Original operating instructions
Self-propelled High-Performance
Mower-Conditioner
BiG M 420
(from serial no.: 932 743)
Order no.: 150 000 130 06 en
25.04.2016
Table of Contents
2
CV0
EC Declaration of Conformity
We
Maschinenfabrik Bernard Krone GmbH & Co. KG
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: BiG M 420 CV, BiG M 420 CRI
to which this declaration refers is in compliance with the following relevant provisions of:
• EC Directive 2006/42/EC (machines),
• EU Directive 2014/30/EU (EMC). Within the meaning of the Directive the
harmonised standard EN ISO 14982:2009 was taken as a basis.
The signing Managing Director is authorised to compile the technical documents.
Spelle, 20.04.2016
Dr.-Ing. Josef Horstmann
(Managing Director, Design & Development)
Year of manufacture: Machine no.:
Table of Contents
3
Pos: 3 /Layout Mo dule /Inhaltsverzei chnis @ 0\mod_1196861 555655_78.doc x @ 15165 @ 1 @ 1
1 Table of Contents
1 Table of Contents ................................................................................................................................... 3
2 To this Document ................................................................................................................................. 14
2.1 Validity .............................................................................................................................................. 14
2.2 Re-Ordering ...................................................................................................................................... 14
2.3 Information on Direction ................................................................................................................... 14
2.4 Representation and Utilization of Warning Notes ............................................................................ 14
2.5 Identification of the hazard warnings................................................................................................ 14
3 Safety ..................................................................................................................................................... 15
3.1 Intended use ..................................................................................................................................... 15
3.2 Reasonably foreseeable misuse ...................................................................................................... 15
3.2.1 Personnel Qualification and Training ........................................................................................ 16
3.2.2 Dangers in Case of Non-compliance with the Safety Instructions ............................................ 16
3.2.3 Safety-conscious work practices ............................................................................................... 16
3.3 Safety and Accident Prevention Regulations ................................................................................... 17
3.4 Conveying persons, guides, operating personnel ............................................................................ 18
3.5 Self-propelled working machine ....................................................................................................... 18
3.6 Autopilot ........................................................................................................................................... 19
3.7 Implements ....................................................................................................................................... 20
3.8 Hydraulic system .............................................................................................................................. 20
3.9 Battery .............................................................................................................................................. 21
3.10 Cooling system ................................................................................................................................. 21
3.11 Tyres................................................................................................................................................. 21
3.12 Emergency exit ................................................................................................................................. 21
3.13 Working in the vicinity of power transmission lines .......................................................................... 22
3.14 Fire preventions ................................................................................................................................ 22
3.15 Maintenance ..................................................................................................................................... 23
3.16 Telephone and radio sets ................................................................................................................. 23
3.16.1 Wheel chocks ............................................................................................................................ 23
3.16.2 Main battery switch ................................................................................................................... 24
4 Machine Description ............................................................................................................................ 25
4.1 Variants for Machine Equipment ...................................................................................................... 25
4.2 Machine overview ............................................................................................................................. 25
4.3 Identification Plate ............................................................................................................................ 26
4.4 Information Required for Questions and Orders .............................................................................. 26
4.4.1 Contact ...................................................................................................................................... 26
5 Safety ..................................................................................................................................................... 27
5.1 Introduction ....................................................................................................................................... 27
5.2 Position of the Adhesive Safety Stickers on the Machine ................................................................ 28
5.2.1 Basic machine „front -/ rear view“ ............................................................................................. 28
5.2.2 Basic machine „left and right side hand of machine” ................................................................ 30
5.2.3 Lateral mowing unit left / right ................................................................................................... 32
5.2.4 Front mowing unit ...................................................................................................................... 34
6 Technical Data of the Machine ............................................................................................................ 36
6.1 Technical data .................................................................................................................................. 36
6.1.1 Technical Data Air Conditioning System................................................................................... 38
6.1.2 Refrigerant data sheet R 134a (excerpt) ................................................................................... 38
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6.2 Technical Data of Electrical System ................................................................................................. 38
6.3 Consumables ................................................................................................................................... 39
6.4 Lubricants ......................................................................................................................................... 39
6.4.1 Central Lubrication System, NLGI Class 2 ............................................................................... 40
7 Cabin ...................................................................................................................................................... 41
7.1 Ladder to driver's cabin .................................................................................................................... 41
7.2 Opening the cabin door .................................................................................................................... 42
7.3 Operators controls ............................................................................................................................ 43
7.3.1 Overview ................................................................................................................................... 43
7.4 Air comfort seat ................................................................................................................................ 44
7.4.1 Setting the left armrest .............................................................................................................. 46
