KRONE BBiG X TT 2012 Forage Harvester Service Training Manual

Forage Harvester BiG X

Training Name:

Season 2012

No. 150 331 449 04 EN BiG X TT 2012

________________________________

Company: ________________________________ Training dates: __.__. 2012 to __.__. 2012 BiG X ServiceTraining 2012 advanced

Update level: January 2012

© KRONE Training Team, Spelle, Germany

Contents 1. Program Overview

4

2. BiG X Design

9

3. Accessories

16

4. Terminal (settings, optional controls)

23

5. ---

--

6. Intake Drive

31

7. Cutting unit

34

8. Corn Conditioner

45

9. Discharge Accelerator

52

10. ---

--

11. ---

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12. System Technology / Calibration

60

13. ---

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16. Electrical System/Electronics

This documentation has been created for training purposes and does not replace the applicable documentation for service and repair!

114 We reserve the right to make technical changes 212 without notice.

17. Software

252 During training, all of the safety instructions contained

14. ---

--

15. Hydraulics

in the operating instructions apply! The Trainer will carry out a safety briefing at the start of the course of instruction.

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Introduction Symbols and Links 1.

Link to a .pdf file. In Presentation mode the appropriate file can be opened by clicking

WHB_5.1 Speisedruck_DE

on the symbol. In the print version the document and the chapter can be found in the file name under the link.

e.g.

WHB = Workshop Manual BiG X 500 / 650 / 800 / 1000 BA = Operating Instructions BiG X 500 / 650 / 800 / 1000 STLP = Circuit Diagram BiG X 500 / 650 / 800 / 1000 or BiG X 700 / 850 / 1100 SI = Service Information (see Info portal) ET Manual = KRONE spare parts manual BiG Line (to be purchased from spare parts ) 5.1. = Chapter 5.1

2.

Link to an Animation. In Presentation mode the appropriate file can be opened by double clicking on the symbol. This is used only for a more detailed explanation during training Changeover

and is not available in the print file.

Handling Individual pages and chapters of the training manual contain animations which can be started in Presentation mode only. Complex connections can therefore be explained step by step.

Presentation mode is started by pressing the F5 button.

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1. Program Overview 2012: Forage Harvester BiG X Type

Cutting Drum

Composite belt main drive

Engine

Travelling gearsystem

Poclain

960 / 253

250 / 66

(Fuel or silage agent)

500

V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 40 blades) *

5 – groove

MB OM 460 LA 12.8 l / R6

700

V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 40, 48 blades) *

7 – groove

MAN D 2868 LE 16.16 l / V8

Poclain

960 / 253

330 / 87

850

V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 40, 48 blades) *

8 – groove

MAN D 2862 LE 24.24 l / V12

Bosch Rexroth

960 / 253

330 / 87

1100

V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 40, 48 blades) *

8 – groove

MAN D 2862 LE 24.24 l / V12

Bosch Rexroth

960 / 253

330 / 87

* optional ICAN Computer Assistance Network: AutoScan - maturity detection and automatic cutting length adjustment VariCollect - for independent adjustment of header and feed drive speeds SynchroSpeed - for automatic synchronisation of head speed and ground speed DataManager - machine data in ISO-XML format for further processing in many software applications 4

Additional tank L/G

Fuel tank L/G

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1. Program Overview 2012: Forage Harvester BiG X Performance Data - Overview

R 6 engine with 12.8 l capacity (MB OM 460 LA) BiG X 500 Continuous cutting output: 486 HP (ECE R24) V 8 engine with 16.16 l capacity (MAN D 2868 LE) BiG X 700 Continuous cutting output X-Power: 492 kW / 775 HP Continuous cutting output Eco Power: 374 kW / 509 HP

Principle of PowerSplit on BiG X 700/850/1100

V 12 engine with 24.24 l capacity (MAN D 2862 LE) BiG X 850 Continuous cutting output X Power: 607 kW / 825 HP Continuous cutting output Eco Power: 469 kW / 638 HP BiG X 1100 Continuous cutting output X Power: 760 kW / 1,034 HP Continuous cutting output Eco Power: 469 kW / 638 HP

Eco Power – X Power Eco Power is used to reduce fuel consumption when max performance is not required. When additional performance is required, on the BiG X 700, 850 and 1100, press the X Power button to activate full power mode. Power modes can be configured to automatically change (available on select engine models).

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1. Program Overview 2012: Front Attachments Pick-Up Working Width (mm)

Operating elements

300

9’ 10”

Camless pick up

380

12’ 6”

Camless pick up

Type

6

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1. Program Overview 2012: Front Attachments Direct cutting system Type

6200

7

Working Width (mm)

Operating elements

20’ 4”

Disc mower

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1. Programme Overview 2012: Front Attachments Corn Head Working Width

Type

8

Operating elements

Transport position

6000

19’ 8” 8 row

circulating collector

double fold

7500

24’ 7” 10 row

circulating collector

double fold

753

24’ 7” 10 row

circulating collector

Tri-fold

903

29’ 6” 12 row

circulating collector

Tri-fold

1053

34’ 5” 14 row

circulating collector

Tri-fold

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2. BiG X Design: Machine Concept Machine Concept The engine (2) is transverse mounted across the frame (1). This ensures a direct drive with maximum efficiency. The fuel tank is positioned low in the frame for a low center of gravity. The machine is hydraulically driven by four wheel motors. This design provides space for a large cutting drum over the front axle. The design and position of the cutting drum and the position of the engine behind the rear axle, creates optimal weight distribution of 60% on the front and 40% on the rear axle.

Graphic_BiG X

2

3 4 1.

2.

3.

4.

5.

Frame Engine Fuel tank Wheel motors, front Wheel motors at rear

9

1

5 4

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2. BiG X Design: Crop flow Theoretical Crop Flow Rates / Rotation Speeds

BiG X 500 - 650 Big X 700; 850; 1100

Crop Flow Optimum Crop flow: • Six feed rollers provide a tightly held mat of crop for the chopping drum. This results in smooth, quiet operation.

• The four clamping springs hold the intake cabinet closed with 10,000lbs of force.

• High speed accelerator ejects the material at >125mph

v = 64 m/s v = 69 m/s

• The leading edge of the drum bottom adjusts automatically as the shear bar anvil is adjusted.

BiG X 500 - 650 v = 38- m / s Big X 700 v = 41- m / s BiG X 850 - 1100 v = 43- m / s

2

• The chopping drum bottom and accelerator back plate are spring loaded (pos. 1 and 2), allowing uneven crop (such as winter forage) to pass through the crop flow easier while maintaining excellent quality. The benefit is a smoother running machine requiring less fuel consumption while decreasing wear.

BiG X 500 - 650 Big X 700; 850; 1100

v = 42 m/s v = 45 m/s

Cutting drum:

V = 1 – 5.5 m/s 10

1

Ø 660 mm, 1100 rpm (500 / 650) 1187 rpm (700) 1245 rpm (850 / 1100) Bottom grain conditioner roller: Ø 250 mm, 2907 rpm (500 / 650) 3135 rpm (700 / 850 / 1100) Top grain conditioner roller: Ø 250 mm, 3532 rpm (500 / 650) 3809 rpm (700 / 850 / 1100) Crop flow Discharge accelerator:

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Ø 560 mm,

2188 rpm (500 / 650) 2360 rpm (700 / 850 / 1100)

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2. BiG X Design: Drive Drive of the Major Components

Component arrangement BiG X 800 / 1000

In order to vary header and intake speeds independently, the working components are driven hydraulically. The main gearbox (1) is connected to the engine. The pumps for the working hydraulics are mounted to, and powered by, the main gearbox.

These pumps provide the hydraulic flow for: - hydrostatic transmission - hydrostatic drive (intake) - hydrostatic drive (header) - Working / steering hydraulic The intake and header are driven by the hydraulic motors at the transfer gearbox (2) via the PTO shafts.

This makes it possible to automatically adjust the chop length and the speed of the header independently.

Also reversing of both units is possible.

Component arrangement BiG X 500 / 650 / 700 / 850 / 1100

NOTICE: BIG X MODELS EQUIPPED WITH THE M.A.N. ENGINE MUST ENGAGE THE MAIN CLUTCH TO ACTIVATE THE INTAKE AND HEADER DRIVE PUMPS.

Graphic_BiG X

1

1. Main Gearbox

5

2. Intake / Header drive gearbox 3. Hydraulic motor intake drive

closed hydraulic circuit

2

3

4. Hydraulic motor header drive 5. Quick-stop valve 11

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2. BiG X Design: Drive Drive of the Major Components The drive for the main crop flow components comes from the engine. When the clutch (1) is engaged, the main gearbox transfers this power to the main drive belt. The main drive belt is directly connected to the cutting cylinder (2) and the accelerator. The accelerator’s shaft transfers power to the right side of the machine, where a second belt turns the KP (3).

1

1 Graphic_BiG X

3 2

1. Main clutch 2. Main drive belt BiG X 500

5 - groove

BiG X 650 / 700

7 - groove

BiG X 800 / 850 / 1000 / 1100

8 - groove

3. KP drive belt

6 - groove

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2. BiG X Design: Travelling Gear Poclain Transmission - Poclain The transmission is fully hydrostatic through two variable displacement pumps and four wheel motors. Fourwheel drive is standard in the BiG X. 4 Drive modes: I. II.

Road mode: The front wheel motors propel the machine, using multiple displacements allowing it to achieve a maximum speed of 25mph.

Field mode: I. 2 wheel drive: In normal field operation, only the front wheel motors propel the machine. Displacement changes occur based on machine model.

II. 4 wheel drive: In 4wd, all wheel motors power the machine. Fluid from both pumps work together to supply fluid to all four motors. Displacement changes DO NOT occur when in 4wd.

III. Axle Separation: In 4wd axle separation, the hydraulic circuits are separated causing the two pumps to supply power to the front and rear “axles” independently.

I-II III

Maximum Speed Model

Road

Field 2wd

Field 4wd

Axle Sep.

500

25

15

10

10

650

25

12 / 19*

9

7

700**

25

12 / 19*

9

7

800-1100**

25

19

11

6

IV

*denotes optional 3-speed wheel motor

Space for a large chopping drum!

** only applies to machines with Poclain wheel motors!

Changeover

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2. BiG X Design: Travelling Gear Bosch Rexroth Transmission - Bosch Rexroth The Bosch Rexroth transmission consists of a variable displacement pump and 4 variable displacement motors.

Providing continuously variable speeds from 0-25 mph similar to a CVT type transmission.

A machine with Bosch Rexroth transmission can be identified by the outboard planetary (1) on front and rear axles.

Another feature is the switches for the traction control (2) + (3), (TC ON/OFF and TC I/II) which are installed in the console.

TC stands for Traction Control. Whenever the machine is restarted, Stage I is always activated.

1 14

2

3

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2. BiG X Design: Travelling Gear Bosch Rexroth Transmission - Bosch Rexroth: I.

Road mode: Front and rear wheel motors propel the machine to maximum speed of: • Forwards - 25 mph • Reverse - 8 mph.

II.

Field mode: Front and rear wheel motors propel the machine to maximum speed of: • Forwards - 15 mph • Reverse – 8 mph TC Traction Control: Traction Control (traction control, ASR) is active in field mode. If required, this can be switched on or off. Complete deactivation is not possible to protect the wheel motors from overspeeding.

Traction Control is available in 2 stages: TC I is traction control programmed for corn mode. This mode allows increased slip (spinning wheels). This is required to ensure adequate forward drive even under difficult conditions.

TC II is the traction control programmed for grass mode. This mode allows only very little slip (spinning wheels). This ensures that the turf is protected.

Automatic selection of the traction control stage depends on the mode (grass/corn) set in the terminal.

Space for a large foraging unit!

Animation TC

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3. Accessories: Overview Overview of accessories BiG X 2011_2012:  B065 ICAN: WaterProof (crop moisture measurement)  B164 NIR sensor (crop moisture measurement)  B066 ICAN: CropControl (yield recording)  B067 ICAN: RockProtect (rock detector)  B128 ICAN: ForageCam basic package Transmitter and receiver for camera system (for wireless transmission between camera and monitor) (Can be used as a camera system only in conjunction with variant 1310 and retrofit kit "2nd camera")  B129 ICAN: ForageCam supplement set No. 1 (Additional receiver and screen for the tractor cab) (Only with ForageCam basic package)  B131 ICAN: ForageCam supplement set No. 2 - BiG X Same as supplement set No. 1 plus additional camera (can be used as “back-up” camera for forager trailer) (Only in conjunction with ForageCam basic package)  B154 Yield-dependent silage agent (Must have CropControl (B066))  B038 Recutter sieve  B039 Friction base  B127 Additional axle (only with variant 1610)**  B070 Husk comb (Secondary cutting floor for use in extremely dry corn or ground earlidge)  B042 Service cart for cutting drum  B043 Service cart for intake  B053 KP roll 123 teeth  B054 KP roll 144 teeth  B055 KP roll 166 teeth with saw tooth profile  B045 KP speed change 16

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3. Accessories: Rock Protect RockProtect - Rock Detection (optional) a

Acceleration sensor in the area of front upper roller on the feed roller gear box measures rapid movement of the upper feed rolls.

Functional principle: If a foreign object, such as a rock is in the windrow and enters the intake cabinet, the upper rollers will be forced upwards at a rapid rate. If the acceleration sensor outputs a value which is above the preset level, the quick-stop valve disengages the drive similar to a metal detection.

Rock detected!!

The feed drive is stopped the same as if metal is detected!

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3. Accessories: Crop Control (Yield Monitor) Crop Control - Yield Monitoring (optional) Inductive range sensor

a

Pressure sensor

b

Functional principle: The intake opening (measured by the range sensor (a)), force exerted by the intake springs (measured by pressure sensor (b)), and the speed of the intake (chopping length) allows the job computer to calculate the harvested volume. Note: A volume factor has to be determined by weighing a actual load or harvested amount. The harvested volume is then calculated based on this factor.

The display unit in the cab can be switched between the total volume (t), of the yield (t/ha) and the throughput (t/h). All data can also be printed out on the associated CAN BUS printer.

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In the cab:

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3. Accessories: Inoculant Yield-dependent Innoculent Metering (optional, can only be used with Crop Control) Based on the values supplied by Crop Control, a flow rate sensor measures the volume of inoculant applied. Based on the application amount set in the terminal, the inoculant pump is controlled accordingly.

The inoculant can be metered based on the crop throughput (l/t) or volume (l/m3) (only in conjunction with Crop Control) or depending on the time (l/min) (without Crop Control).

