Krone BiG M 500 Operating instructions

O r i g i n a l o p e r a t i n g i n s t r u c t i o n s

Self-propelled High-Performance Mower-

Conditioner

BiG M 500

(from serial no.: 842 990)

Order no.: 150 000 136 01 en

29.03.2012

Table of Contents

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Pos: 1/ BA/Konformitäts erklärungen/Selb stfahrer/Neu ab 201 0/BiGM 500 @ 40\mod_ 1270542274512_78. doc @ 366815 @ @ 1

CV0

EC Declaration of Conformity

We Maschinenfabrik Bernard Krone GmbH

Heinrich-Krone-Str. 10, D-48480 Spelle

hereby declare as manufacturer of the product named below, on our sole responsibility,

that the

Machine: Self-Propelled High-Performance Mower-Conditioner

Type/types: BiG M 500

to which this declaration refers is in compliance with the relevant provisions of

EC Directive 2006/42/EC (Machinery) and EC Directive 2004/108/EC (EMC)

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

Spelle, 31.03.2011

Dr.-Ing. Josef Horstmann

(Managing Director, Design and Development)

Year of manufacture: Machine No.:

Pos: 2/ BA/Vorwort/Sehr ge ehrter Kunde @ 0\mod_11956263 00326_78.doc @ 905 @ @ 1

Dear customer,

You have now received the operating instructions for the KRONE

product which you have purchased.

These operating instructions contain important information for the

proper use and safe operation of the machine.

If these operating instructions should become wholly or partially

unusable, you can obtain replacement operating instructions for

your machine by stating the number given overleaf.

Pos: 3/ BA/-------- -------Seitenumbruch------- --------- @ 0\mod_1196175311 226_0.doc @ 4165 @ @ 1

Table of Contents

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Pos: 4/ BA/Inhaltsverzeich nis @ 0\mod_119686155565 5_78.doc @ 15165 @ 1@ 1

1 Table of Contents

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

2 Foreword ...............................................................................................................................................14

3 Introduction...........................................................................................................................................15

3.1 Validity ............................................................................................................................................. 15

3.2 Identification Plate ........................................................................................................................... 15

3.3 Information Required for Questions and Orders.............................................................................. 16

3.4 Intended use.................................................................................................................................... 16

3.5 Reasonably foreseeable misuse ..................................................................................................... 17

3.6 Machine overview............................................................................................................................ 18

3.7 Technical data ................................................................................................................................. 19

3.7.1 Technical Data / Vehicle.............................................................................................................. 19

3.7.2 Technical Data / Vehicle with Additional Axle (Optional)............................................................. 20

3.7.3 Technical data/CV mowing unit................................................................................................... 20

4 Safety.....................................................................................................................................................21

4.1 Introduction...................................................................................................................................... 21

4.2 Identifying Symbols in the Operating Instructions ........................................................................... 22

4.3 Identification of the hazard warnings............................................................................................... 22

4.3.1 Re-Ordering the Adhesive Safety and Information Labels.......................................................... 23

4.3.2 Affixing the Adhesive Safety and Information Labels.................................................................. 23

4.3.3 Contact......................................................................................................................................... 23

4.4 Position of the Adhesive Safety Stickers on the Machine............................................................... 24

4.4.1 Basic machine „left and right side hand of machine”................................................................... 24

4.4.2 Lateral mowing unit left / right...................................................................................................... 26

4.4.3 Front mowing unit ........................................................................................................................ 28

4.5 Position of the General Information Labels on the Machine............................................................ 30

4.5.1 Basic machine „front -/ rear view“................................................................................................ 30

4.5.2 Basic machine „left and right side hand of machine”................................................................... 32

4.5.3 Lateral mowing unit left / right...................................................................................................... 34

4.5.4 Front mowing unit ........................................................................................................................ 36

4.5.5 Personnel Qualification and Training Fehler! Textmarke nicht definiert...................................... 38

4.5.6 Dangers in Case of Non-compliance with the Safety Instructions............................................... 38

4.5.7 Safety-conscious work practices ................................................................................................. 38

4.6 Safety Instructions and Accident Prevention Regulations............................................................... 39

4.7 Conveying persons, guides, operating personnel ........................................................................... 40

4.8 Self-propelled working machine ...................................................................................................... 40

4.9 Autopilot........................................................................................................................................... 41

4.10 Implements ...................................................................................................................................... 42

4.11 Hydraulic system ............................................................................................................................. 42

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4.12 Battery.............................................................................................................................................. 43

4.13 Cooling system ................................................................................................................................ 43

4.14 Tyres................................................................................................................................................ 43

