Krone BiG M 420 Operating instructions

Original operating instructions

Self-propelled High-Performance

Mower-Conditioner

BiG M 420

(from serial no.: 857 862)

Order no.: 150 000 130 02 us

25.10.2012

Table of Contents

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

1 Table of Contents

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

2 Foreword ...............................................................................................................................................13

3 Introduction...........................................................................................................................................14

3.1 Validity ............................................................................................................................................. 14

3.2 Identification Plate ........................................................................................................................... 14

3.3 Information Required for Questions and Orders.............................................................................. 15

3.4 Intended use.................................................................................................................................... 15

3.5 Reasonably foreseeable misuse ..................................................................................................... 16

3.6 Machine overview............................................................................................................................ 17

3.7 Technical data ................................................................................................................................. 18

3.7.1 Technical Data / Vehicle.............................................................................................................. 18

3.7.2 Technical Data / Mowing Unit CV................................................................................................ 19

3.7.3 Technical Data / Mowing Unit CRI............................................................................................... 19

4 Safety.....................................................................................................................................................20

4.1 Introduction...................................................................................................................................... 20

4.2 Identification of the hazard warnings............................................................................................... 20

4.2.1 Re-Ordering the Adhesive Safety and Information Labels.......................................................... 21

4.2.2 Affixing the Adhesive Safety and Information Labels.................................................................. 21

4.2.3 Contact......................................................................................................................................... 21

4.3 Position of the Adhesive Safety Stickers on the Machine............................................................... 22

4.3.1 Basic machine „front -/ rear view“................................................................................................ 22

4.3.2 Basic machine „left and right side hand of machine”................................................................... 26

4.3.3 Lateral mowing unit left / right...................................................................................................... 30

4.3.4 Front mowing unit ........................................................................................................................ 32

4.4 Identifying Symbols in the Operating Instructions ........................................................................... 34

4.5 Identification of the hazard warnings............................................................................................... 34

4.5.1 Personnel Qualification and Training Fehler! Textmarke nicht definiert...................................... 35

4.5.2 Dangers in Case of Non-compliance with the Safety Instructions............................................... 35

4.5.3 Safety-conscious work practices ................................................................................................. 35

4.6 Safety Instructions and Accident Prevention Regulations............................................................... 36

4.7 Conveying persons, guides, operating personnel ........................................................................... 37

4.8 Self-propelled working machine ...................................................................................................... 37

4.9 Autopilot........................................................................................................................................... 38

4.10 Implements ...................................................................................................................................... 39

4.11 Hydraulic system ............................................................................................................................. 39

4.12 Battery.............................................................................................................................................. 40

4.13 Cooling system ................................................................................................................................ 40

4.14 Tyres................................................................................................................................................ 40

4.15 Emergency exit................................................................................................................................ 40

4.16 Working in the vicinity of power transmission lines ......................................................................... 41

4.17 Fire preventions............................................................................................................................... 41

4.18 Maintenance .................................................................................................................................... 42

4.19 Telephone and radio sets................................................................................................................ 42

4.19.1 Wheel chocks........................................................................................................................... 42

4.19.2 Main battery switch.................................................................................................................. 43

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5 Cabin......................................................................................................................................................44

5.1 Ladder to driver's cabin ................................................................................................................... 44

5.2 Opening the cabin door ................................................................................................................... 45

5.3 Operators controls........................................................................................................................... 46

5.3.1 Overview...................................................................................................................................... 46

5.4 Air comfort seat................................................................................................................................ 47

5.4.1 Setting the left armrest................................................................................................................. 49

5.4.2 Right armrest ............................................................................................................................... 49

5.4.3 Drawer for first-aid kit/operating instructions............................................................................... 50

5.5 Guide's seat..................................................................................................................................... 51

5.5.1 Cooler .......................................................................................................................................... 51

5.5.2 Emergency Exit............................................................................................................................ 52

5.5.3 OBD diagnostics plug (On-Board-plug)....................................................................................... 53

5.6 Steering Column and Foot Pedals................................................................................................... 54

5.6.1 Steering Column Adjustment....................................................................................................... 55

5.6.2 Horn............................................................................................................................................. 56

5.6.3 Indicator Switches........................................................................................................................ 56

5.6.4 Full Beam..................................................................................................................................... 57

5.6.5 Headlamp Flasher ....................................................................................................................... 57

5.6.6 Using the operating brake............................................................................................................ 58

5.7 Switch Group Roof Panel ................................................................................................................ 59

5.8 Lighting ............................................................................................................................................ 60

5.8.1 Overview...................................................................................................................................... 60

5.8.2 Indicator, hazard warning flasher and brake light........................................................................ 61

5.8.2.1 Switching on the indicator.................................................................................................... 61

5.8.2.2 Brake light............................................................................................................................ 61

5.8.2.3 Switching on the hazard warning flasher............................................................................. 61

5.8.3 Side light/dipped beam ................................................................................................................ 62