3

5 4

2 1. Additional tank (optional) 2. Inoculant pump and filter 3. Flow sensor 4. Quick-action coupling 5. Nozzle unit

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3. Accessories:

Connection of Silage Agent Devices in general

Location of the Connections (as standard) for the Inoculant Devices Plugs with pin assignment to control the pump:

Plug XB 77, behind the cab

XY 60 Pin 1: +12 volts switched max. 15 A via fuse 22-F74 XY60 Pin 2: Gnd XY60 Pin 3: +12 volts continuous voltage, max. 15 A via fuse 22-F74 XM16 Pin 1: +12 volts continuous voltage, max. 15 A via fuse 22-F80 or PWM signal to regulate the flow rate XM16 Pin 2: Gnd

Plugs XY60, XB 60 and XM 16 Some machines have the plugs in the right lamp support.

If the machine is already fitted with an additional tank, the plug connections can be extended as far as the back of the machine!

Plug

Function

KMCoutput / input

Position

XM 16

Silage agent pump

KMC 3: controlled internally* / uncontrolled externally*

above the right front wheel

XY 60

Pump silage agent / molasses

DIOM: uncontrolled externally*

above the right front wheel

XB 77

Flow sensor

Signal to KMC 3

behind the cab

XB 60

Filling level of additional tank

Signal to KMC 2

above the right front wheel

*) external: KRONE silage agent device uncontrolled or other manufacturer (variant 1230) internal: KRONE silage agent device controlled (yield-dependent, B 154)

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3. Accessories: Water Proof - Moisture-Measuring Device Water Proof - Moisture-Measuring Device (optional) The moisture-measuring device is used to display the current crop moisture in the cab. Average load values and average field values can also be determined. The system can be used in corn and grass / all-plant silage.

Sensor plate Moisture sensor arranged in the back of the discharge chute Folding clamp

Clamp lock External control unit in the cab

Principle of operation: The system is based on a resistance measurement. The resistance of the crop is measured as it passes between two sensors. As the crop moisture increases, the conductivity of the material also rises. Therefore the resistance drops.

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3. Accessories: NiR Sensor - Humidity-Measuring Device Moisture-Measuring Device with NIR Sensor (optional) The NIR sensor supplies precise data on the moisture of the crop. This data can be assigned to the harvested area in the customer counter. The sensor is protected by highly wear-resistant materials and can used for any crop. The moisture content is measured at the discharge chute. Continuous crop flow is required for reliable data. The sensor is easy to install and is protected from damage by a cover.

Principle of operation: A Near Infra Red light beam is transmitted to the crop. NIR light has the exact wavelength to excite the water molecules. NIR light can ONLY be reflected by the water molecules in the grass or corn (the other molecules absorb the light). The difference between transmitted and reflected light is measured and the moisture content and dry matter content can be calculated.

NIR sensor arranged in the back of the discharge chute 22

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4. Terminal: Basic Screen (Changes to Software 200814613) Date

Intake cleaning valve

Traction control mode

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4. Terminal: Machine Settings Easy Flow Pick up : Set the Easy Flow mode to (Р) pressure control in the "General machine settings" menu.

Value (А) for normal operation should be within the range 20-30 % based on conditions.

P

Header speed (U) must be adjusted to the chopping length or it can be operated dynamically by travelling speed.

Recommendation: 400 - 420 rpm as basic speed.

X-Disc Direct Cutting System: Set the X-Disc mode to (Р) pressure control in the "General machine settings" menu.

In extreme conditions, the machine can be used in (α) mode.

Value (А) for normal operation should be within the range of ~ 10% based on ground conditions.

Header speed (U) must be set to maximum speed 700 rpm.

U А 24

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4. Terminal: Machine Settings Easy Collect Head: Easy Collect without contour sensors should be set to (α) mode in the "General machine settings" menu.

α

Easy Collect with contour sensors should be set to (d) mode in the "General machine settings" menu.

d Header speed (U) must be adjusted to the chop length or can be operated dynamically using travelling speed.

Recommendation: 380 - 420 rpm as basic speed.

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4. Terminal: Joystick Settings Joystick Memory Buttons: The joystick buttons M1 and M2 can be assigned certain functions with the introduction of software version 200814613.

M1 and M2 do not have any function assigned at the factory.

The setup menu can be selected at menu item 1-10 or by pressing button D. The following functions can be assigned to the joystick memory buttons:

M1 M2

- Raise / lower plant divider (only in the corn) / crop roller (only in the grass)

- Increase / reduce working width ± - Retrieve saved cutting lengths 1 or 2 1/2 - Increase / reduce front attachment speed ± - Rotate pendulum frame left / right

If buttons M1/M2 have been assigned functions, the illustrated settings screen appears when the machine is started.

If the mask is not confirmed with button "B", the functions for M1, M2 will be disabled and identified by a "Padlock" symbol in the M1/M2 fields.

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4. Terminal: AutoScan Settings

(as standard)

2 The “AutoScan“ system varies the chop length based on the degree of maturity of plants passing the middle tip of the EasyCollect, where the Auto Scan Sensor is located. The range of regulation is adjustable in the terminal.

3 10

7

8

9

1 4 5

6

"AutoScan setting" menu within the machine settings range

1.

Adjustment min. / max. Chop length

2.

Graphic representation of the settings

3.

Select AutoScan

4.

AutoScan Status:

sensor available / not available

manual adjustment of the chop length active Activation of the automatic cutting length adjustment via button "D" 27

7. Current chop length 8. Current position on characteristic curve

automatic adjustment of the chop length active

5.

6. Current degree of maturity. If the value stays at 50% the sensor is out of range.

9. Min. chop length adjusted by the driver. The degree of maturity connected to this point is adjustable in the AutoScan expert mode (DEF = 33%) 10. Max. chop length adjusted by the driver. The degree of maturity connected to this point is adjustable in the AutoScan expert mode (DEF = 67%)

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4. Terminal: Constant Power Settings Constant Power –

Load Limit Control

(optional) The Constant Power- system varies the forward driving speed based on the engine load. The result is constant load on the engine. This keeps the machine in its optimal performance range and lowers fuel consumption.

Software requirements for Constant Power: Terminal: KMC3: SmartDrive

min. 150 200 104-08 min. 150 200 103-08 greater than A16939C (e.g. A22823H, A33789C.H86, )

Activation of Constant Power: Move joystick 2x to the right (only in Field mode)

4

1

2

5 6 3

1. Adjust engine load based on engine rpm (button “1“) e.g.: 10%  2000 rpm – 10% = 1800 rpm 2. Adjust engine load based on percent of load (button “2“) e.g.: 80%  3. Adjustment of min. / max. forward speed.

Constant Power varies the speed only in that range.

4. Current engine speed (rpm) 5. Current engine load (%) 6. Nominal engine speed 28

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4. Terminal: Settings for Rock Protect RockProtect - Rock Detection (optional) Sensitivity can be adjusted by the driver from 0-100%. Due to varying conditions (swath shape and size), it may be necessary to adjust the sensitivity several times a day. Adjust the sensitivity with parameter 27500 (see the graphic below).

Sensitivity 100 %

0%

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4. Terminal: Submenu Structure (Software 200814613) 3. Calibrations

1. Settings (depending on level - driver / service)

4. Diagnostics 5. Main screen

2. Counters

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6. Intake Drive: Design Design The intake consists of six feed rollers, the bottom three are fixed and the top three are held downward using 4 springs. A spring force of up to 5 tons create a pressure of 23lbs/square inch. The length of the intake cabinet is 32 inches. The front upper roller (1) and the bottom feed roller (4) are made from stainless steel allowing the metal detector to function properly. The teeth on the rollers are replaceable wear strips (9). The metal detector is installed in the bottom roller (4). The intake is cleaned by air pressure (cf. parameter 33651 and 33652).

8

6 5 4

3

2

7

31

1

1.Front upper feed roller 2.Middle upper feed roller 3.Rear upper feed roller 4.Bottom lower feed roller 5.Middle lower feed roller 6.Smooth roller 7.Bearing plate lower feed rollers 8.Bearing plate upper feed rollers 9.Changeable wear strips

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6. Intake Drive: Drive – BiG X 700/850/1100 The Intake A variable displacement hydraulic motor powers the intake via a PTO shaft connection to the lower roller gearbox (2). Power is sent to the upper rollers by a double joint (BiG X 700/850/1100) or tower gearbox (BiG X 500-1000) to the 900 gearbox (3). From the 900 gearbox, the drive shaft (4) powers the upper roller gearbox (5) on the right side of the machine. The possibility to infinitely vary the speed of the feed drive from the cab enables the cutting length to be infinitely adjusted manually or automatically.

3

5 4 6

2 Beginning year of manufacture 2011 the intake on the BiG X 700 / 850 / 1100 have had a modified drive.

The layout of the rear springs requires a new bottom gearbox (2).

Caution: The direction of rotation has changed. The intake and forage harvester must match.

SI_150371257

1.

2.

3.

4.

5.

6.

1

Input shaft of bottom roller gear Lower roller gearbox Upper 900 gearbox PTO shaft Upper roller gearbox Double joint

Rotation direction intake_EN

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6. Intake Drive: Settings Adjustments The upper rollers are held in position by four springs. As crop enters the housing, the upper rollers are forced upward. The springs should be adjusted equally on both sides to dimension A = 30 mm and B = 50 mm.

BX 700/850/1100

BX 500/650/800/1000

A

A

B

B

3

Scraper (1) should be adjusted as close as possible to the smooth roller (0 – 0.3 mm).

The clearance between rear upper feed roller (2) and scraper (1) should be adjusted to 2 - 5 mm with the spacer plates under the rubber element (3).

Check the thickness of the scraper (D) at regular intervals: D ≥ 24 mm. Replace the scraper when it wears below the minimum thickness.

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2

D 1

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7. Cutting Unit: Design Cutting Cylinder The enclosed cutting cylinder (1) has the knives (4) mounted at 11° to the shear bar (6) . The shaft (2) is bolted to the side and is driven by the pulley (3). The knives (4) are bolted to the knife carrier via 5 bolts with 270 Nm (200 ft/lbs) torque.

3

1 4

2 2 Use new bolts when changing knives!

5 Composite V-belts: BiG X 500 BiG X 650, 700 BiG X 800, 850, 1000, 1100

11°

5– groove 7 – groove 8 – groove

The cylinder is mounted in the housing using two spherical roller bearings (7). The drum housing pivots in the main frame by two copper bushings (8).

7 8

8 7 34

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7. Cutting Unit: Knife / Shear bar Adjusting the Cutting knives The knives must be adjusted parallel to the grinding device to sharpen the knives with the fewest grinding cycles possible.

Sharp tools - risk of injury!

When working with the knife drum always wear gloves.

1. Perform a sharpening operation 2. Manually operate the shear bar adjustment motors to move the shear bar (3) away from the knife drum on both sides. After the knives have been adjusted, ensure that there is still clearance between the knives and shear bar by extending both motors an additional 5 mm.

3. Align shear bar (3) parallel to the sharpened area on the back of the knife. (see chap. Turn / change shear bar).

4. Loosen mounting bolts (2).

5. Set knives to the shear bar.

6. Tighten all mounting bolts (2) using a torque wrench to 200 ft./lbs. (270 Nm).

7. Release the drum lock, turn the drum one row of knives, and lock it in place again.

8. Adjust the next row of knives.

9. Continue until all knives on the drum have been adjusted equally.

10. Release the drum lock.

11. Adjust the grinding stone until there is a 0.5 mm gap between the back of the knife and grinding stone.

2 12. Attach the intake housing 13. Sharpen the knives 14. Adjust the shear bar

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7. Cutting Unit: Knife / Shear bar Replacing the Knives Knives must always be replaced in pairs to prevent an imbalance in the drum. The two knives which are offset by 180° on the drum (e.g. blade 1 and blade 8, blade 1 and blade 6, blade 1 and blade 11).

The drum must always the same knives installed, note P/N on the replacement knives (see also spare-parts list)!

Always clean the knife mounting surface of the drum, the knife mounting surface of the knife, and the mounting surface of the knife holder. Dirty knives, mounting surfaces and / or pressure plates (4) can cause improper torquing. Clean all parts before installing them.

Whenever a knife is changed, replace the mounting bolts!

1. Remove the mounting bolts (2) and (3).

2. Remove the knife (1) to the front.

3. Clean knife mounting surface and mounting plate (4).

4. Replace damaged or heavily worn mounting plates (4).

For safety reasons replace the mounting plates (4) once a year.

5. Install new knives using new bolts. Initially tighten the mounting bolts hand-tight.

When installing the knives (1), observe installation direction of the nut bars (5). The surface (a) with the rounded corners must be placed toward the drum (6), the flat surface (b) must face away from the drum (6).

a 3

b 6

2 36

4

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7. Cutting Unit: Knife / Shear bar Turning or Replacing the Shear bar The shear bar should only be installed on a clean, flat mounting surface. Repair or replace the mounting surface as required. When turning the shear bar, make sure the bottom side of the shear bar is clean.

1. Sharpen the cutting knives 2. Move the shear bar (1) away from the drum using the shear bar adjustment motors. Adjust the shear bar so it is parallel to the knives. Ensure there clearance between the knives and shear bar by extending, both sides and additional 5 mm.

258 ft/lbs 3. Remove mounting bolts (2), washers (3) and (4).

314 ft/lbs* 4. Loosen spring assembly (5) so that the shear bar support is tension-free.

Then retighten spring assembly to a torque of 55 ft./lbs. (75 Nm).

5. Remove the shear bar (1) out the front side of the supports. ! !

6. Clean the mounting surface and bottom of the shear bar.

7. Turn shear bar or install a new one.

155 ft/lbs

Installing a new Shear bar ! = Loctite medium strength 1. Place new shear bar (6) on the support and hand-tighten the middle mounting *) applies only to machines without VariStream bolt (2), detent edged washers (3) and flat washer (4).

2. Align shear bar (6) parallel to the sharpened knives measuring point (m).

3. Adjust the shear bar until the outer mounting bolts (2) with detent edged washers (3) and flat washers (4) can be installed tension-free through the holder plate (7).

