal work, operating and safety rules issued by the

operator.

The safety and accident prevention regulations of the responsible professional associations are

binding.

The safety instructions provided by the vehicle manufacturer should also be observed.

Observe the applicable traffic laws when using public roads.

Be prepared for emergencies. Keep the fire extinguisher and first aid box within reach. Keep

emergency numbers for doctors and fire brigade close to the telephone.

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Safety

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2.4 Safety and Accident Prevention Regulations

1 Please follow all generally applicable safety and accident prevention regulations in addition

to the safety instructions contained in these operating instructions!

2 The attached warning and safety signs provide important information for safe operation. Pay

attention to these for your own safety!

3 When using public roads, observe the respective traffic regulations!

4 Make sure that you are familiar with all equipment and controls as well as with their

functions before you begin working with the machine. It is too late to learn this when you are

using the machine for work!

5 The user should wear close fitting clothes. Avoid wearing loose or baggy clothing.

6 Keep the machine clean to prevent the danger of fire!

7 Before starting or moving the machine, make certain that nobody is in the vicinity of the

machine! (Watch for children!) Make sure that you have a clear view!

8 Attach implements correctly! Attach and secure implements to specified devices only!

9 When attaching or detaching implements, place the supporting devices in the correct

positions!

10 Observe permitted axle loads, total weight and transport dimensions!

11 Check and attach transport equipment, such as lighting, warning devices and any protective

equipment!

12 Actuating mechanisms (ropes, chains, linkage, etc.) for remotely operated devices must be

designed in such a way that, in whatever transport and working position, they cannot trigger

accidental movements.

13 Ensure that implements are in the prescribed condition for road travel and lock them in

place in accordance with the manufacturer's instructions!

14 Never leave the driver's seat while the vehicle is moving!

15 Always drive at the correct speed for the prevailing driving conditions! Avoid sudden

changes in direction when travelling uphill and downhill or across a gradient!

16 Hitched implements and ballast weights affect the driving, steering and braking response of

the machine. Make sure that you are able to brake and steer the machine as required!

17 Take into account the extension radius and/or inertia of an implement when turning corners!

18 Start up implements only when all safety devices have been attached and set in the

required position!

19 Keep safety equipment in good condition. Replace missing or damaged parts.

20 Keep clear of the working range of the machine at all times!

21 Never operate the hydraulic folding frames if anyone is inside the swivel range!

22 Parts operated by external power (e.g. hydraulically) can cause crushing and shearing

injuries!

23 Do not stand within the turning and swivel range of the implement!

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24 Before leaving the mower, lower the front mower onto the ground, firmly step on the parking

brake pedal. Switch off the engine and remove the ignition key!

25 No one should stand between the mower and the implement unless the vehicle has been

secured against rolling by means of the parking brake and/or wheel chocks!

26 Caution: When the front mower P.T.O shaft has been removed, the drive shaft at the front

of the machine continues to turn if the engine is running.

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Safety

17

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2.5 Conveying persons, guides, operating personnel

1 Only persons who are guiding the driver or directing the machine may be conveyed on the

guide's seat

2 Persons are not permitted to ride as passengers

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2.6 Self-propelled working machine

1The warning flashers and warning beacon must be used in accordance with local traffic

laws when using public highways.

2Switch on the lighting so that the vehicle can be easily recognised.

3The machine must not be taken into operation if the safety equipment is not functioning.

4Always check the machine for driving and operational safety before use.

5Hold the hand-grip firmly when climbing in and out of the mower.

6It is not permitted to transport people on the platform.

7The road safety switch must be in road position during road travel to ensure that all

hydraulic functions - except for the steering and brakes – are deactivated.

8Only drive the machine at the permitted speed.

9Implements must be in transport position and locked in accordance with the manufacturer's

instructions for road travel.

10If the engine is running in an enclosed space, divert the exhaust fumes and ensure

sufficient ventilation.

11When using starting fluid, avoid ignition sources and naked flames. Keep starting fluid clear

of batteries and electrical cables.

