Krone XXL-RGD User manual

Operating instructions No. 4045-4 GB
Short-cut feeder wagon
XXL-RGD
4XL-RGD
(from Machine no. 515 000)

Dear customer,
These are the operating instructions for the KRONE product which
you have just acquired.
These operating instructions contain important information on the
correct and safe operation of this machine.
If these operating instructions for any reason become partly or totally
unusable, you can obtain a replacement copy for your machine by
quoting the number given overleaf.
Spelle, 01.10.02
(Dr.-Ing. Josef Horstmann, General Manager)
(pp Dr.-Ing. Klaus Martensen, Manager of Construction and Development)
(Wolfgang Ungruh, Manager of Quality Assurance)
We
are solely responsible for the product
to which this declaration refers complying with the relevant fundamental safety and health
requirements of EC Directive 89/392/EEC; 3 and Directive Amendment of 22.07.93.
EC Declaration of Conformance
in compliance with EC Directive 89/392/EEC
Maschinenfabrik Bernard Krone GmbH
Heinrich-Krone-Str. 10, D-48480 Spe e
Short-cut feeder wagon
Mode s: XXL-RGD / 4XL-RGD

Foreword
Dear Customer,
BypurchasingtheXLseriesshort-cutfeederwagon,you
have acquired a quality product from the "House of"
KRONE.
Thankyouforthe confidence which you have expressed
in purchasing this machine.
In order to get the optimum use out of your short-cut
feeder wagon, please read through these operating
instructions carefully before using the machine.
Thecontents are arranged sothat you are providedwith
detailed information on all the necessary activities
accordingtothesequenceofoperations.Wehaveprovided
comprehensive instructions and information on
maintenance,the safe use of themachine, safe working
methods, special safety measures and available
accessories. It is important to follow these instructions
and take in the information they contain to ensure the
operational safety and reliability of your short-cut feeder
wagon and to maintain the value of your investment.
Please note the following
Always store these operating instructions ready to
handin the container provided for them. These
instructions are a component of your machine.
Onlyoperate your machine in accordance with these
instructions.
It is vitally important that you follow the safety
instructions.
Likewise,followtherelevantaccidentprevention
regulationsandtheothergenerallyrecognised
industrial safety, industrial medical and road traffic
regulations.
All information, diagrams and technical data in these
operating instruction are in accordance with the latest
position at the time of publication.
We reserve the right to make structural changes at any
time without notification of the reasons for doing so.
Shouldtheseoperatinginstructionsbecomepartlyor
totally unusable, you can acquire a replacement copy
foryour machine by quoting the number given overleaf.
We wish you every success with your KRONE
machine.
MaschinenfabrikBernardKroneGmbH
Spelle,Germany

Foreword

Contents
Contents
1 General information ............................................................................. I - 1
1.1 Use ..............................................................................................................................I - 1
1.2 Information on the product ...........................................................................................I - 1
2 Safety .................................................................................................... II - 1
2.1 Identification of safety remarks in the operating instructions .......................................II -1
2.2 Personnel qualifications and training..........................................................................II - 1
2.3 Dangers involved in not following the safety instructions............................................II - 1
2.4 Working with the appropriate safety awareness .........................................................II - 1
2.5 Safety and Accident Prevention Regulations .............................................................II - 2
2.6 Hitched-up machines..................................................................................................II - 3
2.7 Operation of the power take-off shaft ..........................................................................II - 3
2.8 Hydraulic unit..............................................................................................................II - 3
2.9 Tyres...........................................................................................................................II - 4
2.10 Maintenance ...............................................................................................................II - 4
2.11 Conversion by the customer and making spare parts .................................................II - 4
2.12 Non-permitted modes of operation..............................................................................II - 4
2.13 Safety instructions attached to the machine................................................................II - 4
2.14 Position of the general information panels on the machine ......................................II - 10
3 Operation ............................................................................................. III - 1
3.1 General information ...................................................................................................III - 1
3.2 Special safety instructions .........................................................................................III-1
3.3 Hitching up to the tractor ............................................................................................ III- 2
3.4 Connections ..............................................................................................................III- 3
3.5 Pick up.......................................................................................................................III -6
3.5.1 Special safety instructions .........................................................................................III - 6
3.5.2 Normal position (adjusting the working height)..........................................................III - 6
3.5.3 Pick-up drive overload safety device .........................................................................III -6
3.5.4 Pick-up roller feelers rear (on special request) ..........................................................III - 6
3.6 Baffle plate................................................................................................................. III- 6
3.7 Cutter unit ..................................................................................................................III - 7
3.8 Road travel ..............................................................................................................III - 11
3.9 Handling the trailing axle (special fitting) ................................................................. III -11
3.10 Work input ............................................................................................................... III -12
3.11 Shutting down..........................................................................................................III -16
4 Operator-friendly solenoid control unit .......................................... IV - 1
4.1 General information .................................................................................................. IV - 1
4.2 Special safety instructions ........................................................................................ IV - 1
4.3 Control panel ............................................................................................................ IV - 2
4.4 Checking the sensors ............................................................................................... IV - 3
4.4.1 Test „Switch Automatic loader“ ................................................................................. IV - 3
4.4.2 Test "Sensor Kratzboden" ........................................................................................ IV - 3
4.4.3 Test "Sensor cutters retract" ..................................................................................... IV - 3
4.4.4 Test "Sensor cutters retract" ..................................................................................... IV - 4
4.4.5 Test "Sensor metering rollers" .................................................................................. IV - 4
4.4.6 Test "Sensor rear flap".............................................................................................. IV - 4

