Krone Swadro 1000 Operating instructions

Original operating instructions

Rotary Swather

Swadro 1000

(from serial no.: 864 760)

Order no.: 150 000 116 04 en

22.11.2012

Table of Contents

2

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CV0

EC Declaration of Conformity

We, Maschinenfabrik Bernard Krone GmbH

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

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

that the

Machine: Krone Rotary Rake

Type / Types: Swadro 1000

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

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

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

Spelle, 29.03.10

Dr.-Ing. Josef Horstmann

(Managing Director, Design and Development)

Year of manufacture: Machine No.:

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Dear customer,

You have now received the operating instructions for the KRONE

product which you have purchased.

These operating instructions contain important information for the

proper use and safe operation of the machine.

If these operating instructions should become wholly or partially

unusable, you can obtain replacement operating instructions for

your machine by stating the number given overleaf.

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Table of Contents

3

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1 Table of Contents

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

2 Foreword ................................................................................................................................................. 6

3 Introduction ............................................................................................................................................. 7

3.1 Purpose of Use .................................................................................................................................. 7

3.2 Validity ............................................................................................................................................... 7

3.3 Identification Plate ............................................................................................................................. 7

3.4 Information Required for Questions and Orders ................................................................................ 8

3.5 Intended Use ..................................................................................................................................... 9

3.6 Technical data ................................................................................................................................... 9

3.7 Driving and Transport ........................................................................................................................ 9

4 Safety ..................................................................................................................................................... 12

4.1 Introduction ...................................................................................................................................... 12

4.1.1 Re-Ordering the Adhesive Safety and Information Labels .......................................................... 13

4.1.2 Affixing the Adhesive Safety and Information Labels .................................................................. 13

4.1.3 Contact ......................................................................................................................................... 13

4.2 Position of the Adhesive Safety Stickers on the Machine ............................................................... 14

4.3 Identifying Symbols in the Operating Instructions ........................................................................... 16

4.4 Identification of the hazard warnings ............................................................................................... 16

4.4.1 Personnel Qualification and Training ........................................................................................... 17

4.4.2 Dangers in Case of Non-compliance with the Safety Instructions............................................... 17

4.4.3 Safety-conscious work practices ................................................................................................. 17

4.5 Safety Instructions and Accident Prevention Regulations ............................................................... 18

4.6 Hitched Implements ......................................................................................................................... 19

4.7 PTO operation ................................................................................................................................. 20

4.8 Hydraulic system ............................................................................................................................. 21

4.9 Tyres ................................................................................................................................................ 21

4.10 Maintenance .................................................................................................................................... 22

4.11 Working in the vicinity of power transmission lines ......................................................................... 23

4.12 Unauthorised Conversion/Modification and Spare Parts Production .............................................. 23

4.13 Inadmissible Modes of Operation .................................................................................................... 23

4.14 Safety Instructions on the Machine ................................................................................................. 23

5 Commissioning..................................................................................................................................... 25

5.1 First installation ................................................................................................................................ 26

5.2 Preparations on tractor .................................................................................................................... 26

5.2.1 Adjusting the Lifting Height .......................................................................................................... 26

5.3 PTO shaft ......................................................................................................................................... 27

5.3.1 Length adjustment ....................................................................................................................... 27

5.4 Height of tractor lower suspension arms ......................................................................................... 28

6 Medium Control Unit ............................................................................................................................ 29

6.1 Mounting .......................................................................................................................................... 30

6.2 Electrical power supply .................................................................................................................... 30

6.3 Control unit....................................................................................................................................... 31

6.4 Control unit overview ....................................................................................................................... 32

6.5 Operational Readiness .................................................................................................................... 34

6.5.1 Sensor pilot lights ........................................................................................................................ 34

6.6 Settings ............................................................................................................................................ 34

Table of Contents

4

6.6.1 Selecting the Rotors for a Function ............................................................................................. 34

6.7 Lowering the Rotors from Transport to Headland Position ............................................................. 35

6.7.1 Lowering All Rotors to Headland Position ................................................................................... 35

6.8 Lowering the Rotors from Headland to Working Position. ............................................................... 36

6.8.1 Lowering All Rotors to Working Position ..................................................................................... 36

6.8.2 Lowering individual rotors to working position (optional) ............................................................. 36

6.9 Lowering the Rotors from Working to Headland Position ................................................................ 37

6.9.1 Raising All Rotors to Headland Position ...................................................................................... 37