5.8.3.1 Switching on the parking light.............................................................................................. 62

5.8.3.2 Switching on the dipped beam............................................................................................. 62

5.8.4 Working floodlights ...................................................................................................................... 63

5.8.4.1 Working floodlights Cab....................................................................................................... 64

5.8.4.2 Working floodlight Bottom front............................................................................................ 64

5.8.4.3 Working floodlights "down the side and at the right/left mowing units" ............................... 65

5.8.4.4 Working floodlight rear......................................................................................................... 65

5.8.5 Allround lights (optional) .............................................................................................................. 66

5.8.6 Interior Lighting / Spotlight........................................................................................................... 67

5.8.7 Additional Spotlight...................................................................................................................... 68

5.9 Outside mirrors ................................................................................................................................ 69

5.9.1 Left Outside Mirror....................................................................................................................... 69

5.9.2 Right outside mirror and anti-collision mirror............................................................................... 70

5.9.2.1 Setting the right outside mirror............................................................................................. 70

5.9.2.2 Setting the anti-collision mirror ............................................................................................ 70

5.10 Inside mirror..................................................................................................................................... 71

5.11 Sun blind.......................................................................................................................................... 71

5.12 Windshield wipers............................................................................................................................ 72

5.13 Washer system – windshield........................................................................................................... 72

5.14 Switch panel .................................................................................................................................... 73

5.15 Panel Switches and Pilot Lamps..................................................................................................... 74

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5.15.1 Actuating release switches...................................................................................................... 74

5.15.2 Release switch – road/field...................................................................................................... 75

5.15.3 Autopilot release switch / - optional......................................................................................... 76

5.15.4 Release switch - holding brake................................................................................................ 77

5.15.5 Release switch travelling gear................................................................................................. 78

5.15.6 Axle separation key ................................................................................................................. 79

5.15.7 Pilot Lamp Engine Oil Pressure............................................................................................... 80

5.15.8 Charge Indicator Lamp ............................................................................................................ 80

5.15.9 Pilot Lamp Cooling Water Temperature.................................................................................. 80

5.15.10 Ignition lock.............................................................................................................................. 81

5.15.11 Cigarette lighter / 12-V socket ................................................................................................. 82

5.16 Diagnostics Socket (ISO-Bus)......................................................................................................... 82

5.16.1 Diagnostics Socket / USB Connection .................................................................................... 83

5.17 Multi-Function Lever........................................................................................................................ 84

5.17.1 In Field Mode Only................................................................................................................... 84

5.17.2 Multi-Function Lever (Continued) ............................................................................................ 86

5.17.2.1 Driving.............................................................................................................................. 86

5.18 Klimatronik / heating........................................................................................................................ 87

5.18.1 Control and display elements .................................................................................................. 87

5.18.2 Operation................................................................................................................................. 89

5.18.3 Switching on the System ......................................................................................................... 89

5.18.4 Setting the Desired Cab Temperature..................................................................................... 89

5.18.5 Switch air conditioning On / Off ............................................................................................... 90

5.18.6 Switch REHEAT mode On / Off............................................................................................... 91

5.18.7 Manual setting of evaporator fan speed .................................................................................. 92

5.18.8 Switching the Temperature Display to ° Fahrenheit................................................................ 93

5.18.9 Showing Faults in the Display.................................................................................................. 93

5.19 Adjustable Fan Nozzles................................................................................................................... 95

5.20 Radio................................................................................................................................................ 96

6 Info centre "EasyTouch" .....................................................................................................................97

6.1.1 Overview...................................................................................................................................... 97

6.2 Information Section.......................................................................................................................... 99

6.2.1 Status line (I).............................................................................................................................. 100

6.2.2 Motor Data (II) Information Section............................................................................................ 101

6.2.3 Information section of the travelling gear data (III).................................................................... 102

6.2.4 Information section of settings (IV and V).................................................................................. 103

6.2.5 Information Section Drive Information (VI) ................................................................................ 103

6.3 Quick Access Keys in the Basic Screen........................................................................................ 104

6.3.1 Quick access "Hydraulically adjustable cutting height" (optional)............................................. 104

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

106

6.3.3 Quick Access „Customer Data Counter“ ................................................................................... 108

6.3.4 Changing a customer record (1) or creating a new one............................................................ 109

6.3.4.1 Switching the counter on or off.......................................................................................... 110

6.3.4.2 Delete customer counter.................................................................................................... 111

6.3.4.3 Switching to General Counters (Machine Data Counters) ................................................ 111

6.3.5 Quick access "Hydraulic axle suspension"................................................................................ 112

6.3.5.1 From the "Road travel" basic screen................................................................................. 112

6.3.5.2 From the "Field mode" basic screen.................................................................................. 113

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6.3.6 Quick access "Machine settings"............................................................................................... 114

6.4 Menu level...................................................................................................................................... 115

6.4.1 Bringing up a Menu Level.......................................................................................................... 120