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Safety

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2.7 Autopilot

1Autopilot must only be used for its intended purpose. It must only be used in open fields, off

public and semi-public roads, away from open areas frequented by people and far away

from any persons that could be endangered. They must only be used for their intended

purpose: - Automatic guide of the machine by GPS (Global Positioning System).

2Before placing the autopilot in service, check the functionality of safety elements that can be

checked and make a visual inspection of all the components.

To do this, the user should proceed as follows:

• Check switching off of the autopilot when the steering wheel is moved and the seat

switch engages

• Check for proper operating condition - i.e. free of mechanical damages and leaks

3When autopilot is in operation, there must be on one within 50 m of the machine in any

direction.

4The operator is not permitted to leave the driver's cabin of the machine while autopilot is in

operation.

5While the autopilot is in operation, the driver must regularly check the direction in which the

machine is moving and its travel path to be able to take over manual control of the machine

immediately if obstructions or interruptions come up in the vehicle's path.

6After autopilot has been in operation and before leaving the field, autopilot must always be

switched off on the autopilot release switch on the console.

7Manipulating safety-related elements of the autopilot is prohibited, as is making changes to

the hydraulic, electrical or electronic components.

8The autopilot should only be installed by an authorised service centre.

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2.8 Implements

1 Caution! The flywheel will continue to rotate for some time even after the drive has been

disengaged! Keep away from the implement during this time. Do not work on the machine

until it has come to a standstill.

2 Cleaning, lubricating and adjusting the implements must be carried out only when the drive

is switched off, the engine switched off and the ignition key removed!

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2.9 Hydraulic system

1 The hydraulic system is pressurised!

2 When connecting hydraulic cylinders and engines, make sure that the hydraulic hoses are

connected correctly!

3 When connecting the hydraulic hoses to the mower-conditioner hydraulics, take care that

the hydraulic system is depressurised both on the tractor side and on the device side!

4 When functions are connected hydraulically between the mower-conditioner and the

accessory equipment, connecting parts should be identified so that faulty operation is

excluded! If the connectors are interchanged, the functions will be reversed (e.g.

raising/lowering) - Risk of accident!

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

The new hoses must fulfil the technical requirements set by the manufacturer of the

implement!

6 When searching for leaks, use suitable aids to avoid the risk of injury!

7 Liquids escaping under high pressure (hydraulic oil) can penetrate the skin and cause

serious injury! Seek medical help immediately should injuries occur! Danger of infection!

8 Before working on the hydraulic system, depressurise the system and switch off the engine!

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Safety

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2.10 Battery

1 Maintenance work on the batteries requires sufficient knowledge and the availability of

proper tools!

2 Keep naked flames, burning matches and spark sources clear of the battery; Risk of

explosion!

3 Never check the charging level of the battery by connecting the two poles with a metal

object. Use an acid tester or voltmeter.

4 Do not charge a frozen battery; Risk of explosion! Warm the battery to 16 °C beforehand.

5 Battery acid can cause severe injuries by burning your skin and eyes. For this reason, wear

suitable protective clothing.

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2.11 Cooling system

The heated cooling system is pressurised – Risk of burns! - For this reason, only remove the

radiator cap with the engine switched off and after the engine has been able to cool.

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2.12 Tyres

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1When working on the tyres, make sure that the implement is safely lowered and secured

against rolling (wheel chocks).

2Installing wheels and tyres requires adequate knowledge and suitable tools!

3Repair work on the tyres and wheels should be done by specially trained personnel using

appropriate installation tools only!

4Check tyre pressure regularly! Inflate the tyres to the recommended pressures!

5Check the wheel nuts periodically! Missing wheel nuts can result in a wheel falling off and

the machine tipping over.

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2.13 Emergency exit

The right hand side window in the cabin is designed for being an emergency exit. In case of an

emergency the cabin can be left over the emergency exit. To do this, the right hand side window

must be manually unlocked before opening.

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