7.4.2 Right armrest ............................................................................................................................. 46
7.4.3 Drawer for first-aid kit/operating instructions............................................................................. 47
7.5 Guide's seat...................................................................................................................................... 48
7.5.1 Cooler ........................................................................................................................................ 48
7.5.2 Emergency Exit ......................................................................................................................... 49
7.5.3 OBD diagnostics plug (On-Board-plug) .................................................................................... 49
7.6 Steering Column and Foot Pedals ................................................................................................... 50
7.6.1 Steering Column Adjustment .................................................................................................... 51
7.6.2 Horn........................................................................................................................................... 52
7.6.3 Flashing Light Switch ................................................................................................................ 52
7.6.4 Full Beam .................................................................................................................................. 53
7.6.5 Headlamp Flasher ..................................................................................................................... 53
7.6.6 Using the operating brake ......................................................................................................... 54
7.7 Switch Group Roof Panel ................................................................................................................. 55
7.8 Lighting ............................................................................................................................................. 56
7.8.1 Overview ................................................................................................................................... 56
7.8.2 Indicator, hazard warning flasher and brake light ..................................................................... 57
7.8.2.1 Switching on the indicator .................................................................................................. 57
7.8.2.2 Brake light .......................................................................................................................... 57
7.8.2.3 Switching on the hazard warning flasher ........................................................................... 57
7.8.3 Side light/dipped beam.............................................................................................................. 58
7.8.3.1 Switching on the parking light ............................................................................................ 58
7.8.3.2 Switching on the dipped beam ........................................................................................... 58
7.8.4 Working floodlights .................................................................................................................... 59
7.8.4.1 Working floodlights Cab ..................................................................................................... 60
7.8.4.2 Working floodlight Bottom front .......................................................................................... 60
7.8.4.3 Working floodlights "down the side and at the right/left mowing units" ............................. 61
7.8.4.4 Working floodlight rear ....................................................................................................... 61
7.8.5 Allround lights (optional)............................................................................................................ 62
7.8.6 Interior Lighting / Spotlight ........................................................................................................ 63
7.8.7 Additional Spotlight ................................................................................................................... 64
7.9 Outside mirrors ................................................................................................................................. 65
7.9.1 Left Outside Mirror .................................................................................................................... 65
7.9.2 Right outside mirror and anti-collision mirror ............................................................................ 66
7.9.2.1 Setting the right outside mirror ........................................................................................... 66
7.9.2.2 Setting the anti-collision mirror .......................................................................................... 66
7.10 Inside mirror ..................................................................................................................................... 67
7.11 Sun blind .......................................................................................................................................... 67
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7.12 Windshield wipers ............................................................................................................................ 68
7.13 Washer system – windshield ............................................................................................................ 68
7.14 Switch panel ..................................................................................................................................... 69
7.15 Panel Switches and Pilot Lamps ...................................................................................................... 70
7.15.1 Actuating release switches ....................................................................................................... 70
7.15.2 Release switch – road/field ....................................................................................................... 71
7.15.3 Autopilot release switch / - optional .......................................................................................... 72
7.15.4 Release switch - holding brake ................................................................................................. 73
7.15.5 Release switch travelling gear .................................................................................................. 74
7.15.6 Axle separation key ................................................................................................................... 75
7.15.7 Pilot Lamp Engine Oil Pressure ................................................................................................ 76
7.15.8 Charge Indicator Lamp.............................................................................................................. 76
7.15.9 Cooling Water Temperature Warning Light .............................................................................. 76
7.15.10 Ignition lock ............................................................................................................................... 77
7.15.11 Cigarette lighter / 12-V socket ................................................................................................... 78
7.16 Diagnostics Socket (ISO-Bus) .......................................................................................................... 78
7.16.1 Diagnostics Socket / USB Connection ...................................................................................... 79
7.17 Multi-Function Lever ......................................................................................................................... 80
7.17.1 Multi-Function Lever (Continued) .............................................................................................. 82
7.17.1.1 Driving ................................................................................................................................ 82
7.18 Klimatronik / heating ......................................................................................................................... 83
7.18.1 Control and display elements .................................................................................................... 83
7.18.2 Operation .................................................................................................................................. 85
7.18.3 Switching on the System ........................................................................................................... 85
7.18.4 Setting the Desired Cab Temperature ...................................................................................... 85
7.18.5 Switch air conditioning On / Off ................................................................................................. 86
7.18.6 Switching REHEAT Mode On/Off ............................................................................................. 87