4. Torque the three mounting bolts on the shear bar to the specified torque (see Figure above).

m

2

7

1 2 3

3 4 37

4

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7. Foraging Unit: Bearing Design Cutting Drum Bearing Big X 650 on left (Floating Bearing) 1. 20 023 283 0 Bearing ring

10

9

6

4

3

1

2. 00 911 609 0 Circlip I 160x4 3. 20 021 884 0 Gasket ring Guard 4. 90 000 106 0 Sealing ring A

7

130x160x12

5. 00 931 922 0 Bearing 22216 E 6. 20 023 284 0 Trust ring

80,1x95,2x15

5

7. 20 023 285 0 Bearing housing left 8. 00 936 050 0 Sealing ring A 105x130x12

8

9. 00 214 286 0 Intermediate ring

11

2

10. 00 911 696 0 Circlip 130x4 11. 20 023 294 0 Flange left

WHB_3.2.3.1. cutting drum bearing_EN

1

2

3

4

5

9

10

Cutting Drum Bearing Big X 650 on right (Fixed Bearing) 1. 00 911 696 0 Circlip 130x4 2. 00 224 028 2 Cover

Rd. 150x30

3. 00 937 534 0 O-Ring 130x4 4. 00 911 570 0 Circlip A 75x2,5

7

5. 00 224 030 1 Supporting Disc Rd.85/75x5 6. 00 931 920 0 Bearing 22215 E

6

7. 00 215 483 0 Bearing Housing Right

8

8. 00 936 061 0 Sealing Ring A 85x110x12 9. 00 224 128 2 Intermediate Ring Rd. 109,9/95x3 10. 00 911 691 0 Circlip 110x4

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7. Cutting Unit: Drum Bottom (before YoM 2009) Drum bottom The clearance between the knife (1) and drum bottom (2) is steplessly adjustable via the bolts (3) and (4). To adjust the drum bottom, the bolts (5) must also be loosened. Adjust 2-3 mm at bolt (3) and 3-4 mm at bolt (4) . Tighten bolts (5) again. The blow / crop stream depends on the knife overlap (M) and the distance to the drum bottom. For more aggressive crops a ribbed drum bottom (7) can be installed. Sieve plate (8) can be installed when chopping with a combine head. Or the Leaf drum bottom (9) provides additional cutting for crops with dry leaves.

1 3

4 2

5

5 6

7

M

9

ET_manual Drum base 500_1000_DE

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7. Cutting Unit:

YoM 2010

4 1

VariStream_1

3

ET_manual

2

Drum base700_1100_EN

2

3

Drum Base The clearance between knives and drum bottom (1) in the front area is adjusted automatically by adjusting the shear bar, because of the connection to the shear bar anvil. In the rear area (drum bottom outlet) it should be adjusted to a clearance of 6mm between knives and drum bottom by adjusting bolts (2). Adjust spring tension (3) to 46mm (spring length). Using the rod (4) to adjust the inside drum housing width to 823±3 mm.

5 The drum bottom is centered in the housing by using spacer disks.

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Bolt (5): Md = 258 ft./lbs. (350 Nm), please use detent edge washer and medium loctite

6

Middle bolt (6): Md = 155 ft./lbs.

(210 Nm), use detented edge washer

© KRONE Training Team, Spelle, Germany

7. Cutting Unit:

1

Year of Manufacture 2011 or Later

Big X 700/850/1100 y.o.m. 2011 the position of the springs for the drum bottom has been modified.

Adjust the rear area (drum bottom outlet) clearance between knives and drum bottom to 6mm.

Adjust spring tension to 46mm (spring length). (see previous page) ET_manual Drum base 700_1100_EN

The Vari-Stream is bolted on (1).

This makes mounting and dismounting much easier.

2

Also new is the optional cutting drum bottom to “cut“ dry leaves in corn.

New bushings in the pivot point of the spring loaded drum bottom reduce wear.

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7. Cutting Unit: Sharpening Device Grinding Device The knives are sharpened by grinding stone (1) attached to the cylinder (2). To reduce vibrations from the system, the stone holder (Y.o.M. 2012) is damped by bevel springs (8). The sharpening stone is adjusted down when the adjustment ratchet (4) contacts the gear (3) at the end of the sharpening stroke. Standard in Y.o.M. 2012, only the “home” adjustment ratchet will be installed.

The adjustment gear (3) is mounted in a threaded bushing (5).

Two Namur sensors detect the “home” and “end” positions of the sharpening cycle and count them. When 630 (315 for two adjusters) cycles have been counted, the driver receives an information message in the terminal that automatic sharpening is no longer possible. The sharpening stone must be reset and the cycle counter reset in the terminal before automatic sharpening is available again. The visible thread length of the stone holder (A) should be at least 5 mm. If required, reset or replace the sharpening stone.

The sharpening flap is opened as soon as the maintenance switch is activated.

Otherwise, it is closed by the hydraulic cylinder (7).

The adjustable restrictors / non-return valves (6) located next to the valve block can be used to adjust the sharpening stone speed.

The number of adjustment ratchets (4) and the number of teeth on the gear (3) (24 or 36 teeth) must be set correctly in the terminal under parameters 33657 and 34014!

42

3 7 5

2 4

SI_150388056 Grinding stone guide_EN

4

8 А 1

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7. Cutting Unit: Sharpening Device

7

6 3 5 4 3

Sharpening stone replacement / Sharpening stone adjustment The stone must be replaced as soon as measurement ”X” is more than 100 mm!

Before starting note dimension “Y”.

Remove the latch (9) and turn the locking pin (8) 90° so it can lock in the hole when the threaded housing (2) is screwed out with the cap (7).

Remove the cap from the housing when the threaded housing is locked, so that the stone can be removed. Replace stone and rubber rings (see drawing on the next page) and adjust the new stone to a dimension of “Y” – 0.5 mm. Torque the cap (6) to 133+7 ft/lbs (180+10 Nm). Take the locking pin out, turn 90° and replace the latch (8). The cycle counter in the terminal must be reset.

2 1 1.

2.

3.

4.

5.

6.

7.

8.

9.

Sharpening stone Threaded sleeve Clamping ring Intermediate ring Support washer Sleeve Gear / Cap (Z = 36) Locking bolt Latch 43

7 8

X Y

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7. Cutting Unit: Sharpening Device max.

6

100 mm

Md = 180+10 Nm

3 5

7

4 6

6

2

2 3 5

1

5 1

4

1

5

3 4

Note the position of the bevelled edges!

1.

2.

3.

4.

5.

6.

7.

Sharpening stone Threaded sleeve Rubber ring Intermediate ring Support washer Sleeve Gear (Z=36) 44

Bevelled edge is face down!!

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8. KP:

Design

Design and Drive The KP has toothed rollers installed with a spherical roller bearing at each end. The rollers run at different speeds.

The rear roller is fixed in the bearing housing (3). The front roller is installed in the bearing housing (4). It hinges around the axle (X) and is held in position with the springs (5) and the wedges (6). The distance between the rollers can be set from the cab with the electric motor (7) through the lever (8) and the wedges (6).

From Y.o.M. 2011 the BiG X 700/850/1100 feature lubricated idler rollers on the Grain Conditioner.

L

X 4

8 3

6

1 5 2 7 SI_150376068

9

lubricatable idler pulley_EN

1 2

45

The rollers are driven by the 6 “V” belt on the right side of the machine.

The belt is tensioned by a tensioning pulley pressurized by a hydraulic cylinder (charge pressure). The speed difference of the rollers is 30% as standard.

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8. KP:

Differential Speed

Differential Speeds on the Grain Conditioner To optimise conditioning of the grain, it is possible to change the speed difference of the rollers. 3 differential speed variants are possible. These are set by changing the drive pulleys. 30 % differential speed is the standard on all BiG X since Y.o.M. 2011.

Deflection roller (1) Ø mm Speed difference

20%

Mat. no. Ø mm

30%

Mat. no. Ø mm

40%

Mat. no.

186 20026712.0 224231.4 193 20027146.0 20022939.1 186 20026712.0 224231.4

Lower roller (2) (smooth disc)

Upper roller (3)

226

186

226533.2

226532.2

226

171

226533.2

20020767.0

236

171

20020768.0

20020767.0

S 3

2 1

Spare-part numbers marked in blue refer to KP‘s with lubricated idler rollers. Before converting, please check whether the idler roller is lubricated or not!

If is established, after converting to another differential speed, that the belt is contacting in the area (A) or the path of the tensioning cylinder (S) is not adequate to tension the belt, the idler roller (1) can be replaced with a larger diameter 204 mm (20020769.0, 20027147.0).

If the idler roller is replaced, you must replace the ball bearings (2 x 930569.0 or angular ball bearings 1 x 90001370.0).

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A

8. KP:

Variants

Grain Conditioner Rollers The rollers are made in one piece, and are cylindrical in shape. The diameter of each roller is 250 mm. The rollers differ in their number of teeth, material properties and tooth form. The chromeplated rollers have a very long service life and are optionally available in a "Heavy Duty" design (5) with 123 and 144 teeth in a saw tooth profile (123 tooth chrome saw tooth standard in USA except BiG X 500).

1. Rollers with 123 teeth: Optimum configuration for corn silage with cutting lengths over 18mm. This ensures maximum throughput along with optimum conditioning in long cutting lengths. These rollers are usually used in combination with the 20-knife drum. A roller with chrome-plating and a saw tooth profile is also available (Standard in USA except BiG X 500).

2. Rollers with 144 teeth: This is well suited to cutting lengths up to 20 mm – ideal for almost all conditions. The rollers are optionally available with chrome-plating and a saw tooth profile. The rollers can be used in conjunction with any cutting drum.

3. Rollers with 166 teeth: Fine intermeshing with saw tooth profile, very well suited to cereal all-plant silage. Small grains are reliably worked as a result. The rollers should be used in conjunction with 28, 40 or 48 knife drums.

4. Disc rollers: 4 On account of its V-shaped friction gaps the disc conditioner has a 2.3 times larger friction surface than the standard conditioner. This allows an even higher throughput with optimum conditioning of the grain. The disc rollers operate at the same speed, however a differential speed occurs automatically on account of the disc shape on the circumference.

5

1.

2.

3.

47

00 215 659 1 – roller Z = 123 'standard' straight teeth 20 022 113 0 – roller Z = 123 HD, saw tooth profile 00 226 462 3 – roller Z = 144 'standard' straight teeth 20 022 114 0 – roller Z = 144 HD, saw tooth profile 00 214 030 1 – roller Z = 166 saw tooth profile

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2

3

8. KP: A

3

Roller Settings Basic Setting for KP If the KP is repaired or the rollers become worn, the minimum gap between the rollers must be set. The minimum gap between the rollers is adjusted by turning the turnbuckle (2). The lever (3) must be positioned 12mm in front of its mechanical stop (A) (housing). The minimum gap (X) of the rollers should now be 0.5mm (adjust as required). The two nuts (4) act as a mechanical stop to prevent the rollers from contacting in case of incorrect calibration.

When the spring tension has been set (dimension Y=93 mm) and the nuts (4) have been tightened, the minimum gap must be checked again (re-adjust if required). When the basic setting has been made, the display must be calibrated in the terminal (see chapter Calibration).

2

4 1

KP Motor

Y

The Dunker electric motor (6) replaces the Valeo motor (5) and has been installed as standard since Y.o.M. 2008. The motor type is specified by a parameter setting and may have to be adjusted if the motor is replaced.

X Gap (X) for mechanical limit = 0.5 mm Dimension Y = 93 mm

Parameter 33607 (Service): 0

5

Parameter 33607 (Service): 1

6

WHB_3.4.2 Basic adjustment CC_EN

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8. KP:

Disc Conditioner Settings Basic Setting for Disc KP

4

Y A

2

If the KP is repaired or the discs become worn, the minimum gap between the discs must be set. Before adjusting, relieve spring tension and loosen nuts (4) to move the discs closer together. The minimum gap between the discs is adjusted by the turnbuckle (2). The lever (3) must be positioned 16mm in front of its mechanical stop (A) (housing). The minimum gap (X) at the disc tip should be 3mm or dimension (Z)=1.7mm (between the sides of the disc), (adjust if required). The two nuts (4) act as a mechanical stop to prevent the rollers from contacting in case of incorrect calibration. When the spring tension has been set (dimension Y=93 mm) and the nuts (4) have been tightened, the minimum gap must be checked again (re-adjust if required). When the basic setting has been made, the display must be calibrated in the terminal (see chapter Calibration).

3

General aspects: Because of the different adjustment kinematics between roller conditioner and disc conditioner, the conditioner type is specified by a parameter setting in the terminal. Even the housing of the disc conditioner is different from a roller KP housing.

X = 3mm

To use the disc conditioner, the belt pulley on the discharge accelerator output must be replaced. The new pulley is included with the disc conditioner.

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8. KP:

Disc Design / Settings

Disc Roller The disc rollers consist of individual segments (S) which can be replaced as required. The connection to the shaft is made by a key (F). An O-ring seal between the segments (R) prevents the ingress of silage effluent. Individual discs can be replaced if damaged or highly worn. Worn discs can even be reground once. If all disc segments have to be replaced, the housing, the shafts, etc. can still be reused. When installing the discs, ensure that the direction of rotation is correct!

R Direction of rotation (identical for all discs!)

S

F

Before removing the disc rollers, ensure that the direction of rotation and the installation position (upper/lower) of the respective shaft are marked. This mark is required for re-assembly. Before starting the disassembly work, it is also recommended to measure the gap between the belt pulleys and the housing so that the belts can be re-aligned as easily as possible afterwards. a=b On account of the production tolerances of the discs or any subsequent wear, it may be necessary to align the fixed roller (not spring-mounted one) axially to ensure that the gaps between the disc segments are as equal as possible. In doing so, the gap dimensions of the entire roller must be taken into account and, if required, averaged. The roller is aligned axially by moving the complete roller, including the completely installed bearing blocks, in oblong holes.

When ordering spare parts, ensure that the outside of a roller ends with half disc segment! In this case also note the direction of rotation!

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8. KP: 1

2

3

5

6

7

Design of Bearing for Roller and Disc Cond.

KP Bearing Left (Fixed Bearing)

8 11 13 11 10

1. 00 911 691 0 Circlip 110x4 2. 00 910 716 0 Supporting Disc S 90x110x3,5 3. 00 910 851 1 Shim Ring 90x110x0,1 00 910 849 0 Shim Ring 90x110x0,5 4. 00 223 562 3 Cover left. Rd. 120x23 5. 00 937 577 0 O- Ring 110x3 6. 00 911 561 0 Circlip A 60x2 7. 00 910 740 1 Supporting Disc S 60x75x3 8. 00 911 002 0 Shim Ring 60x75x0,3 00 911 003 0 Shim Ring 60x75x0,5 9. 00 931 914 0 Bearing 22212 ES 10. 00 219 433 3 Bearing Housing Left 11. 00 911 686 0 Circlip I 100x3 12. 00 936 019 1 Sealing Ring BA 70x100x10 13. 00 910 746 0 Supporting Disc S 80x100x3,5

12

4 9

WHB_3.4.1.1.