4.15 Emergency exit................................................................................................................................ 43

4.16 Working in the vicinity of power transmission lines ......................................................................... 44

4.17 Fire preventions............................................................................................................................... 44

4.18 Maintenance .................................................................................................................................... 45

4.19 Telephone and radio sets................................................................................................................ 45

4.19.1 Wheel chocks........................................................................................................................... 46

4.19.2 Main battery switch.................................................................................................................. 47

5 Cabin......................................................................................................................................................48

5.1 Ladder to driver's cab ...................................................................................................................... 48

5.2 Opening the cabin door ................................................................................................................... 50

5.3 Operators controls........................................................................................................................... 51

5.3.1 Overview...................................................................................................................................... 51

5.4 Air comfort seat................................................................................................................................ 52

5.4.1 Setting the left armrest................................................................................................................. 54

5.4.2 Right armrest ............................................................................................................................... 54

5.4.3 Drawer for first-aid kit/operating instructions............................................................................... 55

5.5 Guide's seat..................................................................................................................................... 56

5.5.1 Cooler .......................................................................................................................................... 56

5.5.2 Emergency Exit............................................................................................................................ 57

5.5.3 OBD diagnostics plug (On-Board-plug)....................................................................................... 58

5.6 Steering Column and Foot Pedals................................................................................................... 59

5.6.1 Steering Column Adjustment....................................................................................................... 60

5.6.2 Horn............................................................................................................................................. 61

5.6.3 Indicator Switches........................................................................................................................ 61

5.6.4 Full Beam..................................................................................................................................... 62

5.6.5 Headlamp Flasher ....................................................................................................................... 62

5.6.6 Using the operating brake............................................................................................................ 63

5.7 Roof Panel Switch Group ................................................................................................................ 64

5.8 Lighting ............................................................................................................................................ 65

5.8.1 Overview...................................................................................................................................... 65

5.8.2 Indicator, hazard warning flasher and brake light........................................................................ 66

5.8.2.1 Switching on the indicator.................................................................................................... 66

5.8.2.2 Brake light............................................................................................................................ 66

5.8.2.3 Switching on the hazard warning flasher............................................................................. 66

5.8.3 Side light/dipped beam ................................................................................................................ 67

5.8.3.1 Switching on the parking light.............................................................................................. 67

5.8.3.2 Switching on the dipped beam............................................................................................. 67

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5.8.4 Working floodlights ...................................................................................................................... 68

5.8.4.1 Working floodlight right/left mowing units ............................................................................ 69

5.8.4.2 Working floodlights Cab....................................................................................................... 69

5.8.4.3 Working floodlight Bottom front............................................................................................ 70

5.8.4.4 Working floodlight rear......................................................................................................... 70

5.8.5 Allround lights .............................................................................................................................. 71

5.8.6 Interior Lighting / Spotlight........................................................................................................... 72

5.9 Outside mirrors ................................................................................................................................ 73

5.9.1 Left outside mirror........................................................................................................................ 73

5.9.2 Right outside mirror and anti-collision mirror............................................................................... 74

5.9.2.1 Setting the right outside mirror............................................................................................. 74

5.9.2.2 Setting the anti-collision mirror ............................................................................................ 74

5.10 Inside mirror..................................................................................................................................... 75

5.11 Sun Visor ......................................................................................................................................... 75

5.12 Windshield wipers............................................................................................................................ 76

5.13 Washer system – windshield........................................................................................................... 76

5.14 Switch panel .................................................................................................................................... 77

5.15 Panel Switches and Indicator Lamps .............................................................................................. 78

5.15.1 Actuating release switches...................................................................................................... 79

5.15.2 Release switch – road/field...................................................................................................... 80

5.15.3 Autopilot release switch / - optional......................................................................................... 81

5.15.4 Release switch - holding brake................................................................................................ 82

5.15.5 Release switch travelling gear................................................................................................. 83

5.15.6 Axle separation key ................................................................................................................. 84

5.15.7 Pilot Lamp Engine Oil Pressure............................................................................................... 85

5.15.8 Charge Indicator Lamp............................................................................................................ 85

5.15.9 Pilot Lamp Cooling Water Temperature.................................................................................. 85

5.15.10 Pilot lamp steering fault ........................................................................................................... 85

5.15.11 Ignition lock.............................................................................................................................. 86

5.15.12 Cigarette lighter / 12-V socket ................................................................................................. 87

5.15.13 Diagnostics Socket / USB Connection .................................................................................... 88

5.16 Multi-Function Lever........................................................................................................................ 89

5.16.1 In Field Mode Only................................................................................................................... 89

5.16.2 Multi-Function Lever (Continued) ............................................................................................ 91