7.18.7 Manual setting of evaporator fan speed .................................................................................... 88
7.18.8 Switching the Temperature Display to ° Fahrenheit ................................................................. 89
7.18.9 Showing Faults in the Display ................................................................................................... 89
7.19 Adjustable Fan Nozzles ................................................................................................................... 91
7.20 Radio ................................................................................................................................................ 92
8 Info centre "EasyTouch" ..................................................................................................................... 93
8.1.1 Overview ................................................................................................................................... 93
8.2 Information Section .......................................................................................................................... 95
8.2.1 Status line (I) ............................................................................................................................. 96
8.2.2 Motor Data (II) Information Section ........................................................................................... 97
8.2.3 Information section of the travelling gear data (III) ................................................................... 98
8.2.4 Information section of settings (IV and V) ................................................................................. 99
8.2.5 Information Section Drive Information (VI) ................................................................................ 99
8.3 Quick Access Keys in the Basic Screen ........................................................................................ 100
8.3.1 Quick access "Hydraulically adjustable cutting height" (optional) .......................................... 100
8.3.2 Quick access "Hydraulically adjustable lateral spring compensation" (ground pressure)
(optional) 102
8.3.3 Quick Access „Customer Data Counter“ ................................................................................. 104
8.3.4 Changing a customer record (1) or creating a new one ......................................................... 105
8.3.4.1 Switching the counter on or off ........................................................................................ 106
8.3.4.2 Selecting / Deleting the Area(s) of a Customer Counter ................................................. 107
8.3.4.3 Exporting Customer Counter ........................................................................................... 108
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8.3.4.4 Switching to General Counters (Machine Data Counters)............................................... 108
8.3.5 Quick access "Hydraulic axle suspension" ............................................................................. 109
8.3.5.1 From the "Road travel" basic screen ............................................................................... 109
8.3.5.2 From the "Field mode" basic screen ................................................................................ 110
8.3.6 Quick access "Machine settings" ............................................................................................ 111
8.4 Menu level ...................................................................................................................................... 112
8.4.1 Bringing up a Menu Level ....................................................................................................... 116
8.5 Main menu 1 "Settings" .................................................................................................................. 117
8.6 Menu 1-1 "Parameters" .................................................................................................................. 118
8.6.1 Entering parameters ................................................................................................................ 119
8.7 Menu 1-2 „Machine Setting“ ........................................................................................................... 120
8.7.1 Menu 1-3 "Units" ..................................................................................................................... 125
8.7.2 Menu 1-4 "Language" ............................................................................................................. 126
8.7.3 Menu 1-5 "Display" .................................................................................................................. 127
8.7.4 Menu 1-5-1 "Contrast" ............................................................................................................. 128
8.7.5 Menu 1-5-2 Beeper ................................................................................................................. 129
8.7.6 Beeper limited by time ............................................................................................................. 130
8.7.7 Menu 1-5-4 Direction of Rotation ............................................................................................ 131
8.7.8 Menu 1-5-5 Configure status line ............................................................................................ 132
8.7.9 Menu 1-6 Date/time ................................................................................................................. 133
8.7.10 Menu 1-9 Owner's address ..................................................................................................... 134
8.8 Main Menu 2 Counters ................................................................................................................... 135
8.8.1 Machine Data Counter ............................................................................................................ 135
8.8.1.1 Deleting the Machine Data Counters (Sets 1 to 3) .......................................................... 136
8.8.2 Switching to Customer DataCounters ..................................................................................... 136
8.9 Main Menu 3 Maintenance ............................................................................................................. 137
8.9.1 Menu 3-1 "Calibration of cutting height" .................................................................................. 138
8.10 Calibrating Menu 3-3 ISOBUS Steering System ............................................................................ 140
8.10.1 Calibrating Steering Angle Sensor .......................................................................................... 141
8.11 Calibrating Steering (Valves) Automatically ................................................................................... 142
8.11.1 Calibrating Steering (Valves) Manually ................................................................................... 146
8.12 Setting the Steering Radius ........................................................................................................... 147
8.12.1 Menu 3-5 „Manual Mode“ ........................................................................................................ 148
8.12.2 Status display of general sensors (2) ...................................................................................... 151
8.13 Main Menu 4 Service...................................................................................................................... 153
8.13.1 Menu 4-1 Diagnostics ............................................................................................................. 154
8.13.2 Display of Possible Faults for the Diagnostics ........................................................................ 157
8.13.3 Menu 4-1-1 Diagnostics of axle suspension ........................................................................... 158
8.13.4 Menu 4-1-3 Diagnostics of spring compensation .................................................................... 161
8.13.5 Menu 4-1-4 Diagnostics of cutting height................................................................................ 167
8.13.6 Menu 4-1-5 Diagnostics of hydraulic auger hood (optional) ................................................... 175
8.13.7 Menu 4-1-6 Sideshift diagnostics (optional) ............................................................................ 181
8.13.8 Menu 4-1-7 Diagnostics front guard flaps (optional) ............................................................... 186
8.13.9 Menu 4-1-9 ISOBUS Steering System .................................................................................... 191
8.13.10 Menu 4-1-10 Diagnostics Work ............................................................................................... 194
8.13.11 Menu 4-1-11 CAN Bus ............................................................................................................ 205
8.13.12 Menu 4-1-12 Travelling gear ................................................................................................... 206