KP Bearing Right (Floating Bearing)

Conditioner bearing_EN

1. 00 911 691 0 Circlip 110x4 2. 00 910 716 0 Supporting disc S 90x110x3,5

11

10

9

6

4

3

2

9

3. 00 910 851 1 Shim ring 90x110x0,1

8

00 910 849 0 Shim ring 90x110x0,5 4. 00 937 577 0 O- ring 110x3 5. 00 223 464 1 Ring rd. 120x23

5

6. 00 936 058 0 Sealing ring B2 SL 80x10/12

7

7. 00 931 914 0 Bearing 22212 ES 8. 00 219 433 3 Bearing housing right 9. 00 911 686 0 Circlip I 100x3 10. 00 936 019 1 Sealing ring BA 70x100x10 11. 00 910 746 0 Supporting disc S 80x100x3,5 12. 00 226 462 3 Roller

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12

T = 144

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9. Accelerator: Design Accelerator

4 2 F

1 3

The function of the accelerator is to accelerate the crop from the drum or KP out the spout. The accelerator has a diameter of 22“ (560 mm). At a speed of 2188 rpm we obtain a theoretical crop flow speed of 143 mph (64m/s). The discharge accelerator is mounted with spherical roller bearings. The accelerator back plate is spring loaded so it can move back allowing slugs of material to pass through the gap easier.

(F) – Driving direction (3) – Spherical roller bearing fixed (4) – Spherical roller bearing floating (5) – Back plate (6) – Springs for back plate

6

5 1.

20 020 240 0 – Accelerator paddle left serrated 20 023 196 0 – Accelerator paddle smooth left "X-treme" 20 020 241 0 – Accelerator paddle right serrated 20 023 195 0 – Accelerator paddle smooth right "X-treme"

2.

52

x 2 st. x 2 st. x 2 st. x 2 st.

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9. Accelerator: Design of Bearing BiG X 500 - 1000 2

3

4

7

8

Discharge Accelerator Bearing on Left (Fixed Bearing)

9 10 11 9 12 9 11 14

10

1

8

5 16

1. 00 902 108 0 Screw M 20x1.5x70 2. 00 221 999 2 Limit disk 21x90x15 3. 20 024 533 1 Clamping ring 4. 20 024 533 1 Clamping ring 5. 20 024 534 0 Belt pulley Rd. 256 6. 20 023 626 1 Rotor cpl.

7. 00 911 004 0 Shim ring 60x75x1 00 911 005 1 Shim ring 60x75x2 8. 00 214 113 0 Spacer ring 60x85x30 9. 00 911 696 0 Retaining ring 130x4 10. 00 214 115 0 Washer 86x129.5x2 11. 00 936 002 1 Shaft sealing ring A 85x130x13 12. 00 910 831 0 Shim ring 105x130x1 00 910 827 0 Shim ring 105x130x0.5 13. 90 000 193 0 Pendulum roller bearing 22312 U15-VS 14. 00 214 121 0 Bearing housing on left 15. 00 910 740 1 Support washer S 60x75x3 16. 00 915 018 0 Fit-in key A 18x11x100

13 6

15 WHB_3.5.6.

Accelerator bearing_EN

9

Discharge Accelerator Bearing on Right (Floating Bearing) 1. 00 900 352 0 Screw (left-hand thread) M 20x1.5x70 2. 00 221 999 2 Limit disk 21x90x15 3. 20 024 533 1 Clamping ring 4. 20 024 533 1 Clamping ring 5. 00 911 005 1 Shim ring 60x75x2 00 911 004 0 Shim ring 60x75x1 6. 00 214 113 0 Spacer ring 60x85x30 7. 00 911 696 0 Retaining ring 130x4 8. 00 214 115 0 Washer 86x129.5x2 9. 00 936 002 1 Shaft sealing ring A 85x130x13 10. 90 000 193 0 Pendulum roller bearing 22312 U15-VS 11. 00 910 740 1 Support washer S 60x75x3 12. 00 214 124 0 Bearing housing on right 13. 00 915 004 0 Fit-in key A 18x11x70 14. 20 023 626 1 Rotor cpl.

15. 20 024 535 0 Belt pulley Rd. 300

53

7

8

7

6

5

8

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14

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3

2 1

9. Accelerator: Installation and Setting (Old) a

Before removing the belt pulleys on the discharge accelerator, measure their position with respect to the main frame!

This will be used for re-installation of the belt pulleys.

Rotor When installing new paddles on the rotor make sure that the opposite paddles have the same weight and are always exchanged in pairs. The paddles must be installed at their extreme outer position. This is important for the adjustment of the rear panel to the paddles.

1 b

4 3

54

2

Rotor installation and adjustment in the housing Put rotor in the housing and grease the shaft. Preassemble the right bearing housing on the frame. Install a pre-assembled left bearing housing and line rotor up in the center of the housing. Push spacer ring and circlip onto the shaft. Measure the distance (a) between spacer ring (1) and circlip (2) and install outer shims to make the surface even. Assemble the bearing with a installation tool while supporting the shaft on the opposite side. Measure the distance (b) between bearing (3) and circlip (4) and install appropriate amount of shims.

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9.Accelerator: Installation and Setting (Old) Installing and Aligning Rotor in the Housing

9

2

8

5

4

3

1

Install the support washer (1), for the spacer ring (2), and shaft sealing ring (3). This must be installed in such a way that the grease can be pressed out of the bearing. Then insert the washer (4) and the retaining ring (5).

Installing and Aligning the Left Belt Pulley

6

10 11

12

7 a

Push inner clamping ring (7) and belt pulley (6), initially without fit-in key, all the way on to the shaft (12) and measure the dimension to the frame. Compensate the difference, according to the dimension determined during removal, with shim rings in position (a). Push inner clamping ring (7), fit-in key (11), belt pulley (6) and outer clamping ring (8) on to the shaft. Install limit disc (9) and screw (10). Secure screw (10) with medium-strength Loctite and tighten to a torque of 425 Nm. Finally: Check the position of the bearing in the housing on the right side (floating bearing side) to ensure that the bearing is not on one side of the housing. This can be checked by the grease nipple bore. If you can see the lubrication groove of the bearing, the bearing is in the centre position and can be moved sideways.

WHB_3.5.6.

Accelerator bearing_EN

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9. Accelerator: Design of Bearing BiG X 700/850/1100 (New) 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15

Discharge Accelerator Bearing on Left (Fixed Bearing) 1. 00 902 108 0 Screw M 20x1.5x70 2. 20 026 383 0 Cap 3. 20 024 533 1 Clamping ring 4. 20 026 676 1 Belt pulley Rd. 268 5. 00 915 018 0 Fit-in key A 18x11x110 6. 20 024 533 1 Clamping ring 7. 00 911 005 1 Shim ring 60x75x2.0 00 911 004 0 Shim ring 60x75x1.0 8. 20 024 803 0 Raceway 60x70x27.5 9. 90 000 063 0 Shaft sealing ring AS 70x110x10 10. 20 024 802 0 Cover 11. 90 000 193 0 Pendulum roller bearing 22312 U15-VS 12. 00 936 447 2 Shaft sealing ring A 80x110x10 13. 20 024 801 0 Supporting ring 14. 20 024 799 0 Raceway 15. 20 026 012 0 Bearing housing on left

Discharge Accelerator Bearing on Right (Floating Bearing)

14 13 12 11 10 9

8

7

6

5

1. 00 900 352 0 Screw M 20x1.5x70 2. 20 026 383 0 Cap 3. 20 024 533 1 Clamping ring 4. 00 915 004 0 Fit-in key A 18x11x70 5. 20 024 535 0 Belt pulley Rd. 300 6. 20 024 533 1 Clamping ring 7. 20 024 803 0 Raceway 8. 20 024 802 0 Cover 9. 90 000 063 0 Shaft sealing ring AS 70x100x10 10. 90 000 193 0 Pendulum roller bearing 22312 U 15-VS 11. 20 026 017 0 Bearing housing on right 12. 00 936 447 2 Shaft sealing ring A 80x110x10 13. 20 024 800 0 Cover 14. 20 024 799 0 Raceway

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4

3

2

1

9. Accelerator: Settings BiG X 500 - 1000 Setting the back plate (Through Y.o.M. 2010)

2

Incorrect adjustment of the back plate will cause poor blowing or excessive wear. Adjust the back plate (1) by loosening the screws (5) on right and left hand side. The distance between the paddles and the back plate should be set according to the measurements below. Note how the angle of the back plate affects the crop flow angle (A) through the transition (2).This can be checked in the transition (2) through the inspection window (3) .

X

А 3

Measurement (X) : Grass: 4-5 mm, Corn: 2-4 mm The scraper (4) must be set to 2 mm clearance to the accelerator.

1

4 В 1 4 5 It is important that no steps or edges are in the crop flow (B) The plates (6) must be opened or removed when working with the Corn Conditioner in place.

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9. Accelerator:

BiG X 700 / 850 / 1100

Setting the Back Plate with VariStream Y.o.M. 2011 and later old contour

new contour

BiG X 700/850/1100 y.o.m. 2011 have a new back plate.

The adjustments have changed.

The clearance between back plate and accelerator should be 3 mm in corn and grass.

Adjustment is made with the rubber pads.

It is necessary to check the overlap between back plate and transition.

15 mm should be the minimum dimension.

If necessary adjust the back plate at the bottom pivot point.

Transition approx. 15 mm Rubber pad

Back plate

Lower pivot, Adjustable by stop bolt on the grass channel or KP

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12. System Technology: Namur Sensor Namur Sensors The sensor is switched by reading metal in a range from 2mm – 5mm (without touching the sensor). The sensor is only switched when metal is in this range, this causes a current change. The time for the sensor to switch off is twice as long as to switch on.

0V

+ 8.2 VDC

Sensor measurements.

Current 0 mA = open circuit Current approx 20 % of maximum value = Sensor switched Current approx 60 % of maximum value = Sensor not switched Current maximum value = Short circuit, maximum current

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12. System Technology: Namur Sensor Namur sensor M12x1 00 302 409 1 (Operating distance 4 mm) B25 – Header right B28 – Spout Position Middle B29 – Spout Position up/down B36 – Sharpening Position left B37 – Sharpening Position right B55 – Header left B58 – Cutting cylinder speed B59 – Sharpening lid (only USA)

1

Namur sensor M12x1 00 302 448 0 (operating distance 2 mm) B30 – Spout turning impulses 2 power supply: 8,2 V DC internal resistance: 1 KΩ temperature range min./max: –13 °F / +158 °F

X

Adjustment distance X= 2 mm Torque: max. 10 Nm (7 ft/lbs).

Sensor B30 for the spout turning impulses is mounted with a copper washer A12x18x1,5 into the gearbox housing with 10 Nm (7 ft/lbs) torque.

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12. System Technology: NPN Sensor NPN - normally open contact When actuated, allows current flow NPN - normally closed contact When actuated, prevents current flow

1

3

2 Pin 1 (brown) Pin 2 (black) Pin 3 (blue)

NPN - normally closed contact

– 12V – signal – 0V

NPN sensor 00 302 897 0 Normally closed contact, switching distance 4 mm B40 – operating brake switch

X

When metal is detected, the signal line is disconnected from Gnd. Nominal power supply 12 V DC

Setting dimension X= 1.5 mm Tightening torque: max. 10 Nm. (7 ft/lbs) 61

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12. System Technology: Angle sensor Hall Angle Sensor 00 303 146 0 The angle of the pendulum frame (V) is monitored by a Hall angle sensor. The sensor works with a 12V power supply. The signal voltage changes in two 70° ranges. In the first 70° range (I) the signal voltage increases from 1V to 5V, in the second 70° range (III) the signal voltage decreases from 5V to 1V. In the two 110° ranges, (II) and (IV), the signal voltage remains constant at 1V and 5V respectively.

B52 – Angle of the pendulum frame

Pin 1 – 0V Pin 2 – 12V Pin 3 – signal voltage 1...5 V

3

2

IV 0°

250°

1V

I

III 5V→1V

2

1

1V→5V

V 180°

5V

II 62

70°

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1

12. System Technology: Angle sensor Hall angle sensor The sensor works with a power supply of 8 to 10 V. The signal voltage range depends on the power supply.

Signal voltage min 0.25 x Uvers Signal voltage max 0.75 x Uvers

Uvers=10V

Sensor

Function

Angle

B47

Header contour left

B48

Header contour right

B50

Position lifting gear

B61

Row registration right

B65

Inclination registration left

B64

Steering axle (Autopilot)

82°

B 107

Steering axle (Bosch travelling gear)

110°

Ub+

U signal

Spare part no.

10 V

2.5 V – 7.5 V

8.5 V

2.1 V – 6.4 V

72°

0° 10 V

2.5 V – 7.5 V

303 164 0 (Bosch R 917 005 166)

20 080 435 0 (Bosch R 917 005 170) 20 081 488 0 (Bosch R 917 P07 620)

2.5V→7.5V

3 2 72° (82°)

Pin 1: 0V Pin 2: Signal voltage Pin 3: 8.5V / 10V

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12. System Technology: Angle sensor Swash Plate Angle Potentiometer for Ground Drive Pumps The swash plate angle potentiometer is monitored by the Smart Drive. The Smartdrive supplies 5 volts to the potentiometer.

The potentiometer has a working range of 0–5 volts. When the pump is in the neutral position (machine stationary), the potentiometer must be set to 2.5 +/- 0.02 volts. When installed, a value range of 1.8–4.3 volts is set.

Forward travel:

value range 2.5–4.3 volts

Reverse travel:

value range 2.5–0.7 volts (partially restricted!!!)

B 38 / B 39

270016270 pivoting angle potentiometer Front Axle / Rear axle

Pin 1: 0 V (earth) Pin 2: 5 V (supply voltage) Pin 3: 0.5 - 4.5 V

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12. System Technology: Angle sensor Brake pedal angle sensor (Bosch transmission) In the case of Big X 700-I, 850-I and 1100-I an angle sensor is attached to the brake valve for recording the position of the brake pedal. A current is output depending on the position of the brake pedal.

After working on the entire brake hydraulics, the brake valve must be recalibrated!

B109 – angle-position sensor 20 081 500 0 Measuring range:

120°

Supply voltage:

12 volts

Signal:

65

Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6:

4–20 mA

ServiceTraining 2012 advanced

GND 12 volts 4 - 20 mA Free Free Free

© KRONE Training Team, Spelle, Germany

12. System Technology: Pressure sensor Pressure sensor This sensor uses a 12V power supply. As pressure (P) from 0 to 250 bar is applied to the sensor, the signal voltage changes from 1V to 5V. The pressure in the brake pressure line is measured by the sensor B16 and transmitted to the computer (A1) SmartDrive. The SmartDrive assess the information from B16 together and the brake pedal position sensor B40.