5.16.2.1 Driving.............................................................................................................................. 91

5.17 Klimatronik / heating........................................................................................................................ 92

5.17.1 Control and display elements .................................................................................................. 92

5.17.2 Operation................................................................................................................................. 94

5.17.3 Switching on the System ......................................................................................................... 94

5.17.4 Setting the Desired Cab Temperature..................................................................................... 94

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5.17.5 Switch air conditioning On / Off ............................................................................................... 95

5.17.6 Switch REHEAT mode On / Off............................................................................................... 96

5.17.7 Manual setting of evaporator fan speed .................................................................................. 97

5.17.8 Switching the Temperature Display to ° Fahrenheit................................................................ 98

5.17.9 Showing Faults in the Display.................................................................................................. 98

5.18 Adjustable Fan Nozzles................................................................................................................. 100

5.19 Radio.............................................................................................................................................. 101

6 Info centre "EasyTouch" ...................................................................................................................102

6.1.1 Overview.................................................................................................................................... 102

6.2 Information Section........................................................................................................................ 104

6.2.1 Status line (I).............................................................................................................................. 105

6.2.2 Motor data (II) information section............................................................................................. 106

6.2.3 Travelling gear data (III) information section............................................................................. 107

6.2.4 Information section of settings (IV and V).................................................................................. 109

6.2.5 Drive data information section (VI) ............................................................................................ 109

6.3 Quick Access Keys in the Basic Screen........................................................................................ 110

6.3.1 Quick access "hydraulically adjustable cutting height".............................................................. 110

6.3.2 Quick access "Mowing unit compensation for lateral mowing units" (ground pressure)........... 112

6.3.3 Quick access "Customer Data Counter".................................................................................... 113

6.3.4 Changing a customer record (1) or creating a new one............................................................ 114

6.3.4.1 Switching the counter on or off.......................................................................................... 115

6.3.4.2 Delete customer counter.................................................................................................... 116

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

6.3.5 Quick access "Machine settings"............................................................................................... 117

6.3.6 Menu Level ................................................................................................................................ 118

6.3.7 Brief Overview............................................................................................................................ 118

6.3.8 Bringing up a Menu Level.......................................................................................................... 119

6.4 Main menu 1 "Settings" ................................................................................................................. 120

6.5 Menu 1-1 "Parameters" ................................................................................................................. 121

6.5.1 Entering parameters .................................................................................................................. 122

6.6 Menu 1-2 "Machine setting"........................................................................................................... 123

6.6.1 Menu 1-3 "Units"........................................................................................................................ 127

6.6.2 Menu 1-4 "Language"................................................................................................................ 128

6.6.3 Menu 1-5 "Display" .................................................................................................................... 129

6.6.4 Menu 1-5-1 "Contrast" ............................................................................................................... 130

6.6.5 Menu 1-5-2 Beeper.................................................................................................................... 131

6.6.6 Beeper limited by time............................................................................................................... 132

6.6.7 Menu 1-5-4 Direction of Rotation............................................................................................... 133

6.6.8 Menu 1-5-5 Configure status line .............................................................................................. 134

6.6.9 Menu 1-6 Date/time ................................................................................................................... 135

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6.6.10 Menu 1-9 Owner's address.................................................................................................... 136

6.7 Main Menu 2 Counters .................................................................................................................. 138

6.7.1 Machine Data Counter............................................................................................................... 138

6.7.1.1 Deleting the Machine Data Counters (Sets 1 to 3)............................................................ 139

6.7.2 Switching to Customer DataCounters ....................................................................................... 139

6.8 Main Menu 3 "Maintenance".......................................................................................................... 140

6.8.1 Menu 3-1 "Calibration of cutting height" .................................................................................... 141

6.8.2 Menu 3-2 Calibration of front mowing unit................................................................................. 143

6.8.3 Menu 3-3 Calibration of right lateral mowing unit...................................................................... 149

6.8.4 Menu 3-4 Calibration of left lateral mowing unit ........................................................................ 156

6.8.5 Menu 3-5 Hydraulic axle suspension......................................................................................... 163

6.8.6 Menu 3-6 Cabin suspension...................................................................................................... 164

6.8.7 Menu 3-8 Manual mode............................................................................................................. 166

6.8.7.1 Manual mode- mowing units.............................................................................................. 166

6.9 Main Menu 4 Service..................................................................................................................... 173

6.9.1 Menu 4-1 Diagnostics................................................................................................................ 174

6.9.2 Display of Release Conditions Not Met for Diagnostics............................................................ 175

6.9.3 Display of possible faults for diagnostics................................................................................... 176

