Krone X-Disc 620 User manual

Original operating instructions
Direct cutting system
X-Disc 620
(from serial no.: 922 361)
Order no.: 150 000 687 00 en
20.05.2015

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 620
to which this declaration refers is in compliance with the relevant provisions of
EC directive 2006/42/EC (machines).
The signing Managing Director is authorised to compile the technical documents.
Spelle, 13.04.2015
Dr.-Ing. Josef Horstmann
(Managing Director, 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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1Foreword.................................................................................................................................................6
2To this Document...................................................................................................................................8
2.1 Validity................................................................................................................................................8
2.1.1 Direction Information...................................................................................................................8
2.2 Representation and Utilization of Warning Notes..............................................................................8
2.3 Identification of the hazard warnings..................................................................................................8
3Safety.......................................................................................................................................................9
3.1 Purpose of Use...................................................................................................................................9
3.2 Intended Use......................................................................................................................................9
3.3 Service life of the machine.................................................................................................................9
3.4 Basic safety instructions...................................................................................................................10
3.4.1 Importance of the operating instructions...................................................................................10
3.4.2 Personnel qualification..............................................................................................................10
3.4.3 Children in danger.....................................................................................................................11
3.4.4 Connecting front attachments or trailers...................................................................................11
3.4.5 Structural changes to the machine ...........................................................................................11
3.4.6 Additional equipment and spare parts ......................................................................................12
3.4.7 Workstations and passengers...................................................................................................12
3.4.8 Operational safety: Technically perfect condition.....................................................................13
3.4.9 Danger zones............................................................................................................................14
3.4.10 Keeping safety devices functional.............................................................................................16
3.4.11 Personal protective equipment .................................................................................................17
3.4.12 Safety signs on the machine.....................................................................................................17
3.4.13 Traffic safety..............................................................................................................................18
3.4.14 Parking the machine safely.......................................................................................................18
3.4.15 Consumables............................................................................................................................19
3.4.16 Sources of danger on the machine...........................................................................................19
3.4.17 Dangers associated with certain activities: Work on the machine............................................21
3.4.18 Behaviour in hazardous situations and when accidents occur.................................................22
3.5 Safety routines .................................................................................................................................23
3.5.1 Stopping and securing the machine..........................................................................................23
3.5.2 Supporting lifted machine and machine parts securely............................................................23
4Machine Description ............................................................................................................................24
4.1 Machine overview.............................................................................................................................24
4.2 Identification Plate............................................................................................................................26
4.3 Information Required for Questions and Orders..............................................................................26
4.3.1 Contact......................................................................................................................................27
4.4 Introduction.......................................................................................................................................27
4.4.1 Re-Ordering the Adhesive Safety and Information Labels .......................................................27
4.4.2 Affixing the Adhesive Safety and Information Labels ...............................................................27
4.5 Position of the Adhesive Safety Stickers on the Machine................................................................28
4.6 Technical data..................................................................................................................................30
4.7 Lubricants.........................................................................................................................................30
4.7.1 Filling Quantities and Lubrication Designations for Gearboxes................................................30
5Commissioning.....................................................................................................................................31
5.1 Checklist for Initial Operation...........................................................................................................31
5.2 Attachment to the forage harvester..................................................................................................31
5.3 Stop points .......................................................................................................................................32

Foreword
4
5.4 Parking the machine.........................................................................................................................32
5.5 Adjusting machine to the forage harvester BiG X 480/580..............................................................33
5.5.1 Adjusting the locking plates ......................................................................................................34
5.5.2 Adjusting the main angular gearbox .........................................................................................36
6Start-up..................................................................................................................................................39
6.1 Checking and Observing Before Start-Up........................................................................................39
6.2 Attachment to the forage harvester..................................................................................................40
6.2.1 Adapter Frame..........................................................................................................................40
6.2.2 Parking supports in transport position on the right/left..............................................................42
7Driving and Transport..........................................................................................................................43
8Operation...............................................................................................................................................45
8.1 From transport into working position................................................................................................45
8.1.1 Working Position.......................................................................................................................45
8.2 Detaching the machine ....................................................................................................................47
9Settings .................................................................................................................................................49
