Krone BiG M 420 Operating instructions

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

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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.:

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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

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

laws when using public highways.

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

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

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

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

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

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

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

8Only drive the machine at the permitted speed.

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

instructions for road travel.

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

sufficient ventilation.

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

of batteries and electrical cables.

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Safety

19

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3.6 Autopilot

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

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

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

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

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

checked and make a visual inspection of all the components.

To do this, the user should proceed as follows:

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

switch engages

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

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

direction.

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

operation.

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

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

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

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

switched off on the autopilot release switch on the console.

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

the hydraulic, electrical or electronic components.

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

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Safety

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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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Krone BiG M 420 Operating instructions

Krone BiG M 420 Operating instructions

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