6.9.2 Raising individual rotors to headland position (optional) ............................................................. 37

6.10 Raising Rotors to Transport Position ............................................................................................... 38

6.10.1 Raising All Rotors to transport Position ................................................................................... 38

6.11 Adjusting the Swath Width ............................................................................................................... 39

6.12 Adjusting the Working Height of the Rotors (optional) .................................................................... 40

6.13 Sensor test ....................................................................................................................................... 41

6.14 Alarm Messages .............................................................................................................................. 42

6.15 Malfunctions - Causes and Remedies ............................................................................................. 43

6.16 Eliminating Alarm Messages ........................................................................................................... 44

6.17 Displaying the Software Version ...................................................................................................... 44

7 Start-up .................................................................................................................................................. 45

7.1 Mounting onto the Tractor ................................................................................................................ 46

7.2 Hydraulics ........................................................................................................................................ 47

7.2.1 Special Safety Instructions .......................................................................................................... 47

7.2.2 Connecting the hydraulic lines ..................................................................................................... 48

7.3 Lighting connection .......................................................................................................................... 49

7.4 Connecting the electrical controls .................................................................................................... 50

7.5 Install the PTO shaft ........................................................................................................................ 51

7.6 Using the safety chain ..................................................................................................................... 52

8 Driving and Transport .......................................................................................................................... 53

9 Operation ............................................................................................................................................... 55

9.1 Overload protection ......................................................................................................................... 55

9.2 From transport into working position ............................................................................................... 56

9.3 Removing the tine protections from the tine tips ............................................................................. 56

9.4 Lower rotor arms to working position ............................................................................................... 56

9.5 Swivel tine arms to working position. ............................................................................................... 57

9.6 Move the hoop guards to the working position. ............................................................................... 59

9.7 Travelling on an incline .................................................................................................................... 60

9.8 Travelling speed und drive speed .................................................................................................... 60

9.9 Switching from working position to transport position ..................................................................... 61

9.10 Move the hoop guards to transport position. ................................................................................... 61

9.11 Swivelling tine arms into transport position ..................................................................................... 62

9.12 Lifting the rotor arms to transport position ....................................................................................... 65

9.13 Securing the tine tips (transport position and swather switched off) ............................................... 65

9.14 Parking ............................................................................................................................................. 66

10 Settings ................................................................................................................................................. 67

10.1 To adjust the rotor running gear ...................................................................................................... 67

10.1.1 Optional .................................................................................................................................... 68

10.2 Setting the Lifting Height in Headland Position ............................................................................... 69

10.3 Adjustable throttles .......................................................................................................................... 70

Table of Contents

5

10.4 Regulating direction of travel ........................................................................................................... 71

11 Maintenance .......................................................................................................................................... 72

11.1 Special Safety Instructions .............................................................................................................. 72

11.2 Compensation Spring(s) .................................................................................................................. 72

11.3 Test run. ........................................................................................................................................... 72

11.4 Tightening Torques .......................................................................................................................... 73

11.5 Tightening Torques (Countersunk Screws) ..................................................................................... 74

11.6 Testing the screws on the tines ....................................................................................................... 74

11.7 Disc springs at collapsible tine arms outside ................................................................................... 75

11.8 Tyres ................................................................................................................................................ 76

11.8.1 Checking and maintaining tyres............................................................................................... 76

11.8.2 Torque of wheels on the running gear ..................................................................................... 77

11.8.3 Tyre air pressure ...................................................................................................................... 77

11.9 Replacing Tines ............................................................................................................................... 80

11.10 Position of sensors and actuators ............................................................................................... 82

11.10.1 Adjusting the Sensors .............................................................................................................. 83

11.10.1.1 Namur sensor d = 30 mm ................................................................................................ 83

12 Maintenance - hydraulic system ......................................................................................................... 84

12.1 Load-sensing connection ................................................................................................................. 85

12.2 Adjusting the hydraulic system ........................................................................................................ 86

12.3 Emergency Manual Activation ......................................................................................................... 86

12.4 Examples of Emergency Manual Activation .................................................................................... 87

12.5 Hydraulic System Circuit Diagrams ................................................................................................. 90

13 Maintenance – lubrication chart ......................................................................................................... 91

13.1 Special Safety Instructions .............................................................................................................. 91

13.2 PTO shaft ......................................................................................................................................... 91

13.3 Lubrication Chart ............................................................................................................................. 92