6.5 Main menu 1 "Settings" ................................................................................................................. 121

6.6 Menu 1-1 "Parameters" ................................................................................................................. 122

6.6.1 Entering parameters .................................................................................................................. 123

6.7 Menu 1-2 „Machine Setting“ .......................................................................................................... 124

6.7.1 Menu 1-3 "Units"........................................................................................................................ 129

6.7.2 Menu 1-4 "Language"................................................................................................................ 130

6.7.3 Menu 1-5 "Display" .................................................................................................................... 131

6.7.4 Menu 1-5-1 "Contrast" ............................................................................................................... 132

6.7.5 Menu 1-5-2 Beeper.................................................................................................................... 133

6.7.6 Beeper limited by time ............................................................................................................... 134

6.7.7 Menu 1-5-4 Direction of Rotation............................................................................................... 135

6.7.8 Menu 1-5-5 Configure status line .............................................................................................. 136

6.7.9 Menu 1-6 Date/time ................................................................................................................... 137

6.7.10 Menu 1-9 Owner's address.................................................................................................... 138

6.8 Main Menu 2 Counters .................................................................................................................. 139

6.8.1 Machine Data Counter............................................................................................................... 139

6.8.1.1 Deleting the Machine Data Counters (Sets 1 to 3).............................................................. 140

6.8.2 Switching to Customer DataCounters......................................................................................... 140

6.9 Main Menu 3 Maintenance ............................................................................................................ 141

6.9.1 Menu 3-1 "Calibration of cutting height" .................................................................................... 142

6.10 Menu 3-3 Calibrating Autopilot ...................................................................................................... 144

6.10.1 Calibrating Steering Angle Sensor......................................................................................... 146

6.11 Calibrating Steering (Valves) Automatically .................................................................................. 147

6.11.1 Calibrating Steering (Valves) Manually ................................................................................. 152

6.12 Setting the Steering Radius........................................................................................................... 153

6.12.1 Menu 3-5 „Manual Mode“ ...................................................................................................... 154

6.12.2 Status display of general sensors (2) .................................................................................... 157

6.13 Main Menu 4 Service..................................................................................................................... 159

6.13.1 Menu 4-1 Diagnostics............................................................................................................ 160

6.13.2 Display of Possible Faults for the Diagnostics....................................................................... 163

6.13.3 Menu 4-1-1 Diagnostics of axle suspension.......................................................................... 164

6.13.4 Menu 4-1-3 Diagnostics of spring compensation .................................................................. 167

6.13.5 Menu 4-1-4 Diagnostics of cutting height .............................................................................. 173

6.13.6 Menu 4-1-5 Diagnostics of hydraulic auger hood (optional).................................................. 181

6.13.7 Menu 4-1-6 Sideshift diagnostics (optional) .......................................................................... 187

6.13.8 Menu 4-1-7 Diagnostics front guard flaps (optional) ............................................................. 192

6.13.9 Menu 4-1-9 Autopilot ............................................................................................................. 197

6.13.10 Menu 4-1-10 Diagnostics Work ............................................................................................. 200

6.13.11 Menu 4-1-11 CAN-Bus .......................................................................................................... 211

6.13.12 Menu 4-1-12 Travelling gear.................................................................................................. 212

6.13.13 Menu 4-1-13 Electronics........................................................................................................ 223

6.13.14 Menu 4-1-14 Diesel Engine................................................................................................... 224

6.13.15 Menu 4-1-15 Joystick............................................................................................................. 227

6.13.16 Menu 4-1-16 Control unit console ......................................................................................... 229

6.13.17 Menu 4-1-17 Display.............................................................................................................. 232

6.14 Menu 4-2 Error list......................................................................................................................... 233

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6.15 Menu 4-3 "Service level"................................................................................................................ 238

6.16 Menu 4-4 Information..................................................................................................................... 239

6.16.1 Menu 4-4-1 Joystick............................................................................................................... 240

6.16.2 Menu 4-4-2 Software ............................................................................................................. 241

6.16.3 Menu 4-4-3 Machine.............................................................................................................. 243

6.17 Menu 5 Basic Screen..................................................................................................................... 244

6.17.1 Error Messages...................................................................................................................... 245

6.17.2 Information message ............................................................................................................. 246

7 Commissioning...................................................................................................................................247

7.1 Fitting the guard cloths .................................................................................................................. 247

7.2 Folding Down Lateral Mowing Units.............................................................................................. 247

7.2.1 Description of Installation........................................................................................................... 249

7.2.2 Guard cloths (CRI with upper roller drive) ................................................................................. 250

7.2.3 Adjusting the Warning Panel ..................................................................................................... 251

7.3 Installation of Cutter Blades........................................................................................................... 251

8 Start-up................................................................................................................................................252

8.1 Check before Start-up.................................................................................................................... 252

8.2 Daily checks................................................................................................................................... 252

8.2.1 On the Basic Machine................................................................................................................ 253

8.2.2 On the mowing units.................................................................................................................. 253