Contents
5 Hydraulic system................................................................................ V - 1
5.1 Special safety instructions ......................................................................................... V - 1
5.2 Adjusting the hydraulic system .................................................................................. V - 2
5.2.1 Examples of emergency manual operation................................................................ V - 3
5.2.2 Hydraulic unit - comfort .............................................................................................. V - 3
5.2.3 Hydraulic circuit diagram of the feeder wagon - Comfort operation Model GD........... V - 4
6 Maintenance....................................................................................... VI - 1
6.1 Special safety instructions ........................................................................................ VI - 1
6.2 General information .................................................................................................. VI - 1
6.3 Tyres......................................................................................................................... VI - 2
6.4 Towing eyes on the tow-bar...................................................................................... VI - 3
6.5 Adjusting the sensors ............................................................................................... VI - 4
6.6 Hydraulik .................................................................................................................. VI - 5
6.7 Maintenance instructions for the hydraulic system.................................................... VI - 6
6.8 Checking and changing the oil ................................................................................. VI - 7
6.9 Chain tension ........................................................................................................... VI - 9
6.10 Scrapers ................................................................................................................. VI - 10
6.11 Checking the safety rollers of the single cutter safety system ................................. VI - 11
6.12 Lubrication.............................................................................................................. VI - 12
6.13 Brake system .......................................................................................................... VI - 15
6.14 Care after daily use................................................................................................. VI - 17
7 Overwintering.................................................................................... VII - 1
7.1 Special safety instructions ....................................................................................... VII - 1
7.2 General information ................................................................................................. VII - 1
8 Recommissioning ............................................................................VIII - 1
8.1 Special safety instructions ...................................................................................... VIII- 1
8.2 General information ................................................................................................ VIII - 1
9 Faults – causes and removal........................................................... IX - 1
9.1 Special safety instructions ........................................................................................ IX - 1
9.2 Table of faults, their causes and removal ................................................................. IX - 1
A1 Initial hitch up............................................................................................ 1
A1.1 Adjusting the tow-bar to the appropriate height and adjusting the towing eye ........... A - 2
A1.2 Attaching the articulated shaft.................................................................................... A - 4
A1.3 Assembling the superstructure .................................................................................. A - 6
A2 Electrical circuit diagram.......................................................................................... A - 10