9.1 Adjusting the distance between the scraper bars and the auger conveyor.....................................50
9.1.1 Set Ground Skid........................................................................................................................51
9.2 Setting Infeed Sheets.......................................................................................................................51
10 Maintenance..........................................................................................................................................53
10.1 Special Safety Instructions...............................................................................................................53
10.1.1 Test run.....................................................................................................................................53
10.2 Spare Parts ......................................................................................................................................53
10.3 Maintenance table............................................................................................................................54
10.4 Tightening torques............................................................................................................................55
10.4.1 Metric Thread Screws with Control Thread ..............................................................................55
10.4.2 Metric Thread Screws with Fine Thread...................................................................................56
10.4.3 Metric Thread Screws with Countersunk Head and Hexagonal Socket...................................56
10.5 Main angular gearbox ......................................................................................................................57
10.6 L corner gearbox..............................................................................................................................58
10.7 Cutter bar drive gear ........................................................................................................................59
10.8 Oil level check and oil change on the cutter bar..............................................................................60
10.8.1 Oil change.................................................................................................................................60
10.8.2 Checking the oil level................................................................................................................60
10.8.3 Aligning the Cutter Bar..............................................................................................................60
10.9 Checking the Cutter Blades and Blade Holder ................................................................................62
10.9.1 Cutter Blades ............................................................................................................................62
10.9.2 Blade screw connection............................................................................................................63
10.9.3 Blade Quick-Fit Device .............................................................................................................64
10.9.4 Periodical Inspection of the Leaf Springs .................................................................................65
10.9.5 Periodical Inspection of the Cutting Discs / Blade Drums.........................................................66
10.9.6 Abrasion Limit ...........................................................................................................................67
10.10 Blade Changing on Cutting Discs ....................................................................................................68
10.10.1 Blade Screw Connection...........................................................................................................69
10.10.2 Blade Quick-Fit Device .............................................................................................................70
10.11 Replacing the linings........................................................................................................................71
10.12 Rotary hub with shear fuse (optional) ..............................................................................................72
10.12.1 After Shearing Off .....................................................................................................................74
10.13 Wear Sheets for Trough...................................................................................................................76

Foreword
5
10.14 Infeed Sheets...................................................................................................................................76
10.15 Rubber Strip.....................................................................................................................................77
10.16 Drive chains......................................................................................................................................77
11 Maintenance – lubrication chart .........................................................................................................78
11.1 Special Safety Instructions...............................................................................................................78
11.2 PTO shaft.........................................................................................................................................78
11.3 Lubrication Chart..............................................................................................................................79
12 Placing in Storage................................................................................................................................80
13 Before the Start of the New Season ...................................................................................................81
13.1 Special Safety Instructions...............................................................................................................81
13.2 Test run............................................................................................................................................82
14 Disposal of the machine......................................................................................................................83
14.1 Disposal of the machine...................................................................................................................83
15 Index......................................................................................................................................................84
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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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Foreword
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To this Document
8
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2 To this Document
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2.1 Validity
These operating instructions are valid for the direct cutting system of the series:
X-Disc 620
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2.1.1 Direction Information
Direction information in this document such as front, rear, right and left always applies in the
direction of travel.
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2.2 Representation and Utilization of Warning Notes
Warning of dangers are highlighted in this document as warning notes and they are marked with
danger signs and signal words.
The warnings must be read completely and the measurements must be strictly adhered to in
order to avoid personal injury.
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2.3 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 Safety
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3.1 Purpose of Use
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The direct cutting system of the X-Disc 620 series is a header especially for the KRONE forage
harvester BiG X. It is used to cut thin crops growing on the ground.
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3.2 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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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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3.3 Service life of the machine
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– The service life of this machine strongly depends on proper use and maintenance as well as
the operating conditions.
– Permanent operational readiness as well as long service life of the machine can be
achieved by observing the instructions and notes of these operating instructions.
– After each season of use, the machine must be checked thoroughly for wear and other
damage.
– Damaged and worn parts must be replaced before placing the machine into service again.
– After the machine has been used for five years, carry out full technical inspection of the
machine. According to the results of this inspection, a decision concerning the possibility of
reuse of the machine should be taken.
– Theoretically, the service life of this machine is unlimited as all worn or damaged parts can
be replaced.