9 Driving and Transport........................................................................................................................254

9.1 Transport / Road Travel................................................................................................................. 254

9.2 Preparation for transport/road travel.............................................................................................. 255

9.2.1 Folding Up the Guards............................................................................................................... 255

9.2.2 Moving the Front Mowing Unit To Central Position (with Sideshift Option)............................... 256

9.2.3 Check lock ................................................................................................................................. 257

9.2.4 Disable the shut-off valve on the front outrigger........................................................................ 258

9.2.5 Release switch – road/field........................................................................................................ 258

9.2.6 Release switch travelling gear................................................................................................... 259

9.3 Starting the engine......................................................................................................................... 260

9.3.1 Killing the engine ....................................................................................................................... 262

9.3.2 Starting with an Auxiliary Battery............................................................................................... 262

9.4 Starting to Drive............................................................................................................................. 262

9.4.1 Setting the Acceleration Behaviour............................................................................................ 263

9.4.2 General on Driving..................................................................................................................... 263

9.4.3 Preventing an overheating of the hydrostatic system................................................................ 264

9.4.4 Driving Forwards........................................................................................................................ 265

9.4.5 Reversing................................................................................................................................... 266

9.5 Cruise Control................................................................................................................................ 267

9.5.1 Saving the Speed for Cruise Control Mode............................................................................... 267

9.5.2 Activating Cruise Control ........................................................................................................... 268

9.5.3 Deactivating Cruise Control....................................................................................................... 268

9.6 Stopping......................................................................................................................................... 269

9.6.1 Stopping with the Multi-Function Lever ..................................................................................... 269

9.6.2 Stopping with Foot Brakes......................................................................................................... 270

9.7 Parking Brake ................................................................................................................................ 271

9.8 Switch off the engine ..................................................................................................................... 272

9.9 Switch off the machine................................................................................................................... 272

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9.10 Towing ........................................................................................................................................... 273

9.10.1 Releasing the holding brake manually................................................................................... 273

10 Operation – Mowing Units.................................................................................................................274

10.1 Intended Use ................................................................................................................................. 274

10.2 Operation of Mowing Units ............................................................................................................ 275

10.3 Folding Down the Mowing Units.................................................................................................... 276

10.3.1 Lowering All Mowing Units from Transport Position to Headland Position............................ 277

10.3.2 Lowering All Mowing Units from Headland Position to Working Position.............................. 278

10.3.3 Lowering the Lateral Mowing Units from Transport Position to Headland Position .............. 279

10.3.4 Lowering the Lateral Mowing Units from Headland Position to Working Position................. 279

10.3.5 Lowering the Front Mowing Unit from Transport Position to Headland Position................... 280

10.3.6 Lowering the Front Mowing Unit from Headland Position to Working Position..................... 280

10.4 Mowing Unit Drive.......................................................................................................................... 281

10.4.1 Switching the Mowing Unit Drives On and Off....................................................................... 282

10.4.2 Switching the Left Mowing Unit Drive On/Off ........................................................................ 282

10.4.3 Switching the Right Mowing Unit Drive On/Off...................................................................... 283

10.4.4 Switching the Front Mowing Unit Drive On/Off...................................................................... 284

10.4.5 Switching All Mowing Unit Drives On/Off............................................................................... 285

10.5 Folding up the Mowing Units ......................................................................................................... 286

10.5.1 Checking the Lock on the Lateral Mowing Units ................................................................... 287

10.5.2 Lifting All Mowing Units from Working Position to Headland Position................................... 288

10.5.3 Folding All Mowing Units from Headland Position to Transport Position .............................. 288

10.5.4 Lifting the Lateral Mowing Units from Working Position to Headland Position...................... 289

10.5.5 Folding the Lateral Mowing Units from Headland Position to Transport Position................. 289

10.5.6 Check lock ............................................................................................................................. 290

10.5.7 Lifting the Front Mowing Unit from Working Position to Headland Position.......................... 291

10.5.8 Lifting the Front Mowing Unit from Working Position to Headland Position.......................... 291

10.6 Folding the Front Mowing Unit from Headland Position to Transport Position.............................. 292

10.7 Mowing........................................................................................................................................... 293

10.8 Game animal protection................................................................................................................. 294

10.8.1 Moving the guards into the working position ......................................................................... 295

10.8.2 Mowing with Individual Mowing Units.................................................................................... 295

10.8.3 Quick Stop ............................................................................................................................. 296

10.8.4 Fast Direction Change (Fast Reversing) ............................................................................... 296

10.8.5 Switching Axle Separation On and Off .................................................................................. 297

11 Adjusting the mowing units ..............................................................................................................298

11.1 Special Safety Instructions ............................................................................................................ 298

11.2 Adjusting the cutting height............................................................................................................ 299

11.2.1 Front mowing unit .................................................................................................................. 299

11.2.2 Adjusting the Lifting Height.................................................................................................... 300