I - 1
General information
1 General information
1.1 Use
The short-cutfeeder wagon isa feederwagonwith
metering rollers. It is designed for the collection,
transportand putting down of agricultural stalk material.
The variable cutter theoretically provides for cutting
lengths up to 40mm.
1.2 Information on the product
1.2.1 General information
Theseoperatinginstructionapplytoshort-stalk loading
wagonModels XXL-RGDand4XL-RGDfromMachine
no.515000
1.2.2 Manufacturer’s address
MaschinenfabrikBernardKroneGmbH
Heinrich-Krone-Strasse10
D-48480Spelle(Germany)
Telephone:[phone]
Facsimile05977/935-339
E-mail:[email protected]
1.2.3 Certification
Declarationofconformance(requirementsofEC
Directive89/392/EEC; 3 and Directive amendmentof
22.07.93arecompliedwith)
See inside title page
1.2.4 Identification label
Maschinenfabrik Bernard Krone GmbH
Heinrich-Krone-Str. 10 D-48480 Spelle
Made in
Germany
Model
Yearof
manufacture
Vehicle-
ident-no.
The whole identification label has
documentation value and must not be
altered or made unrecognisable
1.2.5 Information for enquiries and
orders
Whenorderingspareparts,themodelnumber,vehicle
identificationnumber and theyear of manufactureof
thecorrespondingmachinemustbequoted.
Spare parts form other manufacturers
may only be used after consultation
with the manufacturer of this
equipment. In the interest of safety,
only genuine parts and accessories
authorised by the manufacturer should
be used. No liability can be accepted
for consequences resulting from the
use of other parts.
KDW00050
1

I - 2
General information
1.2.6 Connections
See Hydraulic system circuit diagram - See Page V - 5
See Electrical system circuit diagram - See Page A -10
1.2.7 Intended use
The XL series short-cut feeder wagons are built
exclusivelyforagricultural work(properuse).
Any other use is considered improper use. The
manufacturer is not liable for any damage resulting from
improper use; the risk is borne solely by the user.
Properuseincludesfollowingtheoperating,maintenance
and service instructions stipulated by the manufacturer.
Permittedloads:
agricultural storks such as hay, straw and grass silage.
The collection and loading of other
materials is only permitted after
agreement with the manufacturer.
In any case, the basic requirement is
that the load material is laid in
swathes and picked up independently
by the pick-up when it passes over.
1.2.8 General technical data
The weights shown on the serial plate must not be
exceededwhentheshort-cutfeederwagonisin
operation.

I - 3
General information
Technical data XXL R/GD 4XL-R/GD
Totallength mm 9580 10480
Totalwidth mm 2548 2620
Totalheight mm 3740 3990
Totalheightfoldeddown mm 3040 3290
Platformheight mm 1260 1580
Trackwidth mm 1950 1950
Tyres 555/45-17FRT 600/55-22.5/12PR
DIN capacity for dry material
(DIN11741) approx.m3 31 36
KRONEprotectionfrom foreignobjects Individual cutter protection Individual cutter protection
Cuttinglengthfor
20 cutters approx.mm 80 80
39 cutters approx.mm 40 40
Pick-upworkingwidth
(DIN11200) mm 1800 1800
Powerconsumption approx.kW(HP)95(130) 105(143)
Permittedladenweight kg 16.000 19.500
(19.500)
Loadingtime approx.min. 6-9 7-10
Unloadingtime approx.min. 4,5 5,5
Groundclearanceofthe
hydraulicarticulated tow-bar approx.mm 750 750
Single- or double-acting
hydraulic connection with free
return must be available yes yes
1.2.9 Technical data
Notallweightsanddimensionsnecessarily correspond
to the serial design and are not binding.