P

B16 – pressure sensor 00 302 647 0

1

2

P 1

U

2 3

3

66

Pin 1 – 12V Pin 2 – 0V Pin 3 – signal voltage 1...5 V Pin 4 – not assigned

ServiceTraining 2012 advanced

© KRONE Training Team, Spelle, Germany

12. System Technology: Pressure sensor Head Pressure (weight) Sensor The sensor works with a power supply of 8V to 10V. The signal voltage range depends on the power supply.

Signal voltage min 0.25 x Uvers Signal voltage max 0.75 x Uver If pressure (P) from 0 to 250 bar is applied to the sensor, the signal voltage changes.

1

3

3

P

U

B49 – pressure sensor 00 302 530 0

1

2 Pin 1 – 0V Pin 2 – signal voltage 2.5–7.5V Pin 3 – 10V

U (V) 8,0 7,5 7,0 6,0 5,0 4,0 3,0 2,5 2,0 1,0

P (bar)

0 20 67

40

60

80 100 120 140 160 180 200

ServiceTraining 2012 advanced

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© KRONE Training Team, Spelle, Germany

12. System Technology: Pressure sensor Hydac Pressure Sensor 250 bar – Steering Pressure The sensor uses a 12V power supply. As the pressure (P) at the sensor varies from 0 to 250 bar, the signal voltage changes from 1 V to 5 V. The pressure in the line from the steering pump and the steering unit is measured by sensor B63. This pressure is recorded and evaluated by the autopilot control (A5).

B63 – pressure sensor 302 647 0

Measuring range:

0–250 bar

Supply voltage:

12 volts

Signal voltage:

1–5 volts

Pin 1: 12V Pin 2: 0V Pin 3: Signal voltage 1–5V Pin 4: not assigned

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12. System Technology: Pressure sensor Hydac Pressure Sensor 500 bar – High-Pressure Sensor (Poclain Transmission) This sensor records the pressure in the “High pressure forward" loop of the ground drive system.

The sensor uses a 12V power supply. As the pressure (P) at the sensor varies from 0 to 500 bar, the signal voltage changes from 1 V to 5 V. The pressure in the circuit is measured by the sensor B13 and transmitted to the computer (A1) SmartDrive.

B13 – pressure sensor 302 473 2

Measuring range:

0–500 bar

Supply voltage:

12 volts

Signal voltage:

1–5 volts

Pin 1: 12V Pin 2: 0V Pin 3: Signal voltage 1–5V Pin 4: not assigned

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12. System Technology: Pressure sensor Bosch pressure sensor 600 bar – High-Pressure Sensor (Bosch Transmission) Big X with Bosch transmission two high-pressure sensors are installed. They record the pressure in both high-pressure lines of the circuit. They are installed in the drive pump, directly next to the SAE flanges.

B101 / B 102 – pressure sensor 27 007 711 0

Measuring range:

0–600 bar

Supply voltage:

10 volts

Signal voltage:

0.5–4.5 volts

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12. System Technology: Pressure sensor Hydac Pressure Sensor 4 bar – Leakage Oil Filter Pressure Sensor The sensor works with a power supply of 12 V. As the pressure (P) varies from 0 to 4 bar, the signal voltage changes from 1 V to 5 V. Big X 700 / 850 / 1100 this sensor measures the pressure on the leakage oil return filter. If the pressure in front of the filter reaches a certain value, corresponding error messages are output.

B91 – pressure sensor 27 005 687 0 Measuring range: Supply voltage: Signal voltage:

0–4 bar 12 volts 1–5 volts

1V = 0 bar 2.5V = 1.5 bar 3.0V = 2.0 bar 5V = 4.0 bar < 1V = Broken cable >5V = Short circuit

• •

If the pressure sensor reads 1.5-2.0 bar for 6 seconds, error code 2603 is output If the pressure sensor reads over 2.0 bar for 5 seconde, error code 2604 is output.

Pin 1: 12V Pin 2: 0V Pin 3: Signal voltage 1–5V Pin 4: not assigned

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12. System Technology: Pressure sensor Overview of Pressure Sensors BiG X Hydraulics Material number

Manufacturer

Pressure range

Location BiG X

Signal

Plug connection

302029-2

Hydac

0–130 bar

Service brake (B16)

1–5 V

Cube plug

302647-0

Hydac

0–250 bar

Autopilot (B 63)

1–5 V

DIN plug M 12

302473-2

Hydac

0–500 bar

Travelling gear highpressure sensor (B 13)

1–5 V

DIN plug M 12

270 056 870

Hydac

0–4 bar

Travelling gear leakage oil filter (B 91)

1–5 V

DIN plug M 12

302530-0

Bosch

0…200 bar

Lifting gear pressure (B 49)

0.25 x Ub…0.75 x Ub

Jet plug 3-pole

20007711-0

Bosch

0–600 bar

Bosch travelling gear high-pressure sensor (B101 / B102)

0.5–4.5 V

Deutsch plug 3-pole

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12. System Technology: Speed sensor Speed sensor This speed sensor is used on BiG X 700 / 850 / 1100 in the rear wheel motor on the right hand side. The Smart Drive uses this signal to calculate the machine speed. This value is used for driving speed, acre counter and distance displayed in the terminal. It replaces the signal from the feedback sensors in the pump, which delivered the signal for those values in earlier models.

3

B90 – speed sensor 270071420 Signal voltages (frequency signal): - Voltage if sensor not alive: < 1.5 V - Voltage if sensor alive: > 8.5 V (supply voltage – 3.5 V)

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4

Pin 1 – supply voltage 12V Pin 3 – 0V (earth) Pin 4 – frequency signal

© KRONE Training Team, Spelle, Germany

12. System Technology: Speed sensor Speed Sensor (Bosch Transmission) Big X 700-I, 850-I and 1100-I a speed sensor is installed on each variable speed motor for each wheel.

This speed sensor is used for recording the travelling speed, anti-lock system and for the traction control system.

B103 / B104 / B105 / B106 – speed sensor 20 081 687 0 Supply voltage:

74

10 volts

ServiceTraining 2012 advanced

Pin 1:

+10 volts

Pin 2:

GND

Pin 3:

Frequency signal

Pin 4:

Direction of rotation signal

© KRONE Training Team, Spelle, Germany

12. System Technology: Speed sensor Sauer

Linde

Krone no. 919 938 0

Krone no. 270 016 900

A speed sensor is installed in the hydraulic motors for the header and intake.

-> Observe parameters 25491 and 25492!!! (Engine type: Sauer / Linde) The sensor (Hall Effect Sensor) reads a magnetic ring attached around the cylinder of the unit.

The sensor emits a digital frequency signal depending on the magnetic ring speed.

The connection and the setting of the speed sensor are described in the Service Manual.

The speed sensor is used only to calibrate and indicate the actual speed.

Active control of the head and intake is not required.

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12. System Technology: Temperature Sensor Temperature Sensor The semi-conductor temperature sensor can be used to measure temperatures from 32°F to 248°F. The BiG X 700/850/1100 uses this sensor to measure the temperature of the hydraulic oil returning to tank. This reading is used to control the hydraulic fan drive.

Connection diagram

B85 – temperature sensor 20081040.0

Pin 1 – 12V Pin 3 – 0V Pin 4 – signal voltage 1-5 V

Tightening torque: 14.75 ft/lbs

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12. System Technology: Seat Contact Switch Seat Switch for Self-Propelled Machine – S 69 (before Y.o.M. 2011) New seat switches have been installed in the new cabs since Y.o.M. 2011 to improve protection against failure and manipulation.

Integrated resistors impede manipulation ncreasing safety for the user.

The new seat switch can be identified by the connector on the driver's seat:

Observe parameter!

BiG X:

33659

Simple switch (digital): 2-pole plug connection at rear right on the driver's seat

Manipulations may result in serious or even fatal injuries! Any manipulation is therefore absolutely forbidden!

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12. System Technology: Seat Contact Switch Seat Switch for Self-Propelled Machine – S 69 (Y.o.M. 2011 and later) Big X 500, 650, 700, 800, 850, 1000, 1100: Big X 700-I, 850-I, 1100-I:

Intake / Head / automatic DC / autopilot (with latest SW) Intake / head / automatic DC / autopilot

Observe parameter!

BiG X:

33659

Diagnosable switch: 16-pin plug connection at rear left in the driver's seat (removed here)

> 333 digits: Seat switch

Manipulations may result in serious or even fatal injuries! Any manipulation is therefore absolutely forbidden!

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< 261 digits: Seat switch < 142 digits: Broken cable  452 digits: Broken cable

© KRONE Training Team, Spelle, Germany

12. System Technology: Electric Solenoid Valve Electric Solenoid Valve The solenoid consist mainly of a spool and a coil.

If current flows through the coil, a magnetic field is built.

The streamlines of this field are concentrated in the center and able to shuttle the spool. The pull-spring brings the spool in home position. On some valves it's possible to manually override with the button on the end.

To test the solenoid it's possible to measure the resistance of the coil. The specific resistance is on the housing.

It's also important to measure the resistance to the housing. There must be no continuity.  The magnetic coil is okay.

Iron core

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Coil

Spring

© KRONE Training Team, Spelle, Germany

Knurled head screw

12. System Technology: Electric Motor Electric Motor Electric motors transform electrical energy into mechanical energy.

DC motor Electric motors work by the help of electromagnetism. The armature (2) contains an electromagnet. When you run electricity into this electromagnet, it creates a magnetic field in the armature (2) that attracts and repels the magnets in the stator. So the armature spins through 180 degrees. To keep it spinning, you have to change the poles of the electromagnet. The brushes handle this change in polarity with the commutator (4). They make contact with two spinning electrodes attached to the armature and flip the magnetic polarity of the electromagnet as it spins on the shaft (1).

1

2

3

4 5

1.

2.

3.

4.

5.

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Shaft Armature Armature windings Commutator Ball bearing © KRONE Training Team, Spelle, Germany

12. System Technology: Calibrating the Pendulum Frame Calibrating Pendulum Frame Sensor The calibration of the pendulum frame (1) must be carried out every time work is done on the pendulum frame, sensor or the Job computer KMC3.

General information to calibrate the pendulum frame: - Release switch (2) Road/field in field mode - Release switch Transmission (3) Off. It is best done with the header (EC, EF, X-Disc) on the machine so that an exact level is achieved.

1 The header can be leveled with the soft keys (4) when the hydraulic cylinder is installed .

2 On

3

1

4

Off 81

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12. System Technology: Calibrating the Pendulum Frame

V 1 3 2 D

Calibrating the Pendulum Frame Sensor Open menu 3-3 in the terminal. When the pendulum frame is level the valve (1) from the sensor B52 must be between 350 – 450. If the value is out of range, it can be adjusted at the slotted holes. When installing the sensor it is important that the flat on the pin (W) is in the direction of the plug (S) .

Push the soft key (D) to save the value.

W

1. actual value (V) 2. Saved value (V) 3. Delta Value from saved value (2)

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S

© KRONE Training Team, Spelle, Germany

12. System Technology: Calibrating the Pendulum Frame Latest Generation of Intake Beginning in 2011 BiG X 700/850/1100, have a new intake design.

These machines no longer use angle sensor B52. This sensor is replaced by two namur sensors: B87 Pendulum frame position left up, B88 Pendulum frame position right up (left / right always in driving direction) If the pendulum frame is not in front of either of these sensors, the frame is in the horizontal position.

If the pendulum frame moves, one sensor will read the metal and switch: B87 switched = pendulum frame + header left hand side up B88 switched = pendulum frame + header right hand side up Both sensors are mounted in a fixed position. No calibration is necessary.

Sensor operating distance 1.5 – 2.0 mm.

B 88

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B 87

© KRONE Training Team, Spelle, Germany

12. System Technology: Calibrating the EMR Sensors Sensors of the Lifting Gear Calibration of the lifting gear must be made for each header and the mode that it is used. Also if a hydraulic component has been changed, EMR, sensor for the regulation or the job computer KMC 3, the lifting gear should be recalibrated.

Installing the Angle Sensors (V) The angle sensor (V) should be installed so that the dimple (K) points to the plug (S). The pin (P) must point to the opposite side.

P K

2

1

3 α P

1.

2.

3.

α d

d

1

Pressure sensor (Р) В49 Position sensor (α) В50 Distance sensors (d) on left В47 on right В48

S

2 3

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V

12. System Technology: Calibrating the EMR Sensors 2 1 3 α P

1.

2.

3.

α d

Pressure sensor (Р) В49 Position sensor (α) В50 Distance sensors (d) – on left В47, on right В48

Default Setting of the Lifting Gear Sensors Open menu 4-1-5 in the terminal.

The value (W) of the sensors В47/В48/В50 are displayed. When the header is completely on the ground the values of B47/B48 must not be lower than 20. If out of range, they can be adjusted in the slotted holes. Check the minimum value of sensor B50 with d the head removed.

When the head is in the raised position the value from the sensors B47/B48/B50 must not be greater than 235. This is 100% position.

W

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12. System Technology: Calibrating the EMR Sensors General Information for the Calibration of the Lifting Gear Sensors The following conditions must be met for calibration of the lifting gear sensors: - Engine running - All the release switches in the console (1) switched off.

- Pick up, Corn Header or X-Disc must be attached. In the “machine adjustment” menu, choose the correct head (Easy Collect, Pick up, X-Disc).

- The machine on level ground and the header unfolded - The header in horizontal position.

1

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12. System Technology: Calibrating the EMR Sensors Adjusting the EMR is as easy as 3 – 2 – 1.

3 – Raise head to maximum height (B50). Hold the rocker switch (2) and button (N) for ~7sec. The message “EMR Adjustment 3 OK” will appear on the terminal. The head will automatically lift to its upper limit.

With the corn head attached, the ground contour sensors (B47 and B48) limit will also be set automatically at this time.

1 2

2 – Adjusting hydraulic lifting pressure (B49) at working height. Hold the rocker switch (1) to lower the head to working position (not touching the ground). Press and hold button (N) for ~7sec until the message “EMR adjustment 2 OK” appears in the terminal.

N

1 – Adjusting the minimum height (B50). Hold rocker switch (1) to place all of the head’s weight on the ground. Press and hold rocker switch (1) and button (N) together for ~7sec until the message “EMR Adjustment 1 OK” appears in the terminal. With the corn head attached, contour sensors (B47 and B48) limit will also be set automatically at this time.

В50

В48

В49 α P

В47

α d

d

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12. System Technology: Calibrating the EMR Sensors Functional Test of Pressure Sensor В49 After the three adjustments are finished the digital value (1) (pressure sensor B49) in the lifting gear diagnostics must be negative when the header is in the work position and with no ground contact.

1

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12. System Technology: Calibrating the EMR Sensors Calibrating Absolute Lifting Gear Height (Cutting Height Calibration) After calibrating the lifting gear, the cutting height display must be calibrated: - Release switch Road/field (1) in field mode - Release switch Transmission (2) Off - Corn header is attached to the machine.