11.2.2.1 Front mowing unit .......................................................................................................... 300

11.2.3 Adjusting the cutting height.................................................................................................... 301

11.2.3.1 Lateral Mowing Unit....................................................................................................... 301

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

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

11.3.2 Lateral Mowing Unit............................................................................................................... 305

11.4 Adjusting the Tedder Speed.......................................................................................................... 306

11.4.1 Lateral Mowing Unit............................................................................................................... 306

11.4.2 Front mowing unit (CV).......................................................................................................... 307

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11.5 Adjusting the conditioner plate ...................................................................................................... 308

11.6 Adjusting the roller conditioner (optional extra/BiG M CRI)........................................................... 309

11.6.1 Adjusting the roller distance................................................................................................... 309

11.6.2 Adjusting the roller pressure.................................................................................................. 310

11.7 Setting of the Scraper on the Cross Conveyor (Optional)............................................................. 311

11.8 Adjusting the swath width.............................................................................................................. 312

11.8.1 Front mowing unit .................................................................................................................. 312

11.8.2 Lateral Mowing Unit............................................................................................................... 313

11.9 Adjusting the track control arm on the lateral mowing units.......................................................... 314

11.10 Deflector Plates.......................................................................................................................... 314

11.10.1 Front mowing unit .................................................................................................................. 314

11.11 Deactivating the axle suspension.............................................................................................. 315

12 Special Equipment – Mowing Units..................................................................................................316

12.1 Converting the Tedder Deflector Plate to an Auger-Type Cross Conveyor.................................. 316

12.1.1 Removing the tedder deflector plate...................................................................................... 317

12.1.2 Releasing the tension jacks................................................................................................... 317

12.1.3 Removing the tedder deflector plate...................................................................................... 318

12.1.4 Checking the Tines................................................................................................................ 319

12.1.5 Removing the guard .............................................................................................................. 319

12.1.6 Installing the auger-type cross conveyor............................................................................... 320

12.1.7 Locking the tension jacks....................................................................................................... 321

12.2 Tensioning the V-belts................................................................................................................... 321

12.2.1 Installing the guard ................................................................................................................ 322

12.2.2 Connecting the speed sensor................................................................................................ 322

12.2.3 Removing the floor plates...................................................................................................... 323

12.2.4 Relaying the Lubrication Lines............................................................................................... 325

12.2.5 Installation Instructions – Bulge Bags for BiG M 400 / BiG M 420 with BSS ........................ 326

12.2.6 Switching on the auger monitoring mode.............................................................................. 327

12.2.7 Converting an Auger-Type Cross Conveyor to a "Tedder deflector plate unit"..................... 329

12.3 Additional Equipment – Mulching Device...................................................................................... 330

12.4 Removing Mowing Units................................................................................................................ 331

12.4.1 Front mowing unit .................................................................................................................. 331

12.4.2 Removing of the compensation springs ................................................................................ 332

12.4.3 To remove the PTO shaft: ..................................................................................................... 333

12.4.4 Remove the Weiste Triangle ................................................................................................. 335

12.4.5 Attaching the Front Mowing Unit............................................................................................ 337

12.4.6 Removing the Side Mowing Unit............................................................................................ 338

12.4.7 Attaching the Lateral Mowing Unit......................................................................................... 345

12.4.8 The remainder of the installation is in reverse order to the removal procedure.................... 347

13 Maintenance – Engine........................................................................................................................348

13.1.1 Overview of motor.................................................................................................................. 348

13.2 Overview of maintenance (MAN) excerpt...................................................................................... 348

13.3 Maintenance Table – Engine......................................................................................................... 350

13.4 Contamination in the engine compartment.................................................................................... 352

13.5 Cleaning the Engine Compartment with Compressed Air............................................................. 352

13.6 Engine oil level............................................................................................................................... 353

13.6.1 Engine oil and filter replacement........................................................................................... 353

13.7 Fuel filter/water separator.............................................................................................................. 354

13.7.1 Replacing the fuel filter .......................................................................................................... 354

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13.7.2 Empty the water separator..................................................................................................... 354

13.8 Replacing the fuel filter insert ........................................................................................................ 355

13.8.1 Replacing the filter in the hand pump.................................................................................... 356

13.9 Replacing Urea Filter Inserts......................................................................................................... 357

13.10 Fuel............................................................................................................................................ 359

13.11 Tanks............................................................................................................................................. 360

13.12 Tanks of urea solution ............................................................................................................... 361

13.13 Venting the fuel system ............................................................................................................. 363

13.14 Engine Coolant .......................................................................................................................... 363

13.15 Engine coolant – checks and controls....................................................................................... 364

13.16 Air filter....................................................................................................................................... 365

13.16.1 Safety cartridge...................................................................................................................... 366

14 Maintenance – compressed air system ...........................................................................................367

14.1 Compressed-air reservoir.............................................................................................................. 367

14.1.1 Checking the compressed air reservoir................................................................................. 367