I - 4
General information

II - 1
Safety
2 Safety
Theseoperatinginstructionscontainfundamental
information which must be taken into account when
hitchingup,operatingor maintaining themachine.For
this reason, these operating instructions must be read
by all personnel before starting up and using the
machine and must be made accessible to personnel at
all times.
Not only must the general safety instructions under the
main heading "Safety" be followed but also the special
safety instructions under the other main points.
2.1 Identification of safety
remarks in the operating
instructions
The safety instructions contained in these operating
instructions (which will put personnel at risk if not
followed)arelabelled withthegeneralsymbol for
danger:
Safety symbols in accordance with DIN 4844 - W9
Instructions are indicated as follows:
2.2 Personnel qualifications and
training
The short-cut feeder wagon must only be used,
servicedand maintainedbypersonnelwhoarefamiliar
with this work and have been instructed about the
associated dangers. The owner must specify and
regulate precisely the responsibility, areas of
responsibilityandsupervisionofpersonnel.Personnel
who are not in possession of the necessary knowledge
mustundergoinstructionandtraining.The owner must
also ensure that the contents of the operating
instructions are fully understood by the personnel.
Maintenance work which is not described in these
operation instructions must only be carried out by
authorisedspecialistworkshops.
2.3 Dangers involved in not
following the safety
instructions
Not following the safety instruction will put at risk
personnel,the environmentandthemachine.Not
following the safety instructions may result in the loss
of the right to any claims for damages.
In particular,non-adherence for example mayresultin
thefollowingdangers:
– Dangertopersonnelduetoworkingareasnotbeing
cordonedoff
– Breakdownofimportantmachinefunctions
– Failure to use specified procedures for servicing
andmaintenance
– Dangertopersonnelduetomechanicaland
chemical effects
– Dangerto the environment due to the leakage of
hydraulicoil.
2.4 Working with the
appropriate safety
awareness
The safety instructions contained in these operating
instructions, existing national regulations for the
preventionofaccidentsandany internal working,
operating and safety instructions laid down by the
ownermustbefollowed.
TheWorker’sProtectionandAccidentPrevention
Regulationsoftheresponsible Health and Safety
Executivearebinding.
The safety instructions of the vehicle manufacturer
must be followed.
It is vital that the instructions attached to the machine
are followed and maintained in a fully legible form.

II - 2
Safety
If the vehicle is used on the public highways, the
relevantlegalrequirements(intheFederalRepublicof
Germany:theMotor VehicleRegulations(StVZO)and
theMotorVehicle Construction andUseRegulations
(StVO))must be followed.
2.5 Safety and Accident
Prevention Regulations
1. In addition to the instructions in these operating
instructions, keep to the general Safety and
AccidentPreventionRegulations.
2. Thewarning andinstructionnoticeswhichare
attachedto the machinegive important information
on the safe operation of the machinery and are put
there for your safety.
3. Abide by the regulations when using the public
highways.
4. Before starting work, familiarise yourself with the
devices and controls and their function and
operation.Leaving this until working with the
machine is too late.
5. The users must wear close-fitting clothing. Avoid
wearinglooseclothing.
6. To avoid the risk of fire, keep the machine clean.
7. Check the immediate vicinity before starting up
andputtingintooperation.(Lookoutfor children.)
Ensure that visibility is sufficient.
8. Ridingonthemachineduringoperationand
transport is not permitted.
9. Hitch up the machine according to the instructions
and only fasten and secure it at the devices
stipulatedforthepurpose.
10. Whenhitchingandunhitching,placethe support
devices in the relevant position.
11. Particular care must be taken when hitching and
unhitchingthetractor.
12. Always attach the ballast weights in accordance
with the instructions at the mounting points
designedforthepurpose.
13. Abide by the permitted axle loads, laden weight
andtransportdimensions.
14. Check and attach transport equipment, such as
lights, warning devices and any possible safety
devices.
15. Ancillary equipment (ropes, chains and rods etc.)
andremotelyoperateddevices must be positioned
so that they do not cause any unintentional
movement in all transport and working positions.
16. See that equipment for road travel is in the
stipulated condition and lock it into position in
accordancewiththemanufacturer’s instructions.
17. Never leave the driving position when on the
move.
18. The speed travelled at must always be the
appropriatespeedforthesurroundingconditions.
Whentravelling up anddown hills andacross
slopes, avoid taking sudden turns.
19. Thedrivingbehaviourandsteeringandbraking
responsesareaffectedby equipment attached or
suspended from the vehicle as well as the ballast
weights. For this reason, make sure that the
steeringandbraking ability is adequate.
20. When turning corners, take into account the
overhang and/or parts subject to inertia on the
machine.
21. Only start the machine when all safety devices
have been attached and are in their safety
positions.
22. Lingeringin the working areaisnot permitted.
23. Donotremainwithintheturningandslewingareas
of the machine.
24. Hydraulic folding frames mustonly be operated
when nobody is within the range of swing.
25. Power-operated(e.g.hydraulic)componentshave
crushing and cutting zones.
26. Before leaving the tractor, set down machine on
the ground, switch off engine and remove the
ignition key.
27. Nobodymustremainbetweenthetractorandthe
machinewithout securing thevehicle from rolling
awaybyapplying the brakes and/orusing wheel
chocks.