14 Maintenance - Gearbox ........................................................................................................................ 94

14.1 Filling Quantities and Lubrication Designations for Gearboxes ....................................................... 94

14.2 Rotor gearbox / rotor housing .......................................................................................................... 94

14.3 Main gearbox ................................................................................................................................... 95

14.4 Transfer gearbox ............................................................................................................................. 96

15 Special equipment ................................................................................................................................ 97

15.1 Tine loss safeguard ......................................................................................................................... 97

15.2 Chain for height restriction of suspension arms .............................................................................. 98

16 Placing in Storage ................................................................................................................................ 99

16.1 Special Safety Instructions .............................................................................................................. 99

16.2 At the End of the Harvest Season ................................................................................................. 100

16.3 Before the Start of the New Season .............................................................................................. 101

16.4 Special Safety Instructions ............................................................................................................ 101

17 Malfunctions - Causes and Remedies .............................................................................................. 102

17.1 Special Safety Instructions ............................................................................................................ 102

18 Appendix ............................................................................................................................................. 104

19 Index .................................................................................................................................................... 105

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Foreword

6

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2 Foreword

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Dear Customer,

By purchasing your rotary rake, you have acquired 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 to allow you to use the rotary rake to its full 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. This information and these instructions are essential,

important and useful for the operational safety, reliability and durability of the rotary rake.

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Note

In the operating instructions which follow, the rotary rake will also be referred to as the

"machine".

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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

7

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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 Purpose of Use

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The rotary rake is designed to swathe cut crops. The installation is designed as a CAT II three-

point frame at the tail.

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3.2 Validity

These operating instructions apply to rotary rakes of the series:

Swadro 1000

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3.3 Identification Plate

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SW9070001

1

Figure 1

The machine data is located on the type plate (1).

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Introduction

8

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3.4 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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Introduction

9

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3.5 Intended Use

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The rotary rake is built exclusively for conventionaluse in agricultural work (intended use).

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Any use of the machine for other purposes is deemed not to be in accordance with intended

use. The manufacturer shall not be liable for any resulting damage; the user alone shall bear

the risk.

Operation in accordance with intended use also includes observing the operating, maintenance

and service instructions specified by the manufacturer.

Unauthorised modifications to the machine may affect the properties of the machine or disrupt

proper operation. For this reason, unauthorised modifications shall exclude any liability of the

manufacturer for consequential damage.

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3.6 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 Driving and Transport

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For machines which have an operating permit, follow the conditions contained therein!

The Road Traffic Law varies from one state or country to another.

If there are differences between manufacturer data and the Road Traffic Law, the current

requirements of the relevant state or country always apply.

Speed limits as specified by the Road Traffic Law must be followed. Speed limits differ from one

state or country to another.

For machines which have no brakes, the pulling tractor's empty weight must correspond to the

permitted operating specifications, but in any case twice the axle load of the machine

(depending on the user's country)

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Introduction

10

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Road travel is only permitted with the swivelled rotary arms in transport position. The max.

height of 4 m must not be exceeded.

Type Swadro 1000

Lower suspension arm hitch Unit standard

Number of rotors Unit 2

Number of arms / rotors Unit 15

Number of double tines / arms approx. mm 4

Working width approx. mm 8900 - 10000

Rotor diameter approx. mm 4200

Height with tine arms / transport position approx. mm 4550

Height of retracted tine arms / transport position approx. mm 3900

Height in working position approx. mm 1700

Length approx. mm 7000

Width in transport position approx. mm 2995

Width in working position approx. mm 8900 - 10000

Power consumption approx.

kW/HP

51/70

PTO speed rpm max. 540

Equivalent continuous pneumatic level recorder below 70 d B(A)

Acreage approx./h 9 - 10

Tyres on rotor running gear Tridem axle

Main running gear

16x6.50-8 4PR

15/55-17 10PR

Tyre pressure guide wheels and running gear bar 1

Electrical power indicator light Volt 12

Max. operating pressure of hydraulic system bar 200

Required hydraulic connections

Free backflow required

1 SA *

Yes

Dead weight kg 3300

Permissible axle load kg 1500

Permissible bearing load kg 1800

*) SA= Single-action control unit

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Introduction

11

L

SW1000001

B

Figure 2:

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Safety

12

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4 Safety

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4.1 Introduction

The rotary rake is equipped with all 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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Safety

13

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4.1.1 Re-Ordering the Adhesive Safety and Information Labels

Note

Every adhesive safety and information label is assigned an order number and can be ordered

directly from the manufacturer or from an authorized dealer (see Section "Contact").