14.1.2 Checking the drain valve ....................................................................................................... 368

14.1.3 Retighten tensioning belts ..................................................................................................... 368

14.2 Replace Air Dryer .......................................................................................................................... 368

15 Maintenance – Mowing Units ............................................................................................................370

15.1 Special Safety Instructions ............................................................................................................ 370

15.1.1 Test run.................................................................................................................................. 371

15.2 Spare Parts.................................................................................................................................... 371

15.3 Tool box......................................................................................................................................... 371

15.4 Maintenance Table – Mowing Units .............................................................................................. 372

15.5 Tightening Torques........................................................................................................................ 373

15.6 Tightening Torques (Countersunk Screws)................................................................................... 374

15.6.1 Deviating Torque ................................................................................................................... 374

15.7 Opening the Front Guard............................................................................................................... 375

15.7.1 Lateral mowing unit left / right................................................................................................ 375

15.7.2 Front mowing unit .................................................................................................................. 376

15.8 Eliminating Blockages on the Cross Conveyor.............................................................................. 377

15.9 Shear pins on the conditioner........................................................................................................ 378

15.10 Filling Quantities and Lubrication Designations for Gearboxes................................................. 379

15.10.1 Oil Level Check and Oil Change Intervals (Gearboxes)........................................................ 379

15.11 Main gearbox............................................................................................................................. 380

15.11.1 Lateral Mowing Unit............................................................................................................... 380

15.12 Angular gearbox ........................................................................................................................ 381

15.12.1 Front Mowing Unit (CV+CRI)................................................................................................. 381

15.13 Input gearbox............................................................................................................................. 382

15.13.1 Front Mowing Unit (CV+CRI)................................................................................................. 382

15.14 Speed gearbox........................................................................................................................... 383

15.14.1 Front mowing unit (CV).......................................................................................................... 383

15.15 Angular gearbox ........................................................................................................................ 384

15.15.1 CRI......................................................................................................................................... 384

15.15.2 Bottom part ............................................................................................................................ 384

15.16 Gearbox for Top Roller Drive..................................................................................................... 385

15.17 Oil level check and oil change on the cutter bar........................................................................ 386

15.17.1 Front mowing unit .................................................................................................................. 386

15.17.2 Aligning the Cutter Bar........................................................................................................... 386

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15.17.3 Checking the oil level............................................................................................................. 387

15.17.4 Oil change.............................................................................................................................. 388

15.18 Oil level check and oil change on the cutter bar........................................................................ 389

15.18.1 Lateral Mowing Unit............................................................................................................... 389

15.18.2 Checking the oil level............................................................................................................. 389

15.18.3 Oil change.............................................................................................................................. 390

15.19 Checking the Cutter Blades and Blade Holder.......................................................................... 391

15.19.1 Cutter Blades......................................................................................................................... 391

15.19.2 Blade screw connection......................................................................................................... 392

15.19.3 Blade Quick-Fit Device.......................................................................................................... 394

15.19.4 Checking the Material Thickness of the Retaining Bolts ....................................................... 394

15.19.4.1 Checking the material thickness of the retaining bolts .................................................. 395

15.19.5 Periodical Inspection of the Leaf Springs .............................................................................. 396

15.19.6 Checking the Material Thickness of the Leaf Springs ........................................................... 396

15.19.6.1 Checking the material thickness of the leaf springs ...................................................... 397

15.19.7 Periodical Inspection of the Cutting Discs / Blade Drums..................................................... 398

15.19.8 Abrasion Limit........................................................................................................................ 399

15.20 Blade Changing on Cutting Discs.............................................................................................. 400

15.20.1 Blade Screw Connection ....................................................................................................... 401

15.20.2 Blade Quick-Fit Device.......................................................................................................... 402

15.21 Replacing the linings.................................................................................................................. 403

15.22 Rotary hub with shear protection............................................................................................... 404

15.22.1 After Shearing Off.................................................................................................................. 405

15.22.2 Repairing the Sheared Off Bearing Unit................................................................................ 406

16 Maintenance – Basic Machine...........................................................................................................407

16.1 Brakes............................................................................................................................................ 407

16.2 Hydraulic system ........................................................................................................................... 408

16.3 Maintenance - hydraulic system.................................................................................................... 411

16.3.1 System Description Operating and Brake Hydraulics............................................................ 411

16.3.2 Pumps.................................................................................................................................... 411

16.3.3 Main block.............................................................................................................................. 412

16.3.4 Over-pressure valves............................................................................................................. 413

16.3.5 Adjustable Throttles............................................................................................................... 413

16.4 Hydraulic oil ................................................................................................................................... 414

16.4.1 List of Mineral Oils for the Hydraulic System......................................................................... 414

HEPG VG 46....................................................................................................................................... 414

16.5 Hydraulic oil level........................................................................................................................... 415

16.6 Replacing the hydraulic oil filter..................................................................................................... 416

16.7 Transfer gearbox ........................................................................................................................... 417