Open menu 3-3 in the terminal.

In the terminal open the "Maintenance/Calibration/Pendulum Frame" 3-3 menu.

1 On

2 Off

Upper position: Raise the header until the value (3) displays 80% .

- Measure between the bottom of the pick up tine and the ground (Pick-up head).

- Measure between the cutting knife and the ground (Corn head).

- Use the rotary switch scroll to the sub menu (4) 80%, click once to select, dial in the measured distance and click once again to save the value.

4 3 5

Lower position: Lower the lifting gear until the value (3) displays 20% .

- Measure the new dimensions and enter the values with the rotary switch in the display in position (5) 20% as above.

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12. System Technology: Calibrating the Autopilot Calibrating the Autopilot Sensors The calibration of the auto pilot has to be carried out each time a hydraulic component, mechanical component or an electric component has been changed (that is used by the auto pilot, e.g. valve, sensor or job computer).

1 On

3 2 On

P

General Information on the Calibration of the Autopilot sensors The following conditions must be meet: - Engine running - Release switch (1) Road/field in field mode - Release switch Transmission (2) switched on.

- Release switch auto pilot (3) switched on.

- The driver is sitting on the seat and the door is closed.

- The Easy Collect is attached and folded out.

- The machine on level ground.

К

On

4

5

S Installing Autopilot Sensors When Installing the angle sensor (4) В65 and В61 the dimple (K) must point to the plug (S). The pin (P) must point to the opposite side.

When Installing the angle sensor (5) В64 for the steering angle, the dimple (K) must point to the plug (S). The pin (P) must also point to the plug.

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12. System Technology: Calibrating the Autopilot L 1

R

2

R

L

Calibrating the Autopilot Sensors Open menu 3-4 in the terminal.

Calibration of the row tracer left (L) B65 and right (R) B61: Both row tracer (left and right) must be calibrated in the rest position In the field "row tracer left" (1) the actual value of the sensor (L) В65 is displayed. It must be in the range 265 ± 50 when fully extended, adjust the sensor if necessary using the slotted holes. When the row tracer is pushed to the end of its stroke there must be a difference of 300 – 320 in the value. (important is that the value increases). With the rotary switch: scroll to select the row tracer left (1) and then press the rotary switch twice to select and save the value.

In the field "row tracer right" (2) the actual value of the sensor (R) В61 is displayed. It must be in the range 590 ± 50 when fully extended, adjust the sensor if necessary using the slotted holes. When the row tracer is pushed to the end of its stroke there must be a difference of 300 – 320 in the value. (important is that the value decreases). With the rotary switch: scroll to select the row tracer right (2) and then press the rotary switch twice to select and save the value.

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12. System Technology: Calibrating the Autopilot Calibrating the Steering Angle Sensor (B64)

1 3

2

4

- Steer the rear axle to the straight ahead position. The actual value from the steering angle sensor (1) is displayed in the terminal, it must be in the range of 400 ± 10. Loosen and adjust the sensor at the slotted holes.

Use the rotary switch to scroll to the sub menu (2) and then click once to select and once again to save the value of the steering angle sensor in the middle position.** - Steer the rear axle all the way to the left.

- Use the rotary switch to scroll to select the sub menu (3) and then click once to select and click once again to save the value of the steering angle sensor in the left position. (It is important that the reading from the sensor is not less than 220.

- Steer the axle all the way to the right.

- Use the rotary switch to scroll to select the sub menu (4) and then click once to select and click once again to save the value of the steering angle sensor in the right position. .(Important is that the reading from the sensor is not greater than 630).

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12. System Technology: Calibrating the Autopilot Calibrating the Y39/Y40 Minimum current Bring the machine to a solid level surface, steer the rear axle to the straight ahead position. The minimum and maximum current of the solenoid valves Y39 and Y40 will be calculated. Above software version 150 200 104 – 08 the calibration can be made automatically. Note: The steering angle sensor В64 must be calibrated before auto calibration can be attempted. The auto calibration is started with the soft key (A). A new window opens (F) and the rear axle steering valves steer the axle to the right and left automatically.

А 1 2

F 4

1.

2.

3.

4.

Actual PWM current in %, Actual current to the solenoid.

Actual valve from В64 State of the Calibration:

3 Calibration of the valves Y39 and Y40 Calibration run successfully and values are saved Stop calibration 93

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12. System Technology: Calibrating the Discharge Chute Discharge Chute Sensors The calibration of the chute has to be carried out each time the end or middle positions are not correct. Or if a hydraulic, mechanical, or an electric has been changed that works with the Chute, e.g. valve, sensor or job computer.

1

Sensor B30 (1) checks the spout turning impulses. It is mounted with a copper washer A12x18x1,5 into the gearbox housing with 10 Nm (7ft/lbs) torque. (This washer sets the proper sensing gap). Sensor В29 (2) checks the spout position, up or down. Sensor В28 (3) checks the spout middle (home) position.

2

N

M

M

Installing Sensors В28 / В29 - Adjust sensor (N) until the distance (X) is 2 - 4 mm.

- Torque nut (M) to 10 Nm (7 ft/lbs).

3

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12. System Technology: Calibrating the Discharge Chute 1 M

E

On

2

Off Calibrating the Discharge Chute (M = mechanical end position, E = electronic end position) When calibrating the chute, it is possible to stop the chute electronically (E) before it reaches the mechanical stops (M). This will increase the life of the components because the chute will stop electronically each time before it hits the mechanical stop (see the diagram above). All parts are not symmetrical so it is necessary that the calibration is carried out for both sides separately. The determined values may not be alike! In the parameters it is possible to set the distance that the chute starts to slow down before reaching the calibrated end point or middle point (see the parameter section).

General information for calibrating the chute: The following conditions must be met to carry out the calibration of the chute: - Engine running - Release switch (1) Road/field in field mode - Release switch (2) maintenance Off - The driver is sitting on the seat and the chute in the raised position 95

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12. System Technology: Calibrating the Discharge Chute 1 2 3 5

4 6

1.

2.

3.

4.

5.

6.

Open menu 3-5 in the terminal.

Actual position of the chute (up/down).

Actual position of the chute (middle/right/left) Actual number of impulses counted for left or right side.

Actual current flowing to the valve (left or right) Total number of impulses saved. (electronic max left) Total number of impulses saved. (electronic max right)

Button (А) and (С): Saves the total number of impulses for the right and left side (electronic max) Button (В) and (D): Manually rotates the chute to the left and right side.

Calibrating the chute Rotate the chute with the button (L) on the Joystick all the way until the electronic stop is reached. When it does not rotate far enough, the chute can be rotated further using minimum current by pressing button (B).

The chute must be stopped before the mechanical stop and the value saved with the button (A). This is the new electronic maximum.

Rotate the chute with the button (R) on the Joystick all the way until the electronic stop is reached. When it does not rotate far enough, the chute can be rotated further using minimum current by pressing button (D).

The chute must then be stopped before the mechanical stop and the value saved with the button (C). This is the new electronic maximum.

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L

R

12. System Technology: Calibrating the KP Calibrating the KP

1

Calibration is necessary the first time the KP is installed in the machine, or any time the gap between the rolls is reset.

Or if a mechanical, or an electric component has been changed that works with the KP .ie motor or job computer.

On

General Information on Calibrating the Grain Conditioner The following conditions must be met to carry out the calibration of the KP: - Release switch Road/field (1) in field mode - KP installed.

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12. System Technology: Calibrating the KP 1 S

3

4 F

Calibrating the KP (Roller Version) Adjusting the KP motor: Enter the menu for the KP parameters.

Select parameter no. 33607: 0=> Valeo motor (2 plugs on motor) 1=> Dunker motor (one 7-pin plug on the motor) For the exact calibration it is best to measure the gap between the two rollers (1, 2) with a feeler gauge.

With the rotary switch select the calibration menu 3-6 then select the sub menu (S).

With the softkeys (3) and (4) the rollers can be opened or closed.

With the rotary switch adjust the value to what you have just measured.

Press the rotary switch to store the value you have entered.

Press and hold the ESC button (beside the rotary switch) for a few seconds to return to the main screen.

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2

12. System Technology: Calibrating the Grain Conditioner

3

1

4 X

S

2

Calibrating the KP (Disc Version) Setting the conditioner type (roller or disc conditioner) in parameters menu.

In the terminal open the "Maintenance/Grain Conditioner Calibration" 3-6 menu.

For a more exact calibration, it is necessary to measure the exact distance (X) between the discs (1) and (2) directly on the tip using a suitable measuring tool.

By pressing the button (3) or (4), you can reduce or increase the distance to make it easier to determine the gap dimension.

Enter the value you have just measured using the rotary switch.

Press the rotary switch to store the value.

Press and hold the ESC button (beside the rotary switch) for a few seconds to return to the main screen.

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12. System Technology: Calibrating the Feed Drive/Front Attachment Calibrating the header (speed) The header should be recalibrated any time the actual speed is different from the speed displayed in the terminal and any time a hydraulic, mechanical, or an electric component has been changed that works with the header, e.g. valve, sensor or job computer.

1 On

2 On

3 4

Calibrate feed drive / front attachment only when oil is warm!

Off

Calibrating the intake (speed / cutting length) The intake should be recalibrated any time the actual chopping length differs from the set chop length displayed in the terminal or any time a hydraulic, electrical or mechanical component is changed that is responsible for the intake. E.g. valve, sensor or job computer.

General information for calibrating the intake / header The following conditions must be met to carry out the calibration of the intake / head: - Release switch (1) road/field in field mode - Release switch intake / head (2) on - Engine speed: 2000 rpm (BiG X 500, 650) 1900 rpm (BiG X 700/800/850/1000/1100) - Release switch maintenance (3) off - Transmission switch (4) off - The head is not turning - The intake is not turning - The driver is sitting in the seat - On BiG X 700/850/1100 the main clutch needs to be engaged!

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12. System Technology: Calibrating the Feed Drive/Front Attachment 6 2

1

3

4 5 A

B

C

D

E The currents to be determined: The following 3 currents are determined: "I0" - is the current at which the unit starts to rotate.

"Imin" - is the current at which the unit reaches the minimum speed to be set.

"Imax" - is the current at which the unit reaches the maximum speed to be set.

Open menu 3-7 in the terminal.

Overview of the calibration intake / header: 1. Intake calibration (Set point 1 and Set point 2) 2. Header calibration (Set point 1 and Set point 2) 3. Actual current going to the intake and header hydraulic pumps.

4. Actual speed of the intake / header motors 5. Graph of the current, I0 – Starting current; Imin – min speed current; Imax – max speed current 6. Engine speed Softkey (A) and (C): Start the calibration of intake or head.

Softkey (B) and (D): Stop the calibration of intake or head.

Softkey (E): Auto engine speed of 2000 rpm (BiG X 500 / 650); 1900 rpm (BiG X 700/800/850/1000/1100)

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12. System Technology: Calibrating the Feed Drive/Front Attachment E 2

1

3 4 5 A

B

C

D

Press button (E) to reach the correct engine speed.

Calibrating the head Press button (C) to start the calibration. The valve Y7 “head forward” is activated. The head starts to turn after a short time. The calibration takes ~120 secs. When the correct data is not received in this time then the calibration is aborted. The calibration can be cancelled with the softkey (D). The progress of the calibration can be seen in the display.

Calibrating the intake Press the button (A) to start the calibration. The valve Y5 “intake forward” is activated. The intake starts to turn after a short time. The calibration takes ~120 secs. When the correct data is not received in this time then the calibration is aborted. The calibration can be cancelled with the softkey (B). The progress of the calibration can be seen in the display.

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12. System Technology: Calibrating the Travel Path Calibrating the Travel Path The driving distance calibration is for the acre counter, the driving distance and the speed display. The calibration has to be carried out during the pre-delivery inspection (PDI). You must also perform the calibration any time there is a difference between the actual (speed / acres) and the reading in the terminal. It is also important to carry out a calibration if you change a hydraulic, mechanical, or electric component that is responsible for the driving system, e.g. valve, sensor or job computer.

Before you can perform the driving distance calibration, you must mark out a distance between 50-200m (165660ft). The exact distance will be entered in the terminal and is required information for the calibration.

The driving distance calibration is carried out at two driving speeds: 1. The first step of the calibration is carried out at a constant speed of 1 - 2.5mph.

2. The second step of the calibration is carried out at a constant speed of 1.5 - 5mph.

Both driving speeds(v1 and v2) must be carried out for 2wd road mode, 2wd field mode and also for 4wd field mode(6 times in total).

There is a parameter set in KMC 3 for the respective modes and they are not over-written until saved with the softkey.

General information for calibrating the driving distance The following conditions must be met to carry out the calibration of the driving distance: - Release switch Transmission on - Release switch Road/field (in the mode being calibrated) - Release switch 4wd off / on (4wd) - Release switch axle separation Off

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12. System Technology: Calibrating the Travel Path 1 2

3 4

5 6

8 A

B

C

Calibrating the driving distance 1) Drive modes to calibrate.

2) Calculated distance and speed; the basic info for the acre counter.

3) Distance and speed value that is calculated by the wheel (fixed value).

4) The field to adjust the test-driving distance (165-660ft).

5) Displayed valve for the first test run. (Calculated by machine during test) 6) Displayed valve for the second test run. (Calculated by machine during test) softkey A) Start and then stop the first test run. softkey B) Start and then stop the second test run. softkey C) Resets the values for the test run. softkey 8) Saves the calculated parameter

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12. System Technology: Calibrating the Travel Path 1 2

3 4

5

8

6 A

B

Enter (4) the distance that has been set for the test run in the sub menu. Bring the machine to the start line.

First test run: - start the run V1 with the softkey (A).

- Drive approximately 2.5mph and stay at that constant speed, the terminal displays the average speed in sub menu (5).

C

- End the test run exactly on the marked end point, press button “A” and the run values will be stopped.

Second test run: - Start the run V2 with the softkey (B) - Drive approximately 5 mph and stay at that constant speed as soon as possible, the terminal displays the average speed in sub menu (6) .

- End the test run exactly on the marked end point, press button “B” and the run values will be stopped. When you complete the test runs and everything is within the parameter sets, then the disc symbol will appear and the new parameter set can be stored in the eprom with softkey 8 .

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12. System Technology: Calibrating Rock Protect Calibrating Rock Protect It is important to carry out a calibration during PDI, when the readings are not correct, if you change a mechanical, hydraulic, or electric component that is responsible for the Rock Protect system e.g. valve, sensor or job computer.

Calibration is also necessary if Rock Protect is field installed.

The calibration of Rock Protect takes the signal voltage from the sensor В76 in the rest position.

Open menu 3-9 in the terminal.