6.9.4 Menu 4-1-1 Diagnostics of axle suspension.............................................................................. 177

6.9.5 Menu 4-1-2 Diagnostics cabin suspension................................................................................ 179

6.9.6 Menu 4-1-4 Diagnostics of cutting height .................................................................................. 181

6.9.7 Menu 4-1-5 Diagnostics of hydraulic auger hood...................................................................... 189

6.9.8 Menu 4-1-7 Diagnostics front mowing unit................................................................................ 195

6.9.9 Menu 4-1-8 Diagnostics right lateral mowing unit...................................................................... 201

6.9.10 Menu 4-1-9 Diagnostics left lateral mowing unit.................................................................... 207

6.9.11 Menu 4-1-10 Diagnostics work.............................................................................................. 213

6.9.12 Menu 4-1-11 CAN Bus........................................................................................................... 218

6.9.13 Menu 4-1-12 Travelling gear.................................................................................................. 219

6.9.14 Menu 4-1-13 Electronics........................................................................................................ 230

6.9.15 Menu 4-1-14 Diesel Engine................................................................................................... 231

6.9.16 Menu 4-1-15 Joystick............................................................................................................. 234

6.9.17 Menu 4-1-16 Control unit console ......................................................................................... 236

6.9.18 Menu 4-1-17 Display.............................................................................................................. 239

6.9.19 Menu 4-1-18 Steering............................................................................................................ 240

6.10 Menu 4-2 Error list......................................................................................................................... 241

6.11 Menu 4-3 "Service level"................................................................................................................ 246

6.12 Menu 4-4 Information..................................................................................................................... 247

6.12.1 Menu 4-4-1 Joystick............................................................................................................... 248

6.12.2 Menu 4-4-2 "Software"........................................................................................................... 249

6.12.3 Menu 4-4-3 Machine.............................................................................................................. 251

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6.13 Menu 5 Basic Screen..................................................................................................................... 252

6.13.1 Error Messages...................................................................................................................... 253

6.13.2 Information message ............................................................................................................. 254

7 Commissioning...................................................................................................................................255

7.1 Fitting the guard cloths .................................................................................................................. 255

7.2 Folding Down Lateral Mowing Units.............................................................................................. 255

7.2.1 Lowering All Mowing Units from Transport Position to Headland Position................................ 256

7.2.2 Lowering All Mowing Units from Headland Position to Working Position.................................. 257

7.2.3 Description of Installation........................................................................................................... 258

7.3 Retainer Spring.............................................................................................................................. 260

7.4 Installation of Cutter Blades........................................................................................................... 261

8 Start-up................................................................................................................................................262

8.1 Check before Start-up.................................................................................................................... 262

8.2 Daily checks................................................................................................................................... 262

8.2.1 On the Basic Machine................................................................................................................ 263

8.2.2 On the mowing units.................................................................................................................. 263

9 Driving and Transport........................................................................................................................264

9.1 Transport / Road Travel................................................................................................................. 264

9.1.1 Additional Axle (Optional) .......................................................................................................... 264

9.1.2 Check lock ................................................................................................................................. 265

9.1.3 Release switch – road/field........................................................................................................ 265

9.1.4 Release switch travelling gear................................................................................................... 266

9.2 Starting the engine......................................................................................................................... 266

9.2.1 Killing the engine ....................................................................................................................... 268

9.2.2 Starting with an Auxiliary Battery............................................................................................... 268

9.3 Starting to Drive............................................................................................................................. 268

9.3.1 Setting the Acceleration Behaviour............................................................................................ 269

9.3.2 General on driving ..................................................................................................................... 269

9.3.3 Preventing an overheating of the hydrostatic system................................................................ 270

9.3.4 Driving Forwards........................................................................................................................ 271

9.3.5 Reversing................................................................................................................................... 272

9.4 Cruise Control................................................................................................................................ 273

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

9.4.2 Activating Cruise Control ........................................................................................................... 274

9.4.3 Deactivating Cruise Control....................................................................................................... 274

9.5 Stopping......................................................................................................................................... 275

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

9.5.2 Stopping with Foot Brakes......................................................................................................... 276

9.6 Parking Brake ................................................................................................................................ 277

9.7 Switch off the engine ..................................................................................................................... 278

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9.8 Switch off the machine................................................................................................................... 278

9.9 Towing ........................................................................................................................................... 279

10 Operation – Mowing Units.................................................................................................................280

10.1 Intended Use ................................................................................................................................. 280

10.2 Operation of Mowing Units ............................................................................................................ 281

10.3 Folding Down the Mowing Units.................................................................................................... 282