II - 3
Safety
,
2.6 Hitched-up machines
1. Securethemachinesagainst rolling away.
2. Keepto the maximumpermittedsupporting load
for the trailer coupling, towing device or hitch.
3. Make sure that there is sufficient movement for
the tow-bar trailer at the point of attachment.
2.7 Operation of the power take-
off shaft
1. Only articulated shafts which have been specified
by the manufacturer must be used.
2. Both the protective sleeve and protective funnel
for the articulated shaft and the protective device
for the power take-off shaft - both on the tractor
and on the machine - must be in place and must
beinproperworkingorder.
3. Make sure that the tube covers stipulated for
articulated shafts are in the transport and working
position.
4. Only attach or detach articulated shafts with the
power take-off shaft switched off, the engine shut
downand the ignition keyremoved.
5. Whenusingarticulated shafts with an overload or
freewheel clutch which are not covered by the
protective devices on the tractor, the overload or
freewheel clutch must be mounted on the machine
side.
6. Always make sure that the articulated shaft is
correctly assembled and the safety device is in
properorder.
7. Secure the protective device for the articulated
shaft with a chain to prevent it from rotating with
the shaft.
8. Beforeswitchingonthe tractor power take-off
shaft, make sure that the speed selected for the
shaft matches the speed permitted for the
machine.
9. Before switching on the power take-off shaft,
make sure that no one is inside the danger area of
themachine.
10. Never switch on the power take-off shaft with the
engineshutdown.
11. Whenworking with the powertake-off shaft,
nobody must remain inside the area of the rotating
power take-off shaft or articulated shaft.
12. Always shut down the power take-off shaft when
the bend is unnecessarily too great.
13. Caution Aftershuttingdownthepower take-off
shaft, there is a danger that parts which are
subject to inertia will continue running. Do not
approach the machine during this time. Work must
not be carried out on the machine until it is fully at
rest and parts subject to inertia have been
arrestedbyapplying the parkingbrake.
14. Only carry out lubrication or adjustment work on
the machine or the articulated shaft with the power
take-off shaft switched off, the engine shut down
and the ignition key removed. Apply the parking
brake on parts subject to inertia.
15. When disconnected, stow the articulated shaft in
themountingprovidedforthispurpose.
16. After the articulated shaft has been disconnected,
place the protective cover on the power take-off
stub.
17. Whendamaged,removeimmediatelybefore
workingwiththe machine.
2.8 Hydraulic unit
1. Thehydraulicunitis under pressure.
2. Whenconnectinghydraulicramsandmotors,
make sure that the hydraulic hoses are connected
inthestipulatedmanner.
3. When connecting the hydraulic hoses to the
tractor hydraulic system, make sure that the
hydraulic systems on the tractor and the machine
arenotunderpressure.
4. Thecouplingsleevesand plug-in connectors of
thehydraulicfunctionconnectionsbetweenthe
tractor and the machine must be labelled to
prevent faulty operation. If the connections are
connectedthewrongwayround,operations(such
asliftingandlowering) will be reversed and there
will be a risk of accident
5. Checkhydraulicconnectionsregularlyandreplace
if damaged or old. The replacement hoses must
comply with the technical requirements of the
machinemanufacturer.
6. Because of the risk of injury, use suitable
accessories when looking for leaks.