8.13.13 Menu 4-1-13 Electronics ......................................................................................................... 217
8.13.14 Menu 4-1-14 Diesel Engine .................................................................................................... 218
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8.13.15 Menu 4-1-15 Joystick .............................................................................................................. 221
8.13.16 Menu 4-1-16 Control Unit Console ......................................................................................... 223
8.13.17 Menu 4-1-17 Display ............................................................................................................... 226
8.14 Menu 4-2 Error list .......................................................................................................................... 227
8.15 Menu 4-3 "Service level" ................................................................................................................ 232
8.16 Menu 4-4 Information ..................................................................................................................... 233
8.16.1 Menu 4-4-1 Joystick ................................................................................................................ 234
8.16.2 Menu 4-4-2 Software ............................................................................................................... 235
8.16.3 Menu 4-4-3 Machine ............................................................................................................... 237
8.16.4 Menu 4-4-8 Display Software Packages ................................................................................. 238
8.17 Menu 5 Basic Screen ..................................................................................................................... 238
8.17.1 Error Messages ....................................................................................................................... 239
8.17.2 Information message ............................................................................................................... 240
9 Commissioning ................................................................................................................................... 241
9.1 Fitting the guard cloths ................................................................................................................... 241
9.2 Folding Down Lateral Mowing Units ............................................................................................... 241
9.2.1 Description of Installation ........................................................................................................ 243
9.2.2 Guard cloths (CRI with upper roller drive) ............................................................................... 244
9.2.3 Setting the Warning Panels .................................................................................................... 245
9.3 Installation of Cutter Blades ........................................................................................................... 245
9.4 Checking / Setting the Tyre Pressure ............................................................................................ 245
10 Start-up ................................................................................................................................................ 246
10.1 Check before Start-up .................................................................................................................... 246
10.2 Daily checks ................................................................................................................................... 246
10.2.1 On the Basic Machine ............................................................................................................. 247
10.2.2 On the Mowing Units ............................................................................................................... 247
11 Driving and Transport ........................................................................................................................ 248
11.1 Transport / Road Travel ................................................................................................................. 248
11.2 Preparation for transport/road travel .............................................................................................. 249
11.2.1 Folding Up the Guards ............................................................................................................ 249
11.2.2 Moving the Front Mowing Unit To Central Position (with Sideshift Option) ............................ 250
11.2.3 Error Message 1414 or 1415 .................................................................................................. 251
11.2.4 Disable the shut-off valve on the front outrigger ..................................................................... 252
11.2.5 Release switch – road/field ..................................................................................................... 252
11.2.6 Release switch travelling gear ................................................................................................ 253
11.3 Starting the engine ......................................................................................................................... 254
11.3.1 Killing the engine ..................................................................................................................... 256
11.3.2 Starting with an Auxiliary Battery ............................................................................................ 256
11.4 Starting to Drive .............................................................................................................................. 256
11.4.1 Setting the Acceleration Behaviour ......................................................................................... 257
11.4.2 General on Driving .................................................................................................................. 257
11.4.3 Overheating of Hydrostatic System ........................................................................................ 258
11.4.4 Driving Forwards ..................................................................................................................... 258
11.4.5 Reversing ................................................................................................................................ 259
11.5 Cruise Control ................................................................................................................................ 260
11.5.1 Saving the Speed for Cruise Control Mode ............................................................................ 260
11.5.2 Activating Cruise Control......................................................................................................... 261
11.5.3 Deactivating Cruise Control .................................................................................................... 261
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11.6 Stopping ......................................................................................................................................... 262
11.6.1 Stopping with the Multi-Function Lever ................................................................................... 262
11.6.2 Stopping with Foot Brakes ...................................................................................................... 263
11.7 Parking Brake ................................................................................................................................. 264
11.8 Switching Off the Engine ................................................................................................................ 265
11.9 Switch off the machine ................................................................................................................... 265
11.10 Towing ............................................................................................................................................ 266
11.10.1 Releasing the holding brake manually .................................................................................... 266
12 Operation – Mowing Units ................................................................................................................. 267
12.1 Intended use ................................................................................................................................... 267
12.2 Reasonably foreseeable misuse .................................................................................................... 267
12.3 Operation of Mowing Units ............................................................................................................. 268
12.4 Folding Down the Mowing Units ..................................................................................................... 269
12.4.1 Folding down Each Lateral Mowing Unit from Transport Position to Headland Position ....... 270