10.3.1 Lowering All Mowing Units from Transport Position to Headland Position............................ 283

10.3.2 Lowering All Mowing Units from Headland Position to Working Position.............................. 284

10.3.3 Lowering the Lateral Mowing Units from Transport Position to Headland Position .............. 285

10.3.4 Lowering the Lateral Mowing Units from Headland Position to Working Position................. 285

10.3.5 Lowering the Front Mowing Unit from Transport Position to Headland Position................... 286

10.3.6 Lowering the Front Mowing Unit from Headland Position to Working Position..................... 286

10.4 Mowing Unit Drive.......................................................................................................................... 287

10.4.1 Switching the Mowing Unit Drives On and Off....................................................................... 288

10.4.2 Switching the Left Mowing Unit Drive On/Off ........................................................................ 288

10.4.3 Switching the Right Mowing Unit Drive On/Off...................................................................... 289

10.4.4 Switching the Front Mowing Unit Drive On/Off...................................................................... 290

10.4.5 Switching All Mowing Unit Drives On/Off............................................................................... 291

10.5 Folding up the Mowing Units ......................................................................................................... 292

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

10.5.2 Folding All Mowing Units from Headland Position to Transport Position .............................. 293

10.5.3 Lifting the Lateral Mowing Units from Working Position to Headland Position...................... 294

10.5.4 Folding the Lateral Mowing Units from Headland Position to Transport Position................. 294

10.5.5 Lifting the Front Mowing Unit from Working Position to Headland Position.......................... 295

10.5.6 Lifting the Front Mowing Unit from Working Position to Headland Position.......................... 295

10.6 Folding the Front Mowing Unit from Headland Position to Transport Position.............................. 296

10.7 Mowing........................................................................................................................................... 297

10.8 Game animal protection................................................................................................................. 298

10.8.1 Moving the Guards into Working Position ............................................................................. 300

10.8.2 Mowing with Individual Mowing Units.................................................................................... 300

10.8.3 Quick Stop ............................................................................................................................. 301

10.8.4 Fast Direction Change (Fast Reversing) ............................................................................... 301

10.8.5 Switching Axle Separation On and Off .................................................................................. 302

11 Adjusting the mowing units ..............................................................................................................303

11.1 Special Safety Instructions ............................................................................................................ 303

11.2 Adjusting the cutting height............................................................................................................ 303

11.3 Adjusting the Compensation Springs ............................................................................................ 303

11.3.1 Front mowing unit .................................................................................................................. 304

11.4 Adjusting the Tedder Speed.......................................................................................................... 305

11.4.1 Lateral mowing unit left / right................................................................................................ 305

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11.4.2 Front mowing unit right/left .................................................................................................... 306

11.5 Adjusting the conditioner plate ...................................................................................................... 307

11.6 Setting of the Scraper on the Cross Conveyor (Optional)............................................................. 308

11.7 Adjusting the swath width.............................................................................................................. 309

11.7.1 Front mowing unit .................................................................................................................. 309

11.7.2 Lateral mowing unit left / right................................................................................................ 310

12 Maintenance – Engine........................................................................................................................311

12.1 Maintenance Table – Motor........................................................................................................... 312

12.2 Contamination in the engine compartment.................................................................................... 315

12.3 Cleaning the Engine Compartment with Compressed Air............................................................. 315

12.4 Engine oil level............................................................................................................................... 316

12.5 Engine oil....................................................................................................................................... 317

12.6 Fuel filter/water separator.............................................................................................................. 319

12.6.1 Replacing the fuel filter .......................................................................................................... 319

12.6.2 Empty the water separator..................................................................................................... 319

12.7 Replacing the fuel filter insert ........................................................................................................ 320

12.7.1 Replacing the filter in the hand pump.................................................................................... 321

12.8 Replacing Urea Filter Inserts......................................................................................................... 322

12.9 Fuel................................................................................................................................................ 324

12.10 Tanks......................................................................................................................................... 325

12.11 Tanks of urea solution ............................................................................................................... 326

12.12 Venting the fuel system ............................................................................................................. 328

12.13 Engine Coolant .......................................................................................................................... 328

12.14 Engine coolant – checks and controls....................................................................................... 329

12.15 Air filter....................................................................................................................................... 330

12.15.1 Safety cartridge...................................................................................................................... 331

13 Maintenance – compressed air system ...........................................................................................332

13.1 Compressed-air reservoir.............................................................................................................. 332

13.1.1 Checking the compressed air reservoir................................................................................. 332

13.1.2 Checking the drain valve ....................................................................................................... 333

13.1.3 Retighten tensioning belts ..................................................................................................... 333

13.2 Replace Air Dryer .......................................................................................................................... 333