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Safety
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3.4 Basic safety instructions
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Non-compliance with the safety instructions and warnings
Non-compliance with the safety instructions and warnings may result in injuries and damage to
the environment and property.
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3.4.1 Importance of the operating instructions
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The operating instructions are an important document and a part of the machine. They are
intended for the user and contain information relevant to safety.
Only the procedures indicated in the operating instructions are reliable. If the operating
instructions are not followed, people may be seriously injured or killed.
• Before using the machine for the first time, read and follow all the "Basic safety instructions"
in the chapter Safety.
• Before working, also read and observe the respective sections in the operating instructions.
• Retain the operating instructions and ensure that they are always available.
• Hand over the operating instructions to subsequent users.
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3.4.2 Personnel qualification
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If the machine is not used properly, people may be seriously injured or killed. To avoid
accidents, each person who works with the machine must satisfy the following minimum
requirements:
– He is physically capable of controlling the machine.
– He can work safely with the machine in accordance with these operating instructions.
– He understands the method of operation of the machine within the scope of his work and
can identify and avoid the dangers associated with the work.
– He has read the operating instructions and can implement the information in the operating
instructions accordingly.
– He is familiar with driving vehicles safely.
– For road travel he has adequate knowledge of the highway code and has the stipulated
driving licence.
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Safety
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3.4.3 Children in danger
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Children cannot assess danger and behave unpredictably.
As a result, children are especially at risk.
• Keep children away from the machine.
• Keep children away from consumables.
• Especially before starting up and moving the machine, ensure that there are no children in
the danger zone.
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3.4.4 Connecting front attachments or trailers
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If the machine is incorrectly connected to a forage harvester, there is a risk of causing serious
accidents.
• When connecting front attachments or trailers, follow all operating instructions:
– The operating instructions for the machine
– The operating instructions for the forage harvester
– The operating instructions for the universal shaft
• Follow the coupling instructions, see chapter Initial start-up, "Adjusting machine to forage
harvester" and chapter Start-up, "Attaching to the forage harvester".
• Note the modified driving behaviour of the combination.
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3.4.5 Structural changes to the machine
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Structural changes and enhancements may impair the functionality and operational safety of the
machine. As a result, people may be seriously injured or killed.
• Have structural changes and enhancements performed by an authorised service centre
only.
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Safety
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3.4.6 Additional equipment and spare parts
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Additional equipment and spare parts, which do not comply with the requirements of the
manufacturer, may impair the operational safety of the machine and cause accidents.
• To ensure operational safety, use original or standard parts which comply with the
requirements of the manufacturer. If in doubt, have parts verified by the dealer or
manufacturer.
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3.4.7 Workstations and passengers
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Passengers
Passengers may be seriously injured by the machine or fall off the machine and get run over.
Ejected objects may strike and injure passengers.
• Never let people ride on the machine.
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Safety
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3.4.8 Operational safety: Technically perfect condition
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Operation only when the machine has been started up correctly
If the machine is not started up correctly according to these operating instructions, the
operational safety of the machine is not ensured. As a result, accidents may occur and people
may be seriously injured or killed.
• Do not use the machine unless it has been started up correctly, see chapter Start-up.
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Technically perfect condition of the machine
Improper maintenance and adjustment may affect the operational safety of the machine and
cause accidents. As a result, people may be seriously injured or killed.
• Perform all maintenance and adjustment work according to the chapters Maintenance and
Adjustment.
• Before performing any maintenance or adjustment work, shut down and safeguard the
machine, see chapter Safety "Shutting down and safeguarding the machine".
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Danger from damage to the machine
Damage to the machine may affect the operational safety of the machine and therefore
accidents may be caused. Thus there is a risk of serious injuries or death. The following parts of
the machine are of special importance for safety:
– Safety devices
– Connection fittings
– Universal shafts
In case of doubts concerning the reliable state of the machine, for example when consumables
leak out, in the event of visible damage or unexpectedly changed operating behaviour:
• Shut down and safeguard the machine, see chapter Safety, “Shutting Down and
Safeguarding the Machine”.
• Eliminate possible causes for damage immediately, for example gross contamination or
tighten loose screws.
• If possible, repair the damage according to these operating instructions.
