Krone X-Disc 6200 User manual

O r i g i n a l o p e r a t i n g i n s t r u c t i o n s
Direct cutting system
<v>T-Typ1</v> X-Disc 6200 </v>
<v>T-Typ2</v></v>
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<v>T-Typ4</v></v>
<v>T-Typ5</v></v>
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<v>T-Typ7</v></v>
<v>T-Typ8</v></v>
<v>T-Typ9</v></v>
<v>T-Typ10</v></v>
(
<v>T-abMasch.-Nr.</v> from serial no. </v> : 619 449)
<v>T-Bestell-Nr.</v> Order no. </v> : 150 000 056 00 en
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</v>
17 .05.2010

Foreword
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: Direct cutting system
Type/types: X-Disc 6200
to which this declaration refers is in compliance with the following relevant provisions of
EC Directive 2006/42/EC (Machinery)
The signing Managing Director is authorised to compile the technical documents.
Spelle, 17.05.2010
Dr.-Ing. Josef Horstmann
(Managing Director, Director of Design and Development)
Year of manufacture: Machine No.:
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Dear customer,
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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Foreword
3
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1 Foreword .................................................................................................................................................5
2 Introduction.............................................................................................................................................6
2.1 Purpose of Use .................................................................................................................................. 6
2.2 Validity ............................................................................................................................................... 6
2.2.1 Contact........................................................................................................................................... 6
2.3 Identification Plate ............................................................................................................................. 7
2.4 Information Required for Questions and Orders................................................................................ 7
2.5 Intended Use ..................................................................................................................................... 8
2.6 Technical data ................................................................................................................................... 8
3 Safety.......................................................................................................................................................9
3.1 Identifying Symbols in the Operating Instructions ............................................................................. 9
3.2 Identification of the hazard warnings ................................................................................................. 9
3.2.1 Personnel Qualification and Training........................................................................................... 10
3.2.2 Dangers in Case of Non-compliance with the Safety Instructions............................................... 10
3.2.3 Safety-conscious work practices ................................................................................................. 10
3.3 Safety Instructions and Accident Prevention Regulations............................................................... 11
3.4 Attached devices ............................................................................................................................. 12
3.5 PTO Operation................................................................................................................................. 13
3.6 Maintenance .................................................................................................................................... 14
3.7 Unauthorised Conversion/Modification and Spare Parts Production .............................................. 15
3.8 Inadmissible Modes of Operation .................................................................................................... 15
3.9 Introduction ...................................................................................................................................... 16
3.10 Position of the Adhesive Safety Stickers on the Machine ............................................................... 16
3.11 Position of the General Information Labels on the Machine............................................................ 18
3.11.1 Re-Ordering the Adhesive Safety and Information Labels...................................................... 19
3.11.2 Affixing the Adhesive Safety and Information Labels .............................................................. 19
4 Start-up..................................................................................................................................................20
4.1 Stop points ....................................................................................................................................... 21
4.2 Attachment to the forage harvester ................................................................................................. 21
4.2.1 Adjusting the adapter frame......................................................................................................... 22
4.2.2 Pendulum frame........................................................................................................................... 23
4.2.3 Coupling....................................................................................................................................... 24
4.2.4 Aligning the Cutting System......................................................................................................... 26
5 Driving and Transport..........................................................................................................................27
6 Operation...............................................................................................................................................28
6.1 From transport into working position ............................................................................................... 28
6.1.1 Working position .......................................................................................................................... 28
6.2 Detaching the machine .................................................................................................................... 30
7 Settings .................................................................................................................................................32
7.1 Adjusting the distance between the scraper bars and the auger conveyor..................................... 32

Foreword
4
8 Maintenance..........................................................................................................................................33
8.1 Special Safety Instructions .............................................................................................................. 33
8.1.1 Test run........................................................................................................................................ 34
8.2 Spare Parts ...................................................................................................................................... 34
8.3 Torques............................................................................................................................................ 36
8.4 Torques (Countersunk Screws)....................................................................................................... 37
8.5 Filling Quantities and Lubrication Designations for Gearboxes....................................................... 38
8.5.1 Oil Level Check and Oil Change Intervals (Gearboxes).............................................................. 38
8.6 Main angular gearbox ...................................................................................................................... 39