14 Maintenance – Mowing Units ............................................................................................................334

14.1 Special Safety Instructions ............................................................................................................ 334

14.1.1 Test run.................................................................................................................................. 335

14.2 Spare Parts.................................................................................................................................... 335

14.3 Maintenance Table- Mowing Units ................................................................................................ 336

14.4 Tool box......................................................................................................................................... 337

14.5 Tightening Torques........................................................................................................................ 338

14.6 Tightening Torques (Countersunk Screws)................................................................................... 339

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14.6.1 Deviating Torque ................................................................................................................... 339

14.7 Opening the Front Guard............................................................................................................... 340

14.7.1 Lateral mowing unit left / right................................................................................................ 340

14.7.2 Front mowing unit right/left .................................................................................................... 340

14.8 Eliminating Blockages on the Cross Conveyor.............................................................................. 341

14.9 Shearing pins on cross conveyor .................................................................................................. 342

14.10 Filling Quantities and Lubrication Designations for Gearboxes................................................. 343

14.10.1 Oil Level Check and Oil Change Intervals (Gearboxes)........................................................ 343

14.11 Input gearbox............................................................................................................................. 344

14.11.1 Lateral mowing unit left / right................................................................................................ 344

14.12 Speed gearbox........................................................................................................................... 345

14.12.1 Lateral mowing unit left / right................................................................................................ 345

14.13 Transfer gearbox ....................................................................................................................... 346

14.14 Input gearbox............................................................................................................................. 347

14.14.1 Front mowing unit right/left .................................................................................................... 347

14.15 Speed gearbox........................................................................................................................... 348

14.15.1 Front mowing unit right/left .................................................................................................... 348

14.16 Oil level check and oil change on the cutter bar........................................................................ 349

14.16.1 Aligning the Cutter Bar........................................................................................................... 349

14.16.2 Checking the oil level............................................................................................................. 350

14.16.3 Oil change.............................................................................................................................. 351

14.17 Checking the Cutter Blades and Blade Holder.......................................................................... 353

14.17.1 Cutter Blades......................................................................................................................... 353

14.17.2 Blade screw connection......................................................................................................... 354

14.17.3 Blade Quick-Fit Device.......................................................................................................... 355

14.17.4 Periodical Inspection of the Leaf Springs .............................................................................. 356

14.17.5 Periodical Inspection of the Cutting Discs / Blade Drums..................................................... 357

14.17.6 Abrasion Limit........................................................................................................................ 358

14.18 Blade Changing on Cutting Discs.............................................................................................. 359

14.18.1 Blade Screw Connection ....................................................................................................... 360

14.18.2 Blade Quick-Fit Device.......................................................................................................... 361

14.19 Replacing the linings.................................................................................................................. 362

14.20 Rotary hub with shear protection............................................................................................... 364

14.20.1 After Shearing Off.................................................................................................................. 365

14.20.2 Repairing the Sheared Off Bearing Unit................................................................................ 366

15 Maintenance – Basic Machine...........................................................................................................367

15.1 Brakes............................................................................................................................................ 367

15.2 Hydraulic system ........................................................................................................................... 368

15.3 Maintenance - hydraulic system.................................................................................................... 371

15.3.1 System Description Operating and Brake Hydraulics............................................................ 371

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15.3.2 Pumps.................................................................................................................................... 371

15.3.3 Over-pressure valves............................................................................................................. 372

15.3.4 Adjustable Throttles............................................................................................................... 372

15.4 Hydraulic oil ................................................................................................................................... 373

15.4.1 List of Mineral Oils for the Hydraulic System......................................................................... 373

15.4.1.1 HEPG VG 46.................................................................................................................. 373

15.5 Hydraulic oil level........................................................................................................................... 374

15.6 Replacing the hydraulic oil filter..................................................................................................... 375

15.7 Transfer gearbox ........................................................................................................................... 376

15.8 Pressure filter................................................................................................................................. 377

15.9 High-pressure filter ........................................................................................................................ 378

15.10 Replacing the filter on the transfer gearbox............................................................................... 379

15.11 Wheel hub drives on the rear axles........................................................................................... 380

15.12 Air Intake and Air Distribution.................................................................................................... 381

15.12.1 Changing / cleaning the fresh air filter................................................................................... 383

15.12.2 Circulation filter...................................................................................................................... 384

15.13 Windscreen washer system....................................................................................................... 385

15.14 Maintenance - air conditioning system and heating .................................................................. 386

15.15 Special Safety Instructions ........................................................................................................ 386

15.15.1 Air conditioning components.................................................................................................. 386

