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
16
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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
1The warning flashers and warning beacon must be used in accordance with local traffic
laws when using public highways.
2Switch on the lighting so that the vehicle can be easily recognised.
3The machine must not be taken into operation if the safety equipment is not functioning.
4Always check the machine for driving and operational safety before use.
5Hold the hand-grip firmly when climbing in and out of the mower.
6It is not permitted to transport people on the platform.
7The 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.
8Only drive the machine at the permitted speed.
9Implements must be in transport position and locked in accordance with the manufacturer's
instructions for road travel.
10If the engine is running in an enclosed space, divert the exhaust fumes and ensure
sufficient ventilation.
11When 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
1Autopilot 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).
2Before 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
3When autopilot is in operation, there must be on one within 50 m of the machine in any
direction.
4The operator is not permitted to leave the driver's cabin of the machine while autopilot is in
operation.
5While 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.
6After autopilot has been in operation and before leaving the field, autopilot must always be
switched off on the autopilot release switch on the console.
7Manipulating safety-related elements of the autopilot is prohibited, as is making changes to
the hydraulic, electrical or electronic components.
8The 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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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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1When working on the tyres, make sure that the implement is safely lowered and secured
against rolling (wheel chocks).
2Installing wheels and tyres requires adequate knowledge and suitable tools!
3Repair work on the tyres and wheels should be done by specially trained personnel using
appropriate installation tools only!
4Check tyre pressure regularly! Inflate the tyres to the recommended pressures!
5Check 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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