8.7 L corner gearbox.............................................................................................................................. 40
8.8 Cutter bar drive gear........................................................................................................................ 41
8.9 Oil level check and oil change on the cutter bar.............................................................................. 42
8.9.1 Aligning the Cutter Bar................................................................................................................. 42
8.9.2 Checking the oil level................................................................................................................... 43
8.10 Checking the Cutter Blades and Blade Holder................................................................................ 44
8.10.1 Cutter Blades ........................................................................................................................... 44
8.10.2 Blade screw connection........................................................................................................... 45
8.10.3 Blade Quick-Fit Device ............................................................................................................ 46
8.10.4 Periodical Inspection of the Leaf Springs ................................................................................ 47
8.10.5 Periodical Inspection of the Cutting Discs / Blade Drums ....................................................... 48
8.10.6 Abrasion Limit .......................................................................................................................... 49
8.11 Blade Changing on Cutting Discs.................................................................................................... 50
8.11.1 Blade Screw Connection ......................................................................................................... 51
8.11.2 Blade Quick-Fit Device ............................................................................................................ 52
8.12 Replacing the linings........................................................................................................................ 53
8.13 Rotary hub with shear fuse (optional).............................................................................................. 54
8.13.1 After Shearing Off .................................................................................................................... 56
9 Maintenance – lubrication chart .........................................................................................................58
9.1 Special Safety Instructions .............................................................................................................. 58
9.2 PTO shaft......................................................................................................................................... 58
9.3 Lubrication Chart ............................................................................................................................. 59
10 Placing in Storage ................................................................................................................................60
11 Before the Start of the New Season ...................................................................................................61
11.1 Special Safety Instructions .............................................................................................................. 61
11.2 Test run............................................................................................................................................ 62
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Foreword
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1 Foreword
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Dear Customer!
By purchasing the direct cutting system, you have acquired a quality product made by 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 direct cutting system 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 direct cutting
system.
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Note
In the operating instructions which follow, the direct cutting system 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
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2 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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2.1 Purpose of Use
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The direct cutting system of the X-Disc 6200 series is a front attachment unit specially for the
KRONE forage harvester BiG X. It is used to cut crops growing on the ground (except maize).
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2.2 Validity
These operating instructions apply to the direct cutting system of the series:
X-Disc 6200
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2.2.1 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: [e-mail]
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Introduction
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2.3 Identification Plate
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1
Fig. 1:
The machine data are specified on the type plate (1).
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2.4 Information Required for Questions and Orders
Year
Mach. No.
Type
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, machine number and the year of manufacture of the relevant machine: 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 or additional equipment not manufactured, tested or
approved by KRONE will exclude any liability for consequential damage.
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Introduction
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2.5 Intended Use
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The direct cutting system may be attached only to carrier vehicles for which the relevant adapter
frame is released (observe operating permission of the carrier vehicle). It is built exclusively for
customary use in agricultural work (intended use) - see also Introduction chapter entitled
"Purpose of 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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2.6 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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wa
Type X-Disc 6200
Working width [mm] 6200
Number of mower drums (low) 12
Number of mower drums (high) 2
Drive speed [rpm] 750
Service weight [kg] 2650
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Safety
9
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3 Safety
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3.1 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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3.2 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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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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3.2.1 Personnel Qualification and Training Fehler! Textmarke nicht definiert.
The machine may be used, maintained and repaired only by persons who are familiar with it
and have been instructed about the dangers connected with it. The operator must define areas
of responsibility and monitoring of personnel. Should personnel lack the required knowledge,
they must receive the required training and instruction. The operator must ensure that the
contents of these operating instructions have been fully understood by personnel.
Repair work not described in these operating instructions should only be performed by
authorised service centres.
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3.2.2 Dangers in Case of Non-compliance with the Safety Instructions
Failure to follow the safety instructions could result in personal injury and environmental
hazards as well as damage to the machine. If the safety instructions are not respected, this
could result in the forfeiture of any claims for damages.
Failure to follow the safety instructions could result, for example, in the following hazards:
• Endangering of persons due to not protected working areas.