• In the event of damage which could have an effect on the operational safety and which
cannot be remedied on your own using these operating instructions: Damage must be
remedied by qualified specialist workshop.
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Safety
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Technical limit values
When the technical limit values of the machine are not met, the machine may be damaged.
Thus there is a risk of accidents, serious injuries or death. With regard to safety, it is of special
importance to comply with the following technical limit values:
– Maximum drive speed
• Comply with limit value, refer to chapter Machine Description, “Technical Data”.
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3.4.9 Danger zones
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Danger zones on forage harvester and machine
The area around the machine is a danger zone.
In this danger zone, the hazards are as follows:
– The self-propelled machine and the trailer could start to move or roll away and overrun
people.
– Dangerous machine movements may be triggered due to unintentional activation of lifting
unit.
– An exposed, turning shaft or a damaged or incorrectly mounted universal shaft may grasp
clothes and wind them up.
– Machine parts may rotate or swivel when the drive is switched on.
– Hydraulically raised machine parts may lower unnoticeably and slowly.
If the danger zone is not monitored by the driver, there is a risk of serious injuries or death.
• Keep people away from danger zone of header and forage harvester.
• Drives and engine must only be switched on when there is no one in the danger zone.
• Prior to all work in front of and behind the self-propelled machine and in the danger zone of
the machine: Shut down and safeguard the machine, refer to chapter Safety “Shutting Down
and Safeguarding the Machine“. This also applies to short-term control work. Many severe
accidents in front of and behind the self-propelled machine and header are caused by
carelessness and running engine and when the machine is rolling away or is not secured.
• Consider the information in all operating instructions concerned.
– The operating instructions of the machine
– The operating instructions of the forage harvester
– The operating instructions of the universal shafts
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Safety
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Danger zone between machine and front attachment
People situated between the front attachment and forage harvester may be seriously injured or
killed if the machine rolls away or moves.
• Before working between the forage harvester and the front attachment: Shut down and
safeguard the machine, see chapter Safety, "Shutting down and safeguarding the machine".
This also applies to brief inspection work. Many serious accidents occur due to negligence
and with the engine running and the machine rolling away or unsecured.
• If the lifting unit has to be actuated, keep all people away from the movement area of the
machine parts to be raised.
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Danger zone when drive switched on
When the drive is switched on, there is a danger to life from rotating and swivelling machine
parts. There must be nobody in the danger zone of the machine.
• Before starting the machine, direct all people out of the danger zone of the machine.
• If a hazardous situation arises, switch off drives and diesel engine immediately.
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Danger zone of quick connector
People may be caught, pulled in and seriously injured by the quick connector and the driven
components.
Before switching on the quick connector:
• Attach all safety devices and move them into protective position.
• Ensure that the selected speed and direction of rotation of the quick connector agree with
the permitted speed and direction of rotation of the machine.
• Ensure that nobody is in the danger zone of the machine or the universal shaft.
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Danger zone universal shaft
People may become caught by the universal shaft, pulled in and seriously injured.
• Ensure that the universal shaft guards are attached and functional.
• Ensure that nobody is in the danger zone of the PTO shaft or the universal shaft.
• Provide the section tube and universal shaft guards with adequate cover.
• Allow the universal shaft locks to engage.
• Attach the chains to prevent the universal shaft guards from rotating with the shaft.
• Follow the operating instructions for the universal shaft.
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Danger zone due to machine parts continuing to run
After the drives have been switched off, the following machine parts will continue to run:
– Mower drums
Persons may be seriously injured or killed when machine parts continue to run.
• Only touch machine parts when they are at standstill.
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3.4.10 Keeping safety devices functional
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If safety devices are missing or damaged, people may be seriously injured or killed by moving
machine parts.
• Replace damaged safety devices.
• Re-install all removed safety devices and all other parts and move them into protective
position before starting up the machine.
• If it is doubtful whether all safety devices have been correctly installed and are functional,
have a service centre check them.
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Safety
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3.4.11 Personal protective equipment
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The wearing of personal protective equipment is an important safety measure. Missing or
unsuitable personal protective equipment increases health risks and injuries.
Personal protective equipment is for example:
– Work gloves
– Safety boots
– Close-fitting protective clothing
– Hearing protection
– Safety glasses
• Specify and provide personal protective equipment for the particular job.