Before calibration is started, the head must be in the working position and the intake must be clean from crop so that the feed rolls are fully down. The intake must not be switched on. Press the softkey (A) and the calibration runs automatically..

1 2 A 1. Actual signal voltage from the sensor В76 2. Saved signal voltage from the sensor В76 А - Start calibration Rock Protect

The sensitivity can be adjusted in the terminal: Menu 1-1-21. It is adjusted to 50 as a factory setting.

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12. System Technology: Calibrating the Main Coupling Calibration of the main clutch The current of the main clutch can be calibrated in software-Version 150 200 104-08 and higher. The calibration should be made when engagement is too soft / hard, or if you change a mechanical, hydraulic, or electric component that is responsible for the main clutch.

1 On

2

3 Off

General information for the calibration of the main clutch The following conditions must be met to carry out the calibration of the main clutch: - Engine running - Release switch (1) road/field in field mode - Release switch (2) transmission off - Release switch (3) maintenance off - The driver is sitting on the seat and the door is closed

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Off

12. System Technology: Calibrating the Main Coupling 3 1

2

5

6

1. The actual current flowing to the valve Y12 2. The actual speed of the cutting cylinder 3. The actual speed of the engine 5. Start the calibration of the main clutch 6. Stop the calibration of the main clutch

Calibration of the main clutch Open menu 3-10 in the terminal.

Push the softkey (5) to start the calibration, the calibration runs automatically. If the cutting cylinder speed sensor does not detect movement, the calibration is cancelled at 1400 mA. When the calibration is successfully completed, the green check mark appears shortly after the calibration is finished.

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12. System Technology: Calibrating Crop Control 1

2

4

3 9 5 8

1 2, 3, 4 5 6 7 8 9

Display Buttons for softkeys "+" button "Esc" button "OK" button "-" button Menu button

6 7

B73

B72 Crop Control Terminal Inductive range sensor on intake 109

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Pressure sensor in intake

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12. System Technology: Calibrating Crop Control Calibration of range sensor B 72 : Before placing the machine in service the first time and after any assembly work on the range sensor, it must be calibrated. Ensure there is no crop in the intake housing and that the pre-compression rolls are against the bottom limit stop.

Press button (2) to save the current voltage output of the sensor. The calibrated value needs to be between 500mV and 1000mV.

1

2

3

Menu level 1 - 1 Calibrating the path recorder

Adjusting the minimum opening: Use the minimum opening to set the separation of the pre-compression rolls where the measurement is started. The higher the minimum opening, the more crop must flow through the rollers to activate the yield counter.

Standard value for minimum opening: 5mm, to set, press button (1), Softkey ”DEF“.

The minimum opening can be adjusted with buttons ”+“ and ”-“. After that press button “OK“ to save the setting.

1

2

3

Menu level 1 - 3 Setting the minimum opening

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12. System Technology: Calibrating Crop Control Calibrating Pressure Sensor B 73: The pressure sensor must be calibrated before placing the machine in service the first time, after any assembly work and weekly during operation. Ensure that no crop is in the intake and that the pre-compression rolls are against the bottom limit stop. The following conditions need to be fulfilled: • cutting drum engaged • feed roller drive engaged • engine at ~2000 rpm

1

2

• cutting length adjusted to minimum (depends on number of knives)

3

U Menu level 1 - 2 Calibrating pressure sensor

A

O

•) (U) pressure in intake at shortest cutting length (A) current pressure in intake

(O) pressure in intake at longest cutting length 1. Calibration of pressure in the intake for the shortest cutting length: Press button (2), the symbol “calibration“ is shown in inverted colors. An arrow will appear underneath the shaded area on the left. Slowly increase cutting length until the bar is within the shaded area on the left.

After a short time the value (~40-70bar) will be written in the memory and the arrow will appear underneath the shaded area on the right.

2. Calibration of pressure in the intake for the longest cutting length: Slowly increase the cutting length once again until the bar is within the shaded area on the right. After a short time the value (~65-95 bar) will be written in the memory as well and the symbol “calibration“ is no longer displayed in inverted colors.

3. Saving the calibrated values: By pressing the button “OK“ the calibration will be saved.

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12. System Technology:

Calibrating Humidity Measurement

Calibration of the HARVEST TEC moisture meter :

Open control display

K

Menu level 1 - 2 Calibrating pressure sensor (K) Calibration button Before starting the calibration, it is necessary to measure the moisture of crop with an alternative test method. Compare the measured value with the displayed value on the HARVEST TEC unit. It is possible to calibrate alfalfa and corn modes separately.

Select the appropriate mode, press button (K) and hold it. The unit can be calibrated 8 points higher or lower. During calibration no crop should be in contact with the sensor!

1. Switch on the unit 2. Adjust crop (alfalfa or corn) 3. Press button (K) and hold it. The display starts counting at ”0“ and counts up to ”8“, scrolls over to ”- 8“ and goes on counting up until button (K) is released. In that moment the value is written in the memory.

4. Adjust the difference between alternative measurement and HARVEST TEC. E.g.: HARVEST TEC – measurement shows 3 points more than alternative method.  required adjustment: - 3 5. To save the calibration switch the unit off and on once.

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15. Hydraulics: Charge Pressure / Low-Pressure Circuit Overview

5 7

1 3 8

WHB_5.1

4

6

Changeover

2

9

Charge pressure_EN

View of BiG X 500-1000

WHB_5.1 Displacement_EN

(1)

Charge pressure pump with pipes to the transmission pumps. (filling high pressure circuit and pump displacement) (2) Main clutch valve and rear axle shift valve.

(3) Combination block (valve 4 wheel drive and axle separation) (4) Tensioning cylinder main belt (5) Tensioning cylinder KP belt (6) Front axle shift valve (7) Sharpening flap valve (8) Auxiliary function lifting gear (maintenance) (9) 2nd engine clutch valve (only twin engine) (10) Rotary screen drive (only BiG X 700 / 850 / 1100) 113

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15. Hydraulics: Charge Pressure BIG X 500 - 700 High-pressure circuit

4

High-pressure circuit

2

Charge pressure circuit

1

3

3

(1) Charge pump ground drive

Measuring points

(2) High-pressure filter (3) Charge pressure relief valves drive pumps (p = 24 ±3 bar) (4) High-pressure sensor B13 (p = 0–500 bar) 114

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WHB_5.1_Speisedruck_DE

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15. Hydraulics: Charge Pressure BIG X 800 – 1100 (Poclain) 4 High-pressure circuit

Charge pressure circuit

1 2

Measuring points

3

3

(1) Charge pump ground drive (2) Cold start valves (p = 30 bar) (3) Charge pressure relief valves drive pumps (p = 24 ±3 bar) (4) High-pressure sensor B13 (p = 0–500 bar) WHB_5.1_Speisedruck_DE

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15. Hydraulics: Charge Pressure Circuit (Poclain transmission) 8

6

5

4

2

3

1

7

9

12

116

10

11

(1)

Shift valve rear axle, Y11

(2)

Main clutch valve, Y12

(3)

Clutch 2nd engine (BIG X 800 / 1000)

(8) Feed front wheel motors

(4)

Tensioning cylinder - main belt

(9) Auxiliary pressure lifting gear (lower / damping)

(5)

Sharpening flap valve, Y65

(10) Pilot valve axle separation, Y10

(6)

Tensioning cylinder KP

(11) Pilot valve 4-wheel, Y13

(7)

Shift valve front axle, Y14

(12) Rotary screen drive (BIG X 700, 850, 1100)

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WHB_5.1 Charge pressure_EN

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15. Hydraulics: Charge Pressure / Pump Adjustment E2 Charge pressure is present at the highpressure relief valves (1). If the pressure in the high-pressure circuit (supply line or return line) drops below charge pressure, the valve opens and the high-pressure circuit is refilled.

2 The safety valve Y69 or Y70 (2) closes the tank return line of the charge pressure circuit.

Pressure builds up behind the throttle D3. The pilot valve (3) switches to "unthrottled" and charge pressure is present simultaneously at the pump direction control valves Y1 / Y2 or Y3 / Y4.

3

The safety valve Y69 / Y70 (2) and one of the pump adjustment valves Y1 / Y2 or Y3 / Y 4 are always energised simultaneously in the BiG X as soon as the joystick is actuated.  The pump swivels out.

Safety function: If the safety valve Y69 / Y70 is de-energised, the pilot valve (3) is always in the "throttled" position. The swash plate returns to neutral position.

1

LINDE circuit diagramm E2_EN

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15. Hydraulics: Component Overview of Linde Pumps Example: HPV 135 / 75-02

(1) Adapter disc angle sensor

11 11

4

(2) Angle sensor (3) High pressure relief valve (4) Charge pressure relief valve (5) Cold starting valve (6) Charge pressure gear pump

3

1

3

2 8

9

10

1

(7) End plate charge pump

2 8

10

9

(8) Control unit

5

(9) Magnetic safety valves Y69 and Y70 (black / white)

7 6

(10) Control unit magnet valves Y1 to Y4

6

(11) Sealing 4 3 3

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15. Hydraulics: Charge Pressure / Wheel Motor Shifting 2 – stage wheel motor (BiG X 500* / 650 / 700)

Measurepoint Minimess 7

* no shifting of the rear wheel motors on the BiG X 500!!

Y11

Y14

The valves Y14 and Y11 are open when they are not powered.  Charge pressure is supplied to the wheel motor, the motor shifts and is in small displacement (low torque) If Y14 or Y11 is powered, the valve closes.  Charge pressure is blocked from the wheel motor the internal spool is spring loaded to large displacement (high torque).

Diagnostics: Check for charge pressure at Minimess 6 or 7 Observe switching logic!!

WHB_5.1 Displacement_EN

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Changeover

15. Hydraulics: Charge Pressure / Wheel Motor Switchover 3 – stage wheel motor (BiG X 650* / 700* / 850 / 800 / 1000 / 1100) Front axle: MS 50 (1C/2C/3C); 5165 ccm / 3332 ccm / 1833 ccm *Front axle: MS 50 (1C/2C/3C); 4333 ccm / 2833 ccm / 1500 ccm

displacement 1C (maximum torque)

Shift valve(s) in to motor ports: Y14 (switching valve on front axle) -> Y1 (wheel motor)

Y68 (switching valve on front axle) ->Y2 (wheel motor) Changeover

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15. Hydraulics: Charge Pressure / Wheel Motor Switchover 3 – speed wheel motor (BiG X 650* / 700* / 800 / 850 / 1000 / 1100) * optional for BiG X 650 / 700

Measurepoint Minimess 8

Y11 HP circuit front axle

Y14

Valves Y68 and Y11 are open when not powered.

Valve Y14 is closed when not powered!  Charge pressure is blocked so the wheel motors operate in the large volume (high torque).

Y68

Changeover

 When the transmission is in neutral, Y68 and Y11 are powered. Y14 is not powered.

HP circuit front axle

Return air filter wheel motors

Diagnostics: Check for charge pressure at Minimess 6, 7, or 8 to diagnose shifting problems.

Observe switching logic!!

WHB_5.1 Displacement_EN

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15. Hydraulics: Switching Logic Wheel Motor Switchover 2-speed wheel motors

Speeds while accelerating

XY 14 (coil)

Y 14 (valve)

1st speed M = max

BIG X 500: approx. 0–8 mph Big X 650, 700: approx. 0–7 mp/h

12 volts

0 bar

BIG X 500: approx. 8–25 mph Big X 650, 700: approx. 7–25 mph

0 volts

30 bar

Speeds during acceleration

XY 14 (coil)

Y 14 (valve)

XY 68 (coil)

Y 68 (valve)

approx. 0–6 mph

0 volts

0 bar

12 volts

0 bar

approx. 6–12 mph

12 volts

30 bar

12 volts

0 bar

approx. 12–25 mph

0 volts

0 bar

0 volts

30 bar

v = min

2nd speed M = min v = max

3-speed travelling gear 1st speed M = max v = min

2nd speed 3rd speed M = min v = max

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15. Hydraulics:

Charge Pressure / All-Wheel and Axle Separation

Variable displacement pump rear axle

Wheel motors rear axle

2.1

1.1 Variable displacement pump front axle / wheel motors front axle

3

2 1

Pilot valve axle separation (1) Pilot valve 4-wheel drive (2) flush valves (3)

main valve axle separation (1.1) main valve 4-wheel drive (2.1)

When the engine is running, charge pressure of p = 24 ±3 bar is at the connection Ps of the combination valve block.

To activate the single functions 4WD or axle separation the pilot valve Y13 or Y10 have to be powered with 12 volts. The control lines are supplied with charge pressure and the main valve in the high pressure circuit is switched hydraulically.

4-wheel drive can only be activated at a standstill!

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15. Hydraulics: High-Pressure Circuit Travelling Gear Poclain Overview Changeover

WHB_5.1 High pressure transmission_EN

5 System control and monitoring by Smart Drive: Inputs (1)

Axial piston variable displacement pumps (ground drive) (Tandem unit: 105/75 ccm (BiG X 500 / 650 / 700) or 135/75 ccm (BiG X 800 / 850 / 1000 / 1100))

(2)

Front wheel motor (with integrated drum brake) 2-stage (BIG X 500 / 650 / 700) or 3-speed (BIG X 650 (opt.) / 700 (opt.) / 800 / 850 / 1000 / 1100)

(3)

Rear wheel motor constant (BiG X 500) or 2-speed (BiG X 650 / 700 / 800 / 850 / 1000 / 1100)

(4) (5) 124

Combination valve block (flush valves) High-pressure sensor (on pump 1, sometimes connected to short hose) ServiceTraining 2012 advanced

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Outputs

15. Hydraulics: High-Pressure Circuit "Front Axle" Poclain Flush valves (1), hydraulically actuated  Oil is removed from the return side and sent to the cooling system. > 400 bar

1

M

Changeover

System control and monitoring by Smart Drive: Inputs: B13, B14, B38/B39, …(comp. STLP)

Outputs: Y1/Y2, Y3/Y4, Y69/Y70, …(comp. STLP) 125

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15. Hydraulics: High-Pressure Circuit "Rear Axle" Poclain "Front axle" and "rear axle" circuits are connected to the axle separation valve (1) as long as axle separation is not activated.

M

When activating 4-wheel drive, both drive pumps operate in parallel on all 4 wheel motors.  The pumps still work together to power the "front axle" circuit and "rear axle" circuit. -> Controlled by 4-wheel drive valve (2) Wheel motors front axle

2

1

Axle separation: Two circuits separated from each other  "Front axle" pump for front wheel motors and "rear axle" pump for rear wheel motors.

A difference in speed between two wheel motors of an each axle can still be balanced.  Turning with axle separation activated is possible!