16.8 Air intake and distribution .............................................................................................................. 418

16.8.1 Changing / cleaning the fresh air filter................................................................................... 419

16.8.2 Circulation filter...................................................................................................................... 420

16.9 Windscreen washer system........................................................................................................... 420

16.10 Cleaning the adjustment plate on the pre-separator ................................................................. 421

16.11 Position of Sensors (Right-Hand Side of the Machine)............................................................. 422

16.12 Position of sensors (left side of machine).................................................................................. 424

16.12.1 Adjusting the Sensors............................................................................................................ 425

16.12.1.1 Namur sensor d = 12 mm.............................................................................................. 425

16.13 Maintenance - air conditioning system and heating .................................................................. 426

Table of Contents

11

16.14 Special Safety Instructions ........................................................................................................ 426

16.14.1 Air conditioning components.................................................................................................. 426

16.14.2 Refrigerant data sheet R 134a (excerpt) ............................................................................... 427

16.14.3 Technical data........................................................................................................................ 427

16.14.4 Refrigerant............................................................................................................................. 428

16.14.5 Manometric Switch ................................................................................................................ 428

16.14.6 Collector/drier......................................................................................................................... 429

16.14.7 Checking refrigerant condition and level ............................................................................... 430

16.15 Checking the Capacitor ............................................................................................................. 431

16.16 Belt drives.................................................................................................................................. 432

16.16.1 Fan wheel drive...................................................................................................................... 433

16.16.2 Outrigger arms....................................................................................................................... 434

16.16.3 Drive of mowing unit.............................................................................................................. 436

16.16.4 Cross Conveyor Drive............................................................................................................ 437

16.17 Tyres.......................................................................................................................................... 438

16.17.1 Checking and maintaining tyres............................................................................................. 439

16.17.2 Wheel mounting..................................................................................................................... 440

16.17.3 Retightening the Attachment Bolts on the Outrigger............................................................. 440

17 Maintenance – lubrication chart .......................................................................................................441

17.1 Lubricating the PTO shaft.............................................................................................................. 441

17.2 Lubricating the double joints on the main gearbox........................................................................ 441

17.3 Lubrication Chart ........................................................................................................................... 442

18 Maintenance – electrical system.......................................................................................................444

18.1 Electrical equipment - technical data............................................................................................. 444

18.2 Battery............................................................................................................................................ 445

18.2.1 Main battery switch................................................................................................................ 446

18.2.2 Charging Batteries................................................................................................................. 447

18.2.3 Quick charge.......................................................................................................................... 447

18.2.4 Cleaning the battery............................................................................................................... 447

18.2.5 Check battery......................................................................................................................... 448

18.2.6 Check acid level..................................................................................................................... 448

18.2.7 Measuring Acid Density......................................................................................................... 449

18.3 Fitting the batteries and connecting the poles correctly................................................................ 450

18.4 Three-phase generator.................................................................................................................. 451

18.5 Starter............................................................................................................................................ 452

18.6 Control units and fuses.................................................................................................................. 453

18.6.1 Electronic-Diesel-Control (EDC)............................................................................................ 454

18.6.2 Cab relay PCB....................................................................................................................... 454

18.6.3 Console Circuit Board............................................................................................................ 455

18.6.4 Cabin Circuit Board................................................................................................................ 456

18.6.5 Krone Machine Controller circuit board (KMC1).................................................................... 457

19 Maintenance – Central Lubrication...................................................................................................458

19.1 Overview........................................................................................................................................ 458

19.2 Lubricant filling............................................................................................................................... 459

19.3 Fill coupling.................................................................................................................................... 459

19.4 Lubricant........................................................................................................................................ 460

19.4.1 Grease types, NLGIClass 2................................................................................................... 461

19.5 Checking the fill level..................................................................................................................... 462

Table of Contents

12

19.6 Change the Times of the Lubrication Interval................................................................................ 463

19.7 Troubleshooting............................................................................................................................. 463

20 Placing in Storage..............................................................................................................................465

20.1 At the End of the Harvest Season ................................................................................................. 465

20.2 Engine area.................................................................................................................................... 465

20.3 Before the Start of the New Season.............................................................................................. 466

20.4 Friction clutch –ByPy..................................................................................................................... 467

20.4.1 Venting the Friction Clutch on the PTO Shaft........................................................................ 467

21 Appendix .............................................................................................................................................468

21.1 Error Messages ............................................................................................................................. 468

22 index ....................................................................................................................................................469

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Foreword

13

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2 Foreword

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Dear Customer

On buying the Self-Propelled High-Performance Mower-Conditioner BiG M 420 you have

selected a quality product from KRONE.

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

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

machine so that the Self-Propelled High-Performance Mower-Conditioner BiG M 420 may be

used to its maximum capacity.

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

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

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

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

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

BiG M 420, that these notes and information are adhered to.

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Note

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

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

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Please note:

The operating instructions are part of your machine.

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

instructions.

It is essential to observe the safety instructions!

