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
2
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
Pos: 3.2 /BA/Vor wort/Selbstfahrer/Ver ehrter Kunde BiG M 420 @ 49\m od_128695017 6328_78.docx @ 4637 47@ @ 1
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.
Pos: 3.3/ BA/Vorwort/Selb stfahrer/Weiteren Verla ufBig M @ 0\mod_1 195627075279_7 8.docx@ 9 63@ @ 1
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".
Pos: 3.4 /BA/Vor wort/Beachten Sie für Maschi ne@ 0\mod_119562690 4076_78.docx @ 944 @ @ 1
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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Pos: 7.1/ BA/Einleitung/Ei nleitung @ 0\mod_11955624 98677_78.docx @ 416 @ 1 @ 1
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
• Measures for risk prevention.
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