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15. Hydraulics: Speed Measurement Travelling Gear Poclain BIG X 700 / 850 / 1100 (from year of manufacture 2011) with Poclain travelling gear

Speed sensor B 90 on the right rear wheel motor: -> display of the actual speed -> display of the driven distance -> calculating of the worked area

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15. Hydraulics: High-Pressure Circuit Diagnostics (Poclain) M1 : p = 24 – 435 bar

M2 : p = 24 – 435 bar

(Supply line for forward travel)

(Supply line for forward travel)

The transmission high pressure circuit can be measured on minimess M1 to M4.

WHB_5.1 High pressure transmission_EN

M3 : p = 24 – 435 bar

M4 : p = 24 – 435 bar

(Return line for forward travel)

(Return line for forward travel)

Before measuring high pressure, activate 4-wheel drive and axle separation to separate the circuits.

When you remove the connectors from shift valves Y14/Y68 and Y11 it is easier to achieve the maximum pressure.  The wheel motors are in low torque.

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15. Hydraulics:

Overview of Components for Bosch Transmission

Location of the components in the machine 14 4

10 6

8 11

7 3b 5

2

6

13

14

3a 12 4

6 1b 15

12 13 15

1a

2 6

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Components

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1a

Drive motor front left

1b

Drive motor front right

2

Front planetary gearbox

3a

Drive motor rear left

3b

Drive motor rear right

4

Rear planetary gearbox

5

Variable displacement pump

6

Speed sensor

7

High-pressure sensor B101

8

High-pressure sensor B102

9

“Forward” valve

10

“Reverse” valve

11

Pivoting angle sensor

12

Feed valves

13

Drive motor valve at front

14

Drive motor valve at rear

15

Storage for feed

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15. Hydraulics: Bosch Drive Concept Function Sequences of Acceleration in Road and Field Mode 1.

Acceleration forward 0 - Vmax in road mode When the driver moves the joystick forward, the swash plate in the pump begins to displace oil. As the machine accelerates (swash plate increases displacement) the drive pump continues increase displacement until it reaches maximum displacement. Shortly before the pump reaches maximum displacement (approx. 5-5.5 mph), the wheel motors start to reduce their displacement. This gives a continuous, smooth acceleration from standstill up to the maximum speed of 25 mph. Reverse is limited to a maximum speed of approx. 8.5 mph (electronically limited).

2.

Acceleration forwards 0 – Vmax in field mode The sequence for the acceleration process is the same as for road mode. The only difference is that the maximum speed here is limited to 15.5 mph. The maximum reverse speed is approx. 8.5 mph (electronically limited).

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15. Hydraulics: Bosch Drive Concept Function Sequences in Drive Mode: Data Recording Sequence:

The machine was accelerated from standstill to 25 mph and then decelerated to standstill via the drive lever.

5000 4500 4000 3500

High pressure Hochdruck MA [bar]forward

3000

High pressure Hochdruck MB [bar]reverse Swash plate[mV] position Schwenkwinkel

2500

Forward control valve Strom Pumpe vorwärts [mA](ma) 2000

Speed Radmotor right frontvorne wheel motor Drehzahl rechts [Hz] Strom Radmotor vornewheel rechts motor [mA] Power right front

1500

Strom Radmotor hinten rechtsmotor [mA] Power right rear wheel

1000 500 0 0

131

5000

10000

15000

20000

25000 30000 Zeit [ms]

35000

40000

45000

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50000

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15. Hydraulics: Bosch Drive Concept Function Sequences of Traction Control and Anti-Blocking System 3.

Function of traction control (TC) Traction control prevents individual wheels from rotating uncontrollably if the tractive forces on one wheel can no longer be transferred to the ground. This enables all wheels to spin equally.

Depending on the speed of the other wheels and the steering angle, a theoretical speed is calculated for each wheel. If the speed of a wheel is higher, the displacement of the hydraulic motor is reduced on that corresponding wheel. This happens until the torque on the wheel is so low that it is no longer adequate to allow the wheel to spin. At the same time the angle of the pump swash plate is reduced to adjust the displacement required for the current speed.

4.

Function of Anti-Locking System (ABS) To prevent the wheels from Locking when the machine decelerates, ABS is integrated into the system. When the machine is decelerating, the wheel speeds are monitored by the wheel speed sensors. As soon as the sensors detect that a wheel has a lower speed, the displacement is reduced on the corresponding wheel motor and the locking tendency is reduced.

Animation TC

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15. Hydraulics:

Overview of Components for Bosch Transmission

Location of the Components on the Circuit Diagram of the Hydraulic System 2

4 1b

6

3b

6 9

10

B101

12

7

5 11

12

8 B102

1a

3a

6

6

Components 1a

Drive motor front left

3b

Drive motor rear right

7

High-pressure sensor B 101

11

Swash plate sensor

1b

Drive motor front right

4

Planetary gearbox at rear

8

High-pressure sensor B 102

12

Feed valves

2

Planetary gearbox at front

5

Variable displacement pump

9

“Forward” solenoid valve

13

Storage for feed

3a

Drive motor rear left

6

Speed sensor

10

“Reverse” solenoid valve

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15. Hydraulics:

Overview of Components for Bosch Transmission

Components of the Drive Pump on the Circuit Diagram of the Hydraulic System 5

4

6 3a

7

8

3b

1 2

Components

134

1

Charge pump

5

Direction control valve

2

Charge pressure relief valve

6

Swash plate control piston

3

Combination valve

7

High-pressure pump

4

Aperture

8

High-pressure relief valve

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15. Hydraulics: Function of Bosch A4VG Drive Pump Function of hydraulic pump A4VG

5 Animation A4VG

4

6 7

3a

8

3b

1 2

When the engine starts, the charge pressure pump (1) supplies oil to the low-pressure circuit. The charge-pressure relief If the load on the travelling gear is greater, the pressure on the high-pressure side continues rising. When a pressure of valve (2) limits the pressure to approx. 28 bar. This constant 28 bar is applied to the combination / high pressure relief approx. 490 bar is reached, the pressure cut-off (8) responds. valves (3) as well as the direction control valve (5) through the restrictor (4).

This causes the pressure of the throttle (4) to drop and therefore also on the setting valve (5); the pump swivels back until The high-pressure circuits are filled via the combination / high pressure relief valves (3). There is no pressure on the the high pressure drops again. control piston (6).

The pressure limiting valve (3a) responds only to pressure peaks, as it has been set to 510 bar. No pressure cut-off has As soon as the direction control valve (5) for forward is powered on the pump, charge pressure builds at the control piston been integrated for reverse travel; here the pressure limiting valve set to 470 bar safeguards the high-pressure part.

(6) and the piston moves the swash plate (7).

This causes the pump (7) to displace oil on the corresponding high-pressure side. Pressure builds depending on the load.

The combination valve on the high-pressure side (3a) is sealed against the charge pressure circuit. The combination valve on the return side continues to feed charge pressure as required.

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15. Hydraulics: Bosch A4VG Characteristic Data Adjusting Hydraulic Pump A4VG

20

Characteristic data of pump adjustment The pump is adjusted electrohydraulically; this means that the displacement of the pump can be controlled by current.

The graphs opposite describe the adjustment. Important points are:

15

1.

Start of adjustment (Vg/Vg_max = 0 %) Control pressure X = 6 bar Current I = 400 mA

2.

End of adjustment (Vg/Vg_max = 100 %) Control pressure X = 18 bar Current I = 1200 mA

Set Pressure [bar]

25

10 5 0 0

200

400

600 800 1000 Current I [mA]

1200

1400

1600

Current can be checked in diagnostics or with a multimeter.

To measure the pressure, test ports must be installed into the pump (M14 x 1.5 mm).

100 Volume Used Vg/Vgmax [%]

The data is the same for forward and reverse!

80 60 40 20 0 0

136

5

10 15 20 Set Pressure X [bar]

25

30

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15. Hydraulics: Control Circuit Pump Adjustment Bosch Control Circuit Pump Adjustment Feedback Position of Pump

B108

Input IN_37

Drive control

DRC Output Y102



U

Drive pump

Output Y101

Y101

Y102

Control signal pump forwards

When the driver moves the joystick forward, the DRC (BODAS control unit) sends current to the corresponding solenoid valve of the drive pump (Y101/Y102). The angle of the swash plate will be controlled by the amount of current sent. The swash plate angle of the pump is monitored by the angle sensor.

If the control signal and feedback do not agree, an emergency mode will be activated!

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15. Hydraulics: Component Overview of Bosch A4VG Pump Components of Drive Pump 10

12

9

Components

8

11

7

13

1

Drive shaft

2

Housing cover

3

Leakage oil connection

4

Charge pressure relief valve

5

High-pressure relief valve

6

Suction connection

7

High-pressure relief valve

8

Control valves

9

Measurement connection for pressure X2

10

Measurement connection for pressure X1

11

Neutral position centring

12

Swash plate angle sensor

13

Valve for pressure cut-off

14

Charge pressure connection

1

14

3

2

138

6 4

5

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15. Hydraulics: Component Overview of Drive Pump Bosch Components of Drive Pump 5

4

Components 3

2

6 1

7

10

8

139

1

Swash plate angle sensor

2

Measurement connection for pressure X2

3

Measurement connection for pressure X1

4

Forward solenoid

5

Control block

6

Reverse solenoid

7

High pressure port B

8

High pressure port A

9

High-pressure sensor MA

10

High-pressure sensor MB

9

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15. Hydraulics:

Component Overview / Design of Drive Motors Bosch

Hydraulic Motor A6VE Axial piston motors with steplessly adjustable displacement are used as wheel motors. These motors are bent axis motors which control the displacement by the position of the swivel axis with respect to the rotation axis of the motor.

Components 2

1

5

5

Components Power unit 1. Power unit Speed sensorsensor 2. Speed 3. Proportional Proportional valve valve 4. Non-return valve Non-return 5. Flush valve valve 6. Setting Flush valve piston

6

Control piston

1 2

6

3 4

Technical Data: Intake volume Front axle 115 cm³ Rear axle 62 cm³

4 3

4 3

2 140

Currents =

Vg,min Vg,max

Flush valve: Flush rate: approx. 2.6 g/m Resistance of coil

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approx. 400 mA approx. 1200 mA

© KRONE Training Team, Spelle, Germany

approx. 5.5 ohm

15. Hydraulics: Mode of Operation of Bosch Drive Motors Hydraulic Motor A6VE

Mode of operation: As soon as the engine starts, the drive pump starts rotating. After a short time charge pressure of approx. 30 bar builds in both highpressure lines (A + B) on the motor.

The valve controlling wheel motor (1) displacement is powered at maximum.

This causes the same pressure to build up on both sides of the control piston (2).

3

Pump

2 Pump

1

The difference between the areas on the control piston causes the motor to swivel into the maximum displacement.

As soon as the pump conveys oil to the motor, pressure build in a high-pressure line and the motor starts to rotate. At the same time the flush valve (3) is actuated via the differential pressure in the high-pressure lines. 2.6 g/min are flushed out of the low-pressure side to cool the system.

To continue increasing the speed of the motor, the current on the control valve is reduced. As a result, a middle position will be set on the control piston. The speed of the motor depends on the current and the volumn from the pump.

Animation A6VE

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15. Hydraulics:

Design and Components of Bosch Planetary

Planetary gearbox GFT 40

3

2

1

4

10

6 7

8

5

9

Components

142

1

Main frame of machine

6

Planetary stage 1

2

Supporting axle

7

Planetary stage 2

3

Rim

8

Brake plates

4

Wheel bearing

9

Sliding ring seal

5

Hollow wheel/output

10

Brake piston

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15. Hydraulics: Design of Wheel Gearbox 1

Main frame of machine

2

Supporting axle

3

Rim

4

Wheel bearing

5

Hollow wheel/output

6

Planetary stage 1

7

Planetary stage 2

8

Sliding ring seal

9

Drive motor

Design and Components of Bosch Planetary 1

3 2 5 4

9

8

The planetary gearbox on the front axle also contains a disc brake which is used as a service brake and as a parking brake.

On all planetary gearboxes, the hydraulic motors are inserted and flange-mounted in the fixed part of the planetary. The planetaries have separate oil lubrication.

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7

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6

15. Hydraulics: (1)

Intake / Header Drive, Overview

Axial piston variable displacement pump feed drive 105 ccm (BiG X 500 / 650 / 700 / 800 / 850 / 1100), 135 ccm (BiG X 1000)

(2)

Overview

Axial piston variable displacement pump front attachment 55 ccm (all BiG X 500 / 650 / 800 / 1000 BIG X 700 / 850 / 1100 until year of manufacture 2010) 75 ccm (BIG X 700 / 850 / 1100 from year of manufacture 2011)

(3) (4)

Gear pump - charge pressure Fixed displacement motor intake drive 75 ccm (all BiG X)

(5)

Fixed displacement motor header 55 ccm (BiG X 500 / 650 / 800 / 1000) 75 ccm (BIG X 700 / 850 / 1100)

(6)

Quick-stop valve

Design Hydraulic circuit

144

WHB_4.1 High pressure intake_EN

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15. Hydraulics:

Intake / Header Drive, Quick-Stop Valve

Quick-stop function in the feed drive When metal is detected an electrical signal from the controller energizes the 3/2-way pilot valve. The pilot valve hydraulically activates the main spool valve in the quick stop valve. The quick stop valve directs the oil flow to the return side and brakes the motor against a cushion valve to standstill.

The cushion valve is adjusted to p = 350 bar The stop time form the intake drive is less than 60ms.

Parallel to the quick stop valve the pump returns to neutral position.

Emergency manual operation (Reset the main valve by screwing in)

145

Stop valve

Pilot valve

(Main valve)

(Y 35, controlled by Gnd)

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15. Hydraulics:

Charge Pressure Feed Drive / Front Attachment, Pump Adjustment E1

Feed drive pump

1

M

Charge pump (1) When the engine is running, the charge pump provides charge pressure to the variable pump p = 24 ± 3 bar. This pressure is also used to drive the rotary screen. (Only BIG X 500 / 650 / 800 / 1000) The charge pressure relief valve (2) returns the waste oil return to the tank.

One pressure relief valve per pump!  Parallel switching of both valves in one circuit

2

LINDE_Circuit diagram E1_EN

Filter / Tank

For diagnostics charge pressure for the intake / header drive can be measured on minimess 13. p = 24±3 bar WHB_4.1 Charge pressure_intake_header_EN

146

The E1 control unit supplies pressure to the variable pump valves. A safety valve is not installed.

The current on the valve Y5/Y6 or Y7/Y8 determines the displacement of the pump.  More current means higher rotation speed of intake and header drive.

The calibration allows the machine to know how much current is required to achieve any given rpm. An angle sensor is not