4.1.2 Affixing the Adhesive Safety and Information Labels

Note - Affixing an adhesive label

Effect: Adhesion of the label

• The surface for affixing the adhesive label must be clean and free of dirt, oil and grease.

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4.1.3 Contact

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Maschinenfabrik Bernard Krone GmbH

Heinrich-Krone-Strasse 10

D-48480 Spelle (Germany)

Telephone: + 49 (0) 59 77/935-0 (Head Office)

Fax.: + 49 (0) 59 77/935-339 (Head Office)

Fax.: + 49 (0) 59 77/935-239 (Spare parts - domestic)

Fax.: + 49 (0) 59 77/935-359 (Spare parts - export)

Email: [email protected]

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Safety

14

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4.2 Position of the Adhesive Safety Stickers on the Machine

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GL

1 8

5

4

SW1000002_1

6

5

2

6

7

3

Fig. 3

1)

Before starting the

machine, read and follow

the operating instructions

and safety instructions.

Order No. 939 471-1 (1x)

2)

The PTO speeds must not exceed 540 rpm!

The operating pressure of the hydraulic

system must not exceed 200 bar!

939 100-4

MAX.540/min

MAX.200bar

Order No. 939 100-4 (1x)

3)

Before starting work, move

the hoop guard to the

protective position (fold

down).

Order No. 939 574 0 (2x)

4)

Danger in the area where rotors are turning -

keep your distance!

939 472-2

Order No. 939 472-2 (2x)

939 574-0

Safety

15

5)

Do not stay in the swivel range of the

outrigger arms. Keep your distance!

Order No. 939 414-2 (2x)

6)

While parts are moving, never

reach into areas where there

is a risk of being crushed.

Order no. 942 196-1 (4x)

7)

Keep the stipulated safe distance from power

transmission lines.

Order no. 942 293-0 (1x)

8)

The shut-off valve must

always be closed for road

travel.

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942 196 -1

27 002 459 0

Safety

16

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4.3 Identifying Symbols in the Operating Instructions

The safety instructions contained in this manual which could result in personal injury if not

followed are identified by the general danger sign:

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4.4 Identification of the hazard warnings

Danger!

DANGER! - Type and source of the hazard!

Effect: Danger to life or serious injuries.

• Measures for hazard prevention

Warning !

WARNING! - Type and source of the hazard!

Effect: Injuries, serious material damage.

• Measures for hazard prevention

Caution!

CAUTION! - Type and source of the hazard!

Effect: Property damage

• Measures for risk prevention.

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General function instructions are indicated as follows:

Note!

Note - Type and source of the note

Effect: Economic advantage of the machine

• Actions to be taken

Instructions which are attached to the machine need to be followed and kept fully legible.

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Safety

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4.4.1 Personnel Qualification and Training

The machine may be used, maintained and repaired only by persons who are familiar with it

and have been instructed about the dangers connected with it. The operator must define areas

of responsibility and monitoring of personnel. Should personnel lack the required knowledge,

they must receive the required training and instruction. The operator must ensure that the

contents of these operating instructions have been fully understood by personnel.

Repair work not described in these operating instructions should only be performed by

authorised service centres.

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4.4.2 Dangers in Case of Non-compliance with the Safety Instructions

Failure to follow the safety instructions could result in personal injury and environmental

hazards as well as damage to the machine. If the safety instructions are not respected, this

could result in the forfeiture of any claims for damages.

Failure to follow the safety instructions could result, for example, in the following hazards:

• Endangering of persons due to not protected working areas.

• Breakdown of important machine functions

• Failure of prescribed methods for repair and maintenance

• Endangering of persons due to mechanical and chemical effects

• Damage to the environment due to leaking hydraulic oil

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4.4.3 Safety-conscious work practices

Always observe the safety instructions set out in these operating instructions, all existing

accident prevention rules and any internal work, operating and safety rules issued by the

operator.

The safety and accident prevention regulations of the responsible professional associations are

binding.

The safety instructions provided by the vehicle manufacturer should also be observed.

Observe the applicable traffic laws when using public roads.

Be prepared for emergencies. Keep the fire extinguisher and first aid box within reach. Keep

emergency numbers for doctors and fire brigade close to the telephone.

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Safety

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4.5 Safety Instructions and Accident Prevention Regulations

1 Please follow all generally applicable safety and accident prevention regulations in

addition to the safety instructions contained in these operating instructions!