15.15.2 Refrigerant data sheet R 134a (excerpt) ............................................................................... 387

15.15.3 Technical data........................................................................................................................ 387

15.15.4 Refrigerant............................................................................................................................. 388

15.15.5 Manometric switch................................................................................................................. 388

15.15.6 Collector/drier......................................................................................................................... 389

15.15.7 Checking refrigerant condition and level ............................................................................... 390

15.16 Cleaning the radiator and radiator compartment....................................................................... 391

15.17 Belt drives.................................................................................................................................. 392

15.17.1 Suction blower drive .............................................................................................................. 393

15.17.2 Fan wheel drive...................................................................................................................... 394

15.17.3 Cross Conveyor Drive............................................................................................................ 395

15.18 Tyres.......................................................................................................................................... 396

15.18.1 Checking and maintaining tyres............................................................................................. 397

15.18.2 Wheel mounting..................................................................................................................... 398

15.18.3 Tighten the Fastening Screws on the Outrigger.................................................................... 398

16 Maintenance – lubrication chart .......................................................................................................399

16.1 Lubricating the PTO shaft.............................................................................................................. 399

16.2 Lubrication Chart ........................................................................................................................... 403

17 Maintenance – electrical system.......................................................................................................408

17.1 Electrical equipment - technical data............................................................................................. 408

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17.2 Battery............................................................................................................................................ 409

17.2.1 Main battery switch................................................................................................................ 410

17.2.2 Charging Batteries................................................................................................................. 411

17.2.3 Quick charge.......................................................................................................................... 411

17.2.4 Cleaning the battery............................................................................................................... 411

17.2.5 Check battery......................................................................................................................... 412

17.2.6 Check acid level..................................................................................................................... 412

17.2.7 Measuring Acid Density......................................................................................................... 413

17.3 Fitting the batteries and connecting the poles correctly................................................................ 414

17.4 Three-phase generator.................................................................................................................. 415

17.5 Starter............................................................................................................................................ 416

17.6 Control units and fuses.................................................................................................................. 417

17.6.1 Electronic Diesel Control (EDC) ............................................................................................ 418

17.6.2 Cabin relay circuit board........................................................................................................ 418

17.6.3 Circuit board console............................................................................................................. 419

17.6.4 Cab circuit board.................................................................................................................... 420

17.6.5 Circuit board Krone Machine Controller (KMC1)................................................................... 421

17.6.6 Circuit board Krone Machine Controller (KMC2)................................................................... 422

18 Maintenance – Central Lubrication...................................................................................................423

18.1 Overview........................................................................................................................................ 423

18.2 Fill coupling.................................................................................................................................... 424

18.3 Lubricant........................................................................................................................................ 425

18.3.1 Grease types, NLGIClass 2................................................................................................... 426

18.4 Checking the fill level..................................................................................................................... 427

18.5 Change the Times of the Lubrication Interval................................................................................ 428

18.6 Troubleshooting............................................................................................................................. 428

19 Placing in Storage..............................................................................................................................430

19.1 At the End of the Harvest Season ................................................................................................. 430

19.2 Engine area.................................................................................................................................... 430

19.3 Before the Start of the New Season.............................................................................................. 431

19.4 Friction clutch –ByPy..................................................................................................................... 432

19.4.1 Venting the Friction Clutch on the PTO Shaft........................................................................ 432

19.5 Friction Clutch for Lateral Mowing Units........................................................................................ 433

19.6 Friction Clutch for the Front Mowing Unit...................................................................................... 434

20 Appendix .............................................................................................................................................435

20.1 Error Messages ............................................................................................................................. 435

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Foreword

14

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2 Foreword

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Dear Customer

On buying the Self-Propelled High-Performance Mower-Conditioner Big M 500 you have

selected a quality product from KRONE.

We are grateful for the confidence you have invested in us in buying this machine.

It is important to read the operating instructions very carefully before you start operating the

machine so that the Self-Propelled High-Performance Mower-Conditioner Big M 500 may be

used to its maximum capacity.

The contents of this manual are laid out in such a way that you should be able to perform any

task by following the instructions step by step. It contains extensive notes and information about

maintenance, how to use the machine safely, secure working methods, special precautionary

measures and available accessories. It is essential, important and useful for the operational

safety, reliability and durability of the Self-Propelled High-Performance Mower-Conditioner Big

M 500, that these notes and information are adhered to.

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Note

Throughout the remainder of these operating instructions, the "Self-Propelled High

Performance Mowing Conditioner "BiG M" will also be referred to as the "machine / vehicle".

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Please note:

The operating instructions are part of your machine.

Only operate this machine after you have been trained to do so and according to these

instructions.