II - 4
Safety
7. Liquidsleakingunderhighpressure(suchas
hydraulic oil) can penetrate the skin and cause
serous injury. In case of injury, immediately call a
doctor. Risk of infection.
8. Before working on the hydraulic unit, shut down
the machine, release the pressure in the unit and
shutdownthe engine.
2.9 Tyres
1. When working on the tyres, make sure that the
machine is securely shut down and secured
againstrolling away (use wheel chocks).
2. Sufficient knowledge and the specified tools are
requiredtoassemblewheelsand tyres.
3. Repair work on the tyres and wheels must only be
carried out by specialists using the assembly tool
suitableforthepurpose.
4. Check the air pressure regularly. Keep to the
specifiedairpressure.
2.10 Maintenance
1. Whencarryingoutmaintenance work,service
workor cleaning work or correcting faulty
operation, always make sure that the drive unit is
switched off and the engine is shut down and at
rest.
- Remove the ignition key. Apply the parking brake
on parts whihc are subject to inertia.
2. Regularly check if screws and nuts are firmly
seatedand re-tighten if necessary.
3. Whencarryingoutmaintenanceworkonelevated
machines, always secure them using suitable
supportingelements.
4. If cutting instead of using work tools, use suitable
tools and gloves.
5. Dispose of oil and grease filters in the proper
manner.
6. Always isolate equipment from the power supply
before working on the electrical system.
7. Protective devices subject to wear must be
checkedregularlyandreplacedatthepropertime.
8. Whencarrying outelectric welding work onthe
tractorandattachedequipment,disconnectthe
cablefromthe generator and the battery.
9. Spare parts must at least comply with the
technicalrequirements laiddownbytheequipment
manufacturer.
Thisis only guaranteed by using genuine KRONE
spareparts.
10. When storing gases, only use nitrogen for filling -
Risk of explosion.
2.11 Conversion by the customer
and making spare parts
Conversion of or changing the machine is only
permittedafter consultation withthe manufacturer. In
the interest of safety, only genuine parts and
accessoriesauthorisedbythemanufacturershouldbe
used. No liability can be accepted for consequences
resulting from the use of other parts.
2.12 Non-permitted modes of
operation
The operational safety of the machine supplied is only
guaranteedifusedproperly in accordancewiththe
relevantsection of the operating instructions- General
information. On no account must the limits quoted on
the data sheets be exceeded.
2.13 Safety instructions attached
to the machine
The safety instructions on the machine warn against
the remaining dangers on the machine. They consist of
warning symbols and work-safety symbols.
All safety instructions must be followed. Always
maintain safety instructions in a clean and easily
legiblecondition.
Requestreplacementsfor damaged or missingsafety
instructions from the dealer and attach them to the
placesdesigned for them.
Their position and meaning is described in the
following.

II - 5
Safety

II - 6
Safety
KDW01170
3
3
7
6
4
9
10
KDW01160
1
78
5
4
8
9
6
8
2
Position of safety labels on the machine
Left side of the wagon
Right side of the wagon

II - 7
Safety
5
Part no. 939 414-2 (1 x)
Do not walk on the storage
area when the power take-off
shaft is connected and the
engine is running.
4
Part no. 939 521-1 (2 x)
Do not walk under the rear
panel when lifted.
1
Part no. 939 471-1 (1 x)
Before starting, read and
follow the operating
instructions and safety
instructions.
2
Do not exceed
the speed of the
power take-off shaft.
The operating
pressure
of the hydraulic unit
must not exceed
200 bar
939 101-4
MAX. 1000/ min
MAX. 200 bar
Part no. 939 101-4 (1 x)
7
Part no. 942 196-1 (2 x)
Never attempt to access the
crushing or danger zone
while the parts are still able to
move.
3
Part no. 939 407-1 (2 x)
Never attempt to access the
pick-up area while the tractor
engine is switched on and the
power take-off shaft is
running.
6
Part no. 939 412-2 (2 x)
Do not stay within the swing
area of the rear panel while
the tractor engine is running.
8
Part no. 942 002-4 (3x)
Close the guard before putting into operation!

II - 8
Safety
KDW01170
3
3
7
6
4
9
10
KDW01160
1
78
5
4
8
9
6
8
2
Left side of the wagon
Right side of the wagon

II - 9
Safety
10
Part no. 939 529-0 (1x)
The accumulator is subject to gas and oil
pressure.
Disassemble and repair in strict accordance
with the instructions in the technical handbook.
(only with hydr. Deichselfederung)
9
Part no. 942 200-1 (2x)
Keep sufficient distance to
rotating machine parts.

II - 10
Safety
2.14 Position of the general information panels on the machine
Left side of the machine
Right side of the machine
KDW0117
0
4
7
3
5
2
10
KDW01160
19
8
6