12.4.2 Folding down Lateral Mowing Units Simultaneously from Transport Position to Headland
Position 270
12.5 Lowering Mowing Units .................................................................................................................. 271
12.5.1 Lowering Front Mowing Unit from Headland Position to Working Position ............................ 271
12.5.2 Lowering Each Lateral Mowing Unit Individually from Headland Position to Working Position271
12.5.3 Lowering All Mowing Units from Headland Position to Working Position ............................... 272
12.6 Mowing Unit Drive .......................................................................................................................... 273
12.6.1 Switching On Or Switching Off Mowing Unit Drives ............................................................... 274
12.6.2 Switching On / Switching Off Mowing Unit Drive .................................................................... 274
12.6.3 Switching On / Switching Off Mowing Unit Drive .................................................................... 275
12.6.4 Switching On / Switching Off Mowing Unit Drive Front ........................................................... 276
12.6.5 Switching On / Switching Off All Mowing Unit Drives ............................................................. 277
12.7 Lifting the Mowing Units ................................................................................................................. 278
12.7.1 Lifting Front Mowing Unit from Working Position to Headland Position ................................. 278
12.7.2 Lifting Each Lateral Mowing Unit Individually from Working Position to Headland Position ... 279
12.7.3 Lifting All Mowing Units from Working Position to Headland Position .................................... 280
12.8 Folding up the Mowing Units .......................................................................................................... 281
12.8.1 Folding up Each Lateral Mowing Unit Individually from Headland Position to Transport
Position 282
12.8.2 Folding up the Lateral Mowing Units Simultaneously from Headland Position to Transport
Position 282
12.9 Mowing ........................................................................................................................................... 283
12.10 Game animal protection ................................................................................................................. 284
12.10.1 Moving the guards into the working position ........................................................................... 285
12.10.2 Mowing with Individual Mowing Units ..................................................................................... 285
12.10.3 Quick Stop ............................................................................................................................... 286
12.10.4 Fast Direction Change (Fast Reversing) ................................................................................. 286
12.10.5 Switching On/Off Axle Separation ........................................................................................... 287
12.11 Removing the Ground Flaps .......................................................................................................... 288
12.12 Deactivating the axle suspension ................................................................................................... 289
13 Adjusting the mowing units .............................................................................................................. 290
13.1 Special Safety Instructions ............................................................................................................. 290
13.2 Adjusting the cutting height ............................................................................................................ 291
13.2.1 Front mowing unit .................................................................................................................... 291
13.2.2 Adjusting the Lifting Height ..................................................................................................... 292
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13.2.2.1 Front mowing unit ............................................................................................................ 292
13.2.3 Adjusting the cutting height ..................................................................................................... 293
13.2.3.1 Lateral Mowing Unit ......................................................................................................... 293
13.3 Adjusting Skids ............................................................................................................................... 295
13.4 Adjusting the Compensation Springs ............................................................................................. 295
13.4.1 Front mowing unit .................................................................................................................... 296
13.4.2 Lateral Mowing Unit ................................................................................................................ 297
13.5 Adjusting the Tedder Speed ........................................................................................................... 298
13.5.1 Lateral Mowing Unit ................................................................................................................ 298
13.5.2 Front mowing unit (CV) ........................................................................................................... 299
13.6 Adjusting the conditioner plate ....................................................................................................... 300
13.7 Adjusting the roller conditioner (optional extra/BiG M CRI) ........................................................... 301
13.7.1 Adjusting the roller distance .................................................................................................... 301
13.7.2 Adjusting the roller pressure ................................................................................................... 302
13.8 Setting of the Scraper on the Cross Conveyor (Optional).............................................................. 303
13.9 Adjusting the swath width ............................................................................................................... 304
13.9.1 Front mowing unit .................................................................................................................... 304
13.9.2 Lateral Mowing Unit ................................................................................................................ 305
13.10 Mounting/Dismounting BSS Swath Width for BiG M CV ................................................................ 306
13.10.1 Removing Extension on Cross Conveyor Left/Right ............................................................... 306
13.10.2 Dismounting Additional Scraper on Left/Right ........................................................................ 307
13.10.3 Mounting Extension on Cross Conveyor Left/Right ................................................................ 308
13.10.4 Mounting Additional Scraper on Left/Right ............................................................................. 309
13.11 Setting the Transverse Links on the Side Mounted Mowers.......................................................... 310
13.12 Deflector Plates .............................................................................................................................. 310
13.12.1 Front mowing unit .................................................................................................................... 310
14 Special Equipment – Mowing Units .................................................................................................. 311
14.1 Converting the Tedder Deflector Plate to an Auger-Type Cross Conveyor ................................... 311
14.1.1 Hooking Conditioner Baffle Sheet into Hoist ........................................................................... 312
14.1.2 Releasing the tension jacks .................................................................................................... 312
14.1.3 Removing the tedder deflector plate ....................................................................................... 313
14.1.4 Checking the Tines ................................................................................................................. 313
14.1.5 Removing the guard ................................................................................................................ 314
14.1.6 Mounting Auger-type Cross Conveyor .................................................................................... 315
14.1.7 Locking the tension jacks ........................................................................................................ 316
14.1.8 Tensioning the V-belt .............................................................................................................. 316
14.1.9 Installing the guard .................................................................................................................. 317