It is essential to observe the safety instructions!

It is also necessary to observe the relevant accident prevention regulations and other generally

recognised regulations concerning safety, occupational health and road traffic.

All information, illustrations and technical data in these operating instructions correspond to the

latest state at the time of publication.

We reserve the right to make design changes at any time and without notification of reasons.

Should you for any reason not be able to use these operating instructions either wholly or

partially, you can receive a replacement set of operating instructions for your machine by

quoting the number supplied overleaf.

We hope that you will be satisfied with your KRONE machine.

Maschinenfabrik Bernard Krone GmbH

Spelle

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Introduction

15

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3 Introduction

These operating instructions contain fundamental instructions. These must be observed in

operation and maintenance. For this reason, these operating instructions must be read by

operating personnel before commissioning and use, and must be available for easy reference.

Follow both the general safety instructions contained in the section on safety and the specific

safety instructions contained in the other sections.

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3.1 Validity

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

Big M 500.

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3.2 Identification Plate

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Fig. 1

The machine data are located on the type plate (1). This is located on the right side of the

machine on the front of the frame above the right front wheel.

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Introduction

16

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3.3 Information Required for Questions and Orders

Type

Year of manufacture

Vehicle ID number

Note

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

rendered illegible!

When asking questions concerning the machine or ordering spare parts, be sure to provide type

designation, vehicle ID number and the year of manufacture : To ensure that these data are

always available, we recommend that you enter them in the fields above.

Note

Authentic KRONE spare parts and accessories authorised by the manufacturer help to ensure

safety. The use of spare parts, accessories and other devices which are not manufactured,

tested or approved by KRONE will result in the revoking of the liability for damages resulting

thereof.

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Ver

3.4 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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Introduction

17

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3.5 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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Introduction

18

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3.6 Machine overview

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BM 500 0135

1 2

11 3

910

56

4

7

8

Fig. 2

1Lateral mowing unit right 2Outrigger right

3Lifting gear 4Front mowing unit

5Lateral mowing unit left 6Outrigger left

7Cab 8Operating panel

9Engine 10Combination radiator

11Main battery switch

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Introduction

19

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3.7 Technical data

All information, illustrations and technical data in these operating instructions correspond to the

latest state at the time of publication. We reserve the right to make design changes at any time

and without notification of reasons.

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3.7.1 Technical Data / Vehicle

Power {KW/HP} 382 / 520

Transport width/length/height {mm} 3000* / 10500 / 4000

Weight {approx. kg} 21500

Weight distribution approx. 10000- front / 11500- rear

Running gear 4 wheels

Direct drive provided by radial piston drives

Steering All-wheel steering

Tyres / air pressure (as standard) 800/65 R32 front 1.5 bar / rear 2.2 bar

(optional) 900/60 R32 front 1.3 bar / rear 1.8 bar

Tightening torque wheel nuts Nm 700

Hydrostatic traction drive Level I

Level II 0 to 20 km/h continuous (all-wheel drive)

0 to 40 km/h continuous (all-wheel drive)

Connectable axle separation in level 1

Drive pump Delivery volume 100/100 ccm

Filling quantities

{I} Refined oils

Brand name

Diesel tank approx. 970 Please refer to chapter “Maintenance-

Motor”

Urea solution approx. 70 Please refer to chapter “Maintenance-

Motor”

Engine oil approx. 34 – 40 See chapter “Motor"

Hydraulic oil ** approx. 80 See chapter Maintenance-Basic Machine

“Hydraulic Oil”

Coolant approx. - See chapter “Motor"

Transfer gearbox approx. 11.5 Gearbox oil synthetic DIN 51502 –PGLP

ISO VG 220

Wheel hub gearbox approx. 2.5 SAE 90

*) depending on the tyre size

**) Caution: Do not mix with other oils.

Consult customer service before using other oils.

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Introduction

20

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3.7.2 Technical Data / Vehicle with Additional Axle (Optional)

Changes compared to series

Weight {approx. kg} 22000

Weight distribution approx. 10500- front / 11500- rear

Note

The tyre pressure on the front wheels of the towing machine must be increased by 0.1

bar if the additional axle is available as an option.

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3.7.3 Technical data/CV mowing unit

Working width total/individual {mm} 13200/5300 front/4400 side

Transport width {mm} 3000 mowing unit

Number of cutting discs 6 / lateral mowing units - 2 / front mowing units

Number of blade drums 4 / lateral mowing units - 4 / front mowing units

Conditioner system V-shaped prong

Speed of the conditioner {rpm} 700/1000

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Krone BiG M 500 Operating instructions

Krone BiG M 500 Operating instructions

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