2 The attached warning and safety signs provide important information for safe operation.

Pay attention to these for your own safety!

3 When using public roads, make sure to observe the applicable traffic regulations!

4 Make sure that you are familiar with all equipment and controls as well as with their

functions before you begin working with the machine. It is too late to learn this when you

are using the machine for work!

5 The user should wear close fitting clothes. Avoid wearing loose or baggy clothing.

6 Keep the machine clean to prevent the danger of fire!

7 Before starting or moving the machine, make certain that nobody is in the vicinity of the

machine! (Watch for children!) Make sure that you have a clear view!

8 Carrying passengers during operation and transport on the working implement is not

permitted.

9 Couple implements correctly! Attach and secure implements to specified devices only!

10 When attaching or detaching implements, place the supporting devices in the correct

positions!

11 Use extreme caution when attaching or detaching implements onto or from the tractor!

12 Always attach ballast weights properly to the fixing points provided!

13 Observe permitted axle loads, gross weight and transport dimensions!

14 Check and attach transport equipment, such as lighting, warning devices and protective

equipment!

15 Actuating mechanisms (cables, chains, linkages etc.) for remote controlled devices must

be positioned in such a way that no movements are unintentionally triggered in any

transport or working positions.

16 Ensure that implements are in the prescribed condition for on-road travel and lock them in

place in accordance with the manufacturer's instructions!

17 Never leave the driver's seat when the vehicle is moving!

18 Always drive at the correct speed for the prevailing driving conditions! Avoid sudden

changes in direction when travelling uphill or downhill or across a gradient!

19 Hitched implements and ballast weights affect the driving, steering and braking response

of the machine. Make sure that you are able to brake and steer the machine as required!

20 Take into account the extension radius and/or inertia of an implement when turning

corners!

21 Start up implements only when all safety devices have been attached and set in the

required position!

22 Keep safety equipment in good condition. Replace missing or damaged parts.

23 Keep clear of the working range of the machine at all times!

24 Do not stand within the turning and swivel range of the implement!

25 Never operate the hydraulic folding frames if anyone is inside the swivel range!

Safety

19

26 Parts operated by external power (e.g. hydraulically) can cause crushing and shearing

injuries!

27 Before leaving the tractor, lower the implement onto the ground, apply the parking brake,

switch off the engine and remove the ignition key!

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4.6 Hitched Implements

1 Secure implements against rolling.

2 Observe the maximum supported load on the trailer coupling, swing drawbar or hitch!

3 If a drawbar coupling is used, make certain that there is enough play at the coupling

point.

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Safety

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4.7 PTO operation

1 Use only PTO shafts specified by the manufacturer!

2 The guard tube and guard cone of the PTO shaft and the PTO guard must be attached

and in good working condition (on the implement side, too)!

3 Make sure that the required tube covers are in place for PTO shafts in transport and

working position!

4 Before installing or detaching PTO shafts, disengage the PTO, switch off the engine and

remove the ignition key!

5 When using PTO shafts with an overload safety or free-running coupling which are not

shielded by the guard on the tractor, mount the overload safety or free-running coupling

on the implement side!

6 Always make sure that the PTO shaft is properly installed and secured!

7 Attach chains to prevent the PTO shaft guard from rotating with the shaft!

8 Before switching on the PTO, make sure that the selected PTO speed of the tractor

matches the permissible implement speed!

9 Before switching on the PTO shaft make sure that no person is in the danger zone of the

device!

10 Never switch on the PTO if the engine is switched off!

11 No one should be in the vicinity of the rotating PTO or PTO shaft when the PTO is in use.

12 Always switch off the PTO shaft when the angle is too large or the PTO shaft is not

required!

13 Caution! After disengaging the PTO danger due to the flywheel running on! Keep away

from the implement during this time. The machine may be worked on only if it is

completely at standstill and if the flywheel is secured by the parking brake.

14 Cleaning, lubricating or adjusting PTO driven implements or the PTO shaft only with PTO

disengaged, engine switched off and ignition key withdrawn! Secure the fly-wheel with the

parking brake.

15 Place the disconnected PTO shaft onto the support provided!

16 After detaching the PTO shaft, attach the protective cover to the PTO end!

17 If damage occurs, correct this immediately before using the implement!

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Note

The instructions of the manufacturer must be observed with regard to the PTO shaft. (separate

operating instructions)

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