14.1.10 Connecting Speed Sensor and Hydraulics ............................................................................. 317
14.1.11 Relaying the Lubrication Lines ................................................................................................ 318
14.1.12 Installation Instructions – Bulge Bags for BiG M 400 / BiG M 420 with BSS .......................... 318
14.1.13 Switching on the auger monitoring mode................................................................................ 319
14.1.14 Conversion Auger-type Cross Conveyor to “Conditioner Baffle Sheet Unit” .......................... 320
14.2 Additional Equipment – Mulching Device ....................................................................................... 321
14.3 Removing Mowing Units ................................................................................................................ 322
14.3.1 Front mowing unit .................................................................................................................... 322
14.3.2 Removing of the compensation springs .................................................................................. 323
14.3.3 To remove the PTO shaft: ....................................................................................................... 324
14.3.4 Remove the Weiste Triangle ................................................................................................... 325
14.3.5 Attaching the Front Mowing Unit ............................................................................................. 326
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14.3.6 Removing the Side Mowing Unit ............................................................................................. 327
14.3.7 Attaching the Lateral Mowing Unit .......................................................................................... 332
14.3.8 The remainder of the installation is in reverse order to the removal procedure. .................... 333
15 Maintenance – Engine ........................................................................................................................ 334
15.1.1 Engine Overview ..................................................................................................................... 334
15.2 Overview of maintenance (MAN) excerpt ...................................................................................... 334
15.3 Maintenance Table – Engine ......................................................................................................... 336
15.4 Contamination in the engine compartment .................................................................................... 338
15.5 Cleaning the Engine Compartment with Compressed Air.............................................................. 338
15.6 Engine oil level ............................................................................................................................... 339
15.6.1 Engine oil and filter replacement ............................................................................................. 339
15.7 Fuel filter/water separator .............................................................................................................. 340
15.7.1 Replacing the Fuel Pre-Filter .................................................................................................. 340
15.7.2 Emptying the Water Separator ................................................................................................ 340
15.8 Replacing the fuel filter insert ......................................................................................................... 341
15.8.1 Replacing the filter in the hand pump ..................................................................................... 342
15.9 Replacing Urea Filter Inserts .......................................................................................................... 343
15.10 Fuel................................................................................................................................................. 345
15.10.1 Permissible Fuels .................................................................................................................... 345
15.11 Tanks .............................................................................................................................................. 346
15.12 Tanks of urea solution .................................................................................................................... 347
15.13 Venting the fuel system .................................................................................................................. 349
15.14 Engine Coolant ............................................................................................................................... 349
15.15 Engine coolant – checks and controls ............................................................................................ 350
15.16 Air filter ........................................................................................................................................... 351
15.16.1 Safety cartridge ....................................................................................................................... 352
16 Maintenance – compressed air system ........................................................................................... 353
16.1 Compressed-air reservoir ............................................................................................................... 353
16.1.1 Checking the compressed air reservoir .................................................................................. 353
16.1.2 Checking the drain valve ......................................................................................................... 354
16.1.3 Retighten tensioning belts ....................................................................................................... 354
16.2 Replace Air Dryer ........................................................................................................................... 354
17 Maintenance – Mowing Units ............................................................................................................ 355
17.1 Special Safety Instructions ............................................................................................................. 355
17.1.1 Test run ................................................................................................................................... 356
17.2 Spare Parts .................................................................................................................................... 356
17.3 Tool box .......................................................................................................................................... 356
17.4 Maintenance Table – Mowing Units ............................................................................................... 357
17.5 Tightening torques .......................................................................................................................... 358
17.6 Tightening torques (countersunk screws) ...................................................................................... 359
17.6.1 Deviating Torque ..................................................................................................................... 359
17.7 Opening the Front Guard ............................................................................................................... 360
17.7.1 Lateral mowing unit left / right ................................................................................................. 360
17.7.2 Front mowing unit .................................................................................................................... 361
17.8 Cleaning the Tedder Housing ........................................................................................................ 361
17.9 Eliminating Blockages on the Cross Conveyor .............................................................................. 362
17.10 Shear pins on the conditioner ........................................................................................................ 363
17.11 Filling Quantities and Lubrication Designations for Gearboxes ..................................................... 364
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17.11.1 Oil Level Check and Oil Change Intervals (Gearboxes) ......................................................... 364
17.12 Main gearbox .................................................................................................................................. 365
17.12.1 Lateral Mowing Unit ................................................................................................................ 365
17.13 Angular gearbox ............................................................................................................................. 367
17.13.1 Front Mowing Unit (CV+CRI) .................................................................................................. 367