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

recognised regulations concerning safety, occupational health and road traffic.

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

latest state at the time of publication.

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

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

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

quoting the number supplied overleaf.

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

Maschinenfabrik Bernard Krone GmbH

Spelle

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Introduction

14

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3 Introduction

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

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

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

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

safety instructions contained in the other sections.

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3.1 Validity

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

BiG M 420.

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3.2 Identification Plate

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1

BM 420 0059

Fig. 1

The machine data are located on a nameplate (1). It is located on the lower right side of the

machine on the front of the frame.

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Introduction

15

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3.3 Information Required for Questions and Orders

Type

Year of manufacture

Vehicle ID number

Note

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

rendered illegible!

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

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

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

Note

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

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

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

thereof.

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Ver

3.4 Intended use

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

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

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

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

the end of the photosynthetic process).

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

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

process of the mowed crop.

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

conditions set by the manufacturer.

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Introduction

16

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3.5 Reasonably foreseeable misuse

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

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

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

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Examples of such misuse are:

• Mowing undergrowth and bushes

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

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

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

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

Unauthorised modifications shall therefore release the manufacturer of any liability for

consequential damage.

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Introduction

17

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3.6 Machine overview

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1BM 420 0036

2

5 6

34

7

8

9

10

11 12

13

Fig.2

1 Lateral mowing unit right 2 Operating panel

3 Right outrigger arm 4 Engine

5 Lifting gear 6 Combination radiator

7 Front mowing unit 8 Work hydraulics valves

9 Lateral mowing unit left 10 Main battery switch

11 Left outrigger arm 12 Shut-off valve for front outrigger

13 Cab

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Introduction

18

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3.7 Technical data

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

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

and without notification of reasons.

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3.7.1 Technical Data / Vehicle

Power {KW/HP} 309/420

Transport width/length/height {mm} 3000 / 8165 / 4000

Weight {approx. kg} 15500

Weight distribution approx. 10000- at the front / 6000- at the

rear

Running gear 4 wheels

Direct drive provided by radial piston

engines

Steering Rear axle steering

Tyres / air pressure front 750/65 R26 - 1.9 bar (MEGA X BIB)

rear 580/70 R26 - 1.2 bar (XM 27)

front 750/60 R30 - 1.0 bar (CARGO X BIB)

rear 600/60 R30 - 1.0 bar (CARGO X BIB)

Tightening torque wheel nuts Nm 630

Hydrostatic travelling gear Level I

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

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

Connectable axle separation in level 1

Drive pump Delivery volume 105/75 ccm, pressure

430 bar

Filling Quantities

Filling quantities {I} Filtered oils

Brand name Bio-degradable

lubricants

Brand name

Diesel tank approx. 700 please refer to

chapter

“Maintenance-motor”

Carbamide solution approx. 70 please refer to

chapter

“Maintenance-motor”

Engine oil approx. 40 please refer to

chapter

“Maintenance-motor”

Hydraulic oil approx. 80 HLP 46 HE 46 *)

Coolant approx. 70 (please refer to

chapter

“Maintenance-motor”

Transfer gearbox approx. 6.0 Gearbox oil synthetic

DIN 51502 –PGLP

ISO VG 220

*)Caution: Do not mix with other oils.

Consult customer service before using other oils.

Introduction

19

3.7.2 Technical Data / Mowing Unit CV

Working width total/individual {mm} 9720 / 3140 front / 3520 side

Transport width {mm} 3000 mowing unit

Number of cutting discs 4 / side mowing units - 5 front mowing units

Number of blade drums 4 / side mowing units - 2 front mowing units

Conditioner system V-shaped prong

Speed of the conditioner {rpm} 700 / 1000

3.7.3 Technical Data / Mowing Unit CRI

Working width total/individual {mm} 9000 / 3140

Transport width {mm} 3000 mowing unit

Number of cutting discs 5 / Mowing unit

Number of blade drums 2 / Mowing unit

Conditioner system Rollers

Speed of the conditioner {rpm} 760

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Safety

20

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4 Safety

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4.1 Introduction

The Big M 400 Self-Propelled High-Performance Mower-Conditioner is equipped with all the

necessary safety devices (protective devices). However, it is not possible to eliminate all

potential hazards on this machine as this would impair its full functional capability. Hazard

warnings are attached to the machine in the relevant areas to warn against any dangers. The

safety instructions are provided in the form of so-called warning pictograms. Important

information on the position of these safety signs and what they mean is given below!

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Danger! - Danger zone of the machine

Effect: Danger to life or serious injuries.

• Immediately replace damaged or illegible adhesive labels.

• Following repair work, always attach appropriate adhesive safety stickers to all the

replaced, modified or repaired components.

• Never clean areas carrying an adhesive safety label using a high-pressure cleaner.

• Familiarise yourself with the statement of the warning pictograms. The adjacent text and

the selected location on the machine provide information on the special danger spots on

the machine.

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4.2 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