• Breakdown of important machine functions
• Failure of prescribed methods for repair and maintenance
• Endangering of persons due to mechanical and chemical effects
• Damage to the environment due to leaking hydraulic oil
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3.2.3 Safety-conscious work practices
Always observe the safety instructions set out in these operating instructions, all existing
accident prevention rules and any internal work, operating and safety rules issued by the
operator.
The safety and accident prevention regulations of the responsible professional associations are
binding.
The safety instructions provided by the vehicle manufacturer should also be observed.
Observe the applicable traffic laws when using public roads.
Be prepared for emergencies. Keep the fire extinguisher and first aid box within reach. Keep
emergency numbers for doctors and fire brigade close to the telephone.
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Safety
11
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3.3 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 Special care is required when coupling and uncoupling the cutting system onto or from
the forage harvester.
12 Always attach ballast weights properly to the fixing points provided!
13 Observe permitted axle loads, gross weight and transport dimensions!
14 Check and install transport equipment, such as lighting, warning devices and protective
equipment!
15 Actuating mechanisms (ropes, chains, linkage, etc.) for remotely operated devices must
be designed in such a way that, in whatever transport and working position, they cannot
trigger accidental movements.
16 Ensure that the cutting system is in the prescribed condition for on-road travel and lock 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 Take the cutting system into operation only when all protective 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
12
26 Parts operated by external power (e.g. hydraulically) can cause crushing and shearing
injuries!
27 Before leaving the forage harvester, lower the cutting system onto the ground, apply the
parking brake, switch off the engine and remove the ignition key!
28 Nobody may stay between the forage harvester and the cutting system without the
vehicle being secured against rolling off through the parking brake and wheel chocks!
29 Observe all additional information related to safety in the operating instructions for the
forage harvester.
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3.4 Attached devices
1 Special care is required when coupling and uncoupling the cutting system onto or from
the forage harvester!
2 The cutting system may only be attached to the forage harvester for which it is intended.
3 Do not work on the cutting system until the engine has been stopped and the ignition key
has been removed. All operating levers should be in the neutral position and no hydraulic
lines should be under pressure.
4 Only perform jobs under the raised cutting system when it is securely supported.
5 The direct cutting system must only be used on public roads with the transport carriage
designed for that purpose.
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Safety
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3.5 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 forage
harvester matches the permissible speed of the implement!
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. Do not work on the machine until it has come to a
standstill.
14 Cleaning, lubricating or adjusting PTO driven implements or the PTO shaft only with PTO
disengaged, engine switched off and ignition key withdrawn!
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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Safety
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3.6 Maintenance
1Always make certain that the drive and the engine are switched off before doing any
repairs, maintenance or cleaning! - Remove the ignition key!
2Regularly check that nuts and bolts are properly seated and tighten if necessary!
3When performing maintenance work with the machine raised, always secure it with
suitable supporting elements!
4Oils, greases and filters must be disposed of correctly!
5Always disconnect the power supply before working on the electrical system!
6If protective devices and guards are subject to wear, check them regularly and replace
them in good time!
7When performing electrical welding work on the vehicle and mounted devices, turn power
supply off at main battery switch or disconnect generator cable and battery!
8Replacement parts must at least comply with the technical requirements set by the
manufacturer of the implements! This is guaranteed by original KRONE spare parts!
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9 When replacing working tools with cutting edges, use suitable tools and gloves!
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Safety
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3.7 Unauthorised Conversion/Modification and Spare Parts Production
Conversions or modifications of the machine are permitted only with prior consultation with the
manufacturer. Original spare parts and accessories authorised by the manufacturer help to
ensure safety. Use of other parts may void liability for resulting damage.
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3.8 Inadmissible Modes of Operation
The operating safety of the delivered machine is guaranteed only when it is used as intended in
compliance with the introductory section "Intended use" of the operating instructions. The limit
values listed in the data charts should not be exceeded under any circumstances.
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Safety
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3.9 Introduction
The KRONE-attachment 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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3.10 Position of the Adhesive Safety Stickers on the Machine
Pos: 10.11 / BA/Sic herheit/Au fkleber/V orsätze/ X-Disc 62 00 @ 1 2\mod_12 24579064 656_78.d oc @ 1 5165 8
GL
GPS00005_1
3
1
3
3
36
6
4
4
2
Fig. 2:

Safety
17
1)
Before starting the machine,
read and observe the
operating instructions and
safety instructions.