17.14 Input gearbox ................................................................................................................................. 368
17.14.1 Front Mowing Unit (CV+CRI) .................................................................................................. 368
17.15 Speed gearbox ............................................................................................................................... 369
17.15.1 Front mowing unit (CV) ........................................................................................................... 369
17.16 Angular gearbox ............................................................................................................................. 370
17.16.1 Bottom part .............................................................................................................................. 370
17.17 Gearbox for Top Roller Drive ......................................................................................................... 371
17.18 Oil level check and oil change on the cutter bar ............................................................................ 372
17.18.1 Front mowing unit .................................................................................................................... 372
17.18.2 Aligning the Cutter Bar ............................................................................................................ 372
17.18.3 Checking the oil level .............................................................................................................. 373
17.18.4 Oil change ............................................................................................................................... 374
17.19 Oil level check and oil change on the cutter bar ............................................................................ 375
17.19.1 Lateral Mowing Unit ................................................................................................................ 375
17.19.2 Checking the oil level .............................................................................................................. 375
17.19.3 Oil change ............................................................................................................................... 376
17.20 Checking the Cutter Blades and Blade Holder .............................................................................. 377
17.20.1 Cutter Blades .......................................................................................................................... 377
17.20.2 Blade screw connection .......................................................................................................... 378
17.20.3 Blade Quick-Fit Device............................................................................................................ 378
17.20.4 Periodical Inspection of the Leaf Springs................................................................................ 379
17.20.5 Periodical Inspection of the Cutting Discs / Blade Drums ....................................................... 380
17.20.6 Abrasion Limit ......................................................................................................................... 381
17.21 Blade Changing on Cutting Discs .................................................................................................. 382
17.21.1 Blade Screw Connection ......................................................................................................... 383
17.21.2 Blade Quick-Fit Device............................................................................................................ 384
17.22 Replacing the linings ...................................................................................................................... 385
17.23 Rotary hub with shear protection ................................................................................................... 386
17.23.1 After Shearing Off ................................................................................................................... 387
17.23.2 Repairing the Sheared off Bearing Unit .................................................................................. 388
18 Maintenance – Basic Machine ........................................................................................................... 389
18.1 Brakes ............................................................................................................................................ 389
18.2 Hydraulic system ............................................................................................................................ 389
18.3 Maintenance - hydraulic system ..................................................................................................... 392
18.3.1 System Description Operating and Brake Hydraulics ............................................................. 392
18.3.2 Pumps ..................................................................................................................................... 392
18.3.3 Main block ............................................................................................................................... 393
18.3.4 Over-Pressure Valves ............................................................................................................. 394
18.3.5 Adjustable Throttles ................................................................................................................ 394
18.4 Hydraulic oil .................................................................................................................................... 396
18.5 Hydraulic oil level ........................................................................................................................... 397
18.6 Replacing the hydraulic oil filter ..................................................................................................... 398
18.7 High-pressure filter ......................................................................................................................... 399
18.8 Transfer gearbox ............................................................................................................................ 400
Table of Contents
12
18.9 Air intake and distribution ............................................................................................................... 401
18.9.1 Changing / cleaning the fresh air filter .................................................................................... 402
18.9.2 Circulation filter ....................................................................................................................... 403
18.10 Windscreen washer system ........................................................................................................... 404
18.11 Cleaning the adjustment plate on the pre-separator ...................................................................... 405
18.12 Position of the Sensors (Left Machine Side) .................................................................................. 406
18.13 Position of the Sensors (Right Machine Side) ............................................................................... 408
18.13.1 Adjusting the Sensors ............................................................................................................. 410
18.13.1.1 Namur sensor d = 12 mm ................................................................................................ 410
18.13.1.2 Namur Sensor d = 30 mm ................................................................................................ 410
18.14 Maintenance - air conditioning system and heating ....................................................................... 411
18.15 Special Safety Instructions ............................................................................................................. 411
18.15.1 Air conditioning components ................................................................................................... 411
18.15.2 Refrigerant .............................................................................................................................. 412
18.15.3 Manometric Switch .................................................................................................................. 412
18.15.4 Collector/drier .......................................................................................................................... 413
18.15.5 Checking Refrigerant Condition and Filling Quantity .............................................................. 414
18.16 Cleaning the Radiator and the Radiator Compartment .................................................................. 415
18.17 Belt drives ....................................................................................................................................... 416
18.17.1 Fan wheel drive ....................................................................................................................... 417