• Use only personal protective equipment which is in proper condition and offers effective
protection.
• Adjust personal protective equipment to the person, for example the size.
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Wear suitable clothing
Loose clothing increases the risk of it becoming caught or wrapped around rotating parts and of
it becoming caught on protruding parts. As a result, people may be seriously injured or killed.
• Wear tight-fitting clothing.
• Never wear rings, chains or other items of jewellery.
• Cover long hair with a hairnet.
• Wear sturdy shoes or protective work boots.
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3.4.12 Safety signs on the machine
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Safety stickers on the machine warn of hazards in danger areas and are an important
component of the safety equipment of the machine. Missing safety stickers increase the risk of
serious and fatal injuries.
• Clean dirty safety stickers.
• After cleaning, always check that safety stickers are complete and legible.
• Immediately replace missing, damaged and unrecognisable safety stickers.
• Provide spare parts with the designated safety stickers.
Description, explanation and order numbers of the safety stickers, see chapter Safety, "Safety
stickers on the machine".
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Safety
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3.4.13 Traffic safety
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Dangers when driving on roads and in fields
The mounted front attachment changes the handling characteristics of the forage harvester. The
handling characteristics also depend on the operational state and on the ground. If the driver of
the forage harvester does not consider changed handling characteristics, he may cause
accidents.
• Observe procedures for driving on roads and in fields, see chapter "Driving and
transportation".
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Prepare the machine for road travel
If the machine is not prepared properly for road travel, serious accidents may occur with traffic.
• Before travelling on the road, always prepare the machine for road travel, see chapter
Driving and transportation, "Preparations for road travel".
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Danger of overturning
The machine may overturn when driving on slopes. As a result, accidents may occur and
people may be seriously injured or killed. The risk of overturning depends on many factors.
• Observe procedures for driving, see chapter Driving and transportation.
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3.4.14 Parking the machine safely
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The parked machine may overturn. People may be crushed and killed.
• Park the machine on a stable and even surface.
• Before adjusting, repairing, servicing or cleaning the machine, ensure that it is securely
positioned. If in doubt, support the machine.
• In the chapter Driving and transportation note the section "Parking the machine".
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Unattended parking
Adults and playing children are at risk from an inadequately secured and unattended parked
machine.
• Before switching off the machine: Shut down and safeguard the machine, see chapter
Safety, "Shutting down and safeguarding the machine".
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Safety
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3.4.15 Consumables
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Unsuitable consumables
Consumables which do not comply with the requirements of the manufacturer, may impair the
operational safety of the machine and cause accidents.
• Use only consumables which comply with the requirements.
For the requirements of fuels, see chapter Description of machine, "Consumables".
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Protection of the environment and disposal
Consumables such as diesel fuel, brake fluid, antifreeze and lubricants may damage the
environment and the health of people.
• Do not release consumables into the environment.
• Absorb leaked consumables with an absorbent material or with sand, place in a liquid-tight
labelled container and dispose of according to the official regulations.
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3.4.16 Sources of danger on the machine
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Noise may damage your health
When working continuously with the machine, health may be damaged, such as hardness of
hearing, deafness or tinnitus. When the machine is used at high speed, the noise level also
increases.
• Before starting up the machine, estimate the risk caused by noise. Depending on the
ambient conditions, working hours and the working and operating conditions of the
machine, specify and use suitable hearing protection. In doing so, consider the sound
pressure level, see chapter Description of machine, "Airborne noise emission".
• Specify rules for the use of hearing protection and for the working time.
• During operation keep windows and doors of the cab closed.
• Remove hearing protection when travelling on the road.
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Vibrations may damage your health
Vibrations generated by the combination of the self-propelled harvester and front attachment
may seriously damage your health and have long-term consequences. The type of work and the
connected devices, working hours, speeds, tyre pressure and ground conditions also affect the
loads.
• Observe the maintenance intervals for the seat, see chapter Maintenance of basic machine,
"Maintenance table".
• Adjust the driver's seat to the operator, see chapter "Adjusting driver's seat".
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Hot liquids
Risk of burns and scalding from hot liquids!
• When draining hot consumables, wear protective gloves.
• If required, leave liquids and machine parts to cool down before performing repair,
maintenance and cleaning work.
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