Order no. 939 471-1 (1x)
2)
The PTO speed must not exceed 750 rpm!
27 000 166 1
MAX. 750/ min
Order No. 27 000 166 1 (1x)
3) Order No. 939 576-0 (4x)
a) Caution: some machine parts will stay in
operation for an extended period of time
before being switched off completely. Do
not touch any moving parts of the
machine. Wait until they have come to a
complete stop.
b) Move the protective devices into position
prior to start-up.
c) When the machine is running, keep your
distance.
3a 3b 3c
4)
Do not enter the danger zone between the
front attachment unit and the machine.
Order No. 942 312-0 (2x)
6)
Close the protective equipment before
putting into operation.
Order No. 942 002 4 (2x)
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939 410 2
STOP 942 197-1

Safety
18
Pos: 10.13 /Überschrif ten/Überschrifte n 2/K-O/Lage der allge meinen Hinweisaufkl eber an derM aschine @ 0\ mod_11956350 67920_78.doc @ 1039
3.11 Position of the General Information Labels on the Machine
Pos: 10.14 /BA/Sicherheit/ Aufkleber/Vorsätz e/Hinweisaufkleb erX-Disc @ 1 2\mod_1224580031 890_78.doc @ 151755
GPS00006_1
5
6
1
12
3
4
7
7
8
7
7
Fig. 3:
1) 942 576 0 (2x) green
2) 942 575 0 (1x) beige
3)
942 393 0 (1x), length of
1400 (beige)
4)
Farbe: beige
942 577 0 (1x)
5)
Order No. 255 498 1 (1x) with
blade screw connection
255 498-1
min. 14 mm
Ø 17,5 mm
80
5)
Order No. 255 499 2 (1x) with
quick blade release
255 499-2

Safety
19
6)
139 888-0 139 889-0
139-888 139-889
939 567-1 (1x)
7)
942 012-1
942 012 1 (4x)
8)
27 000 167 0
Rope, lenght app: 9ft. (2x)
Seil, Länge ca: 3m (2x)
Rope, lenght app: 6ft. (2x)
Seil, Länge ca: 2m (2x)
Weight of machine: 6200 lb
Maschinengewicht: 2800 kg
120
Qualität: Fas Cal 895 glänzend
Untergrund: blau (ral 5010)
Schrift: weiß
27 000 167 0 (1x)
Pos: 10.15 /BA/Sicherh eit/Nachbestellung/ A nbringung Aufkleber @ 0\mo d_119563733710 7_78.doc @ 1079
3.11.1 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").
3.11.2 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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Start-up
20
Pos: 12.1 /Überschrift en/Überschrift en1/F -J/Inbetriebn ahme @0 \mod_119632 7075811_78.doc @ 6 375
4 Start-up
Pos: 12.2 /BA/ Sicher heit/Gefahr enhinweis e/Vors ätze/An-/ Ab au u nd B edienung X-Disc 6200 @ 1 2\mod _12246 673228 28_78.doc @ 1523 73
DANGER! – Attaching / removing and operating the machine
Effect: Danger to life or serious injuries.
• The machine may only be attached to the forage harvester for which it is intended!
• Use extreme caution when attaching the machine to or detaching it from the forage
harvester! The accident prevention regulations must be complied with absolutely.
• The machine is suitable for and intended for cutting crops growing on the ground!
• Maintain an adequate safety distance from the cutting tools during operation.
• The glide skids must rest on the ground before start-up and during work!
• Stones and other objects may be hurled up, even when the machine is used as intended.
For this reason, no one is permitted in the danger zone. Special care should be taken
when working near roads and buildings.
• Check the guard cloths regularly. Worn or damaged guard cloths must be replaced!
• The protective equipment on the machine, e.g. cloths and hoods, protects against flying
stones and similar objects, and prevents access to hazardous areas. For this reason you
must always move them to their protective position before starting work.
• Do not enter the area between the forage harvester and the machine while the machine
is being converted from the transport to the working position and vice versa.
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