18.17.2 Outrigger arms ........................................................................................................................ 418
18.17.3 Drive of mowing unit ................................................................................................................ 420
18.17.4 Cross Conveyor Drive ............................................................................................................. 421
18.17.5 Checking / Tensioning / Replacing Belt on Conditioner Drive ................................................ 422
18.18 Tyres............................................................................................................................................... 423
18.19 Changing the Tyre Size .................................................................................................................. 423
18.19.1 Checking and maintaining tyres .............................................................................................. 424
18.19.2 Wheel mounting ...................................................................................................................... 425
18.19.3 Retightening the Attachment Bolts on the Outrigger .............................................................. 425
19 Maintenance – lubrication chart ....................................................................................................... 426
19.1 Lubricating the PTO shaft .............................................................................................................. 426
19.2 Lubricating the double joints on the main gearbox ........................................................................ 426
19.3 Lubrication Chart ............................................................................................................................ 427
20 Maintenance – electrical system ....................................................................................................... 428
20.1 Battery ............................................................................................................................................ 428
20.1.1 Main battery switch ................................................................................................................. 429
20.1.2 Charging Batteries .................................................................................................................. 430
20.1.3 Quick charge ........................................................................................................................... 430
20.1.4 Cleaning the battery ................................................................................................................ 430
20.1.5 Check battery .......................................................................................................................... 431
20.1.6 Check acid level ...................................................................................................................... 431
20.1.7 Measuring Acid Density .......................................................................................................... 432
20.2 Fitting the batteries and connecting the poles correctly ................................................................. 433
20.3 Three-phase generator................................................................................................................... 434
20.4 Starter ............................................................................................................................................. 435
20.5 Control Units and Fuses ................................................................................................................. 436
20.5.1 Electronic-Diesel-Control (EDC) ............................................................................................. 437
20.5.2 Cabin Relay Circuit Board ....................................................................................................... 437
20.5.3 Console Circuit Board ............................................................................................................. 438
Table of Contents
13
20.5.4 Cab Circuit Board .................................................................................................................... 440
20.5.5 Circuit Board KRONE Machine Controller (KMC1) ................................................................. 442
21 Maintenance – Central Lubrication................................................................................................... 443
21.1 Overview ........................................................................................................................................ 444
21.2 Lubricant filling ............................................................................................................................... 448
21.3 Fill coupling .................................................................................................................................... 448
21.4 Lubricant ......................................................................................................................................... 449
21.5 Checking the fill level...................................................................................................................... 450
21.6 Change the Times of the Lubrication Interval ................................................................................ 451
21.7 Troubleshooting .............................................................................................................................. 451
22 Placing in Storage .............................................................................................................................. 453
22.1 At the End of the Harvest Season .................................................................................................. 453
22.2 Engine area .................................................................................................................................... 453
22.3 Before the Start of the New Season ............................................................................................... 454
22.4 Friction clutch –ByPy ...................................................................................................................... 455
22.4.1 Venting the Friction Clutch on the PTO Shaft ......................................................................... 455
23 Disposal of the machine .................................................................................................................... 456
23.1 Disposal of the machine ................................................................................................................. 456
24 Appendix ............................................................................................................................................. 456
24.1 Error Messages .............................................................................................................................. 456
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To this Document
14
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2 To this Document
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2.1 Validity
The Operating Instructions apply to all Self-Propelled High Performance Mowing Conditioners
BiG M 420.
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2.2 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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2.3 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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2.4 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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2.5 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
15
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3 Safety
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Ver
3.1 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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3.2 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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Safety
16
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3.2.1 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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3.2.2 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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3.2.3 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
17
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3.3 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
18
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3.4 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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3.5 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
19
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3.6 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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3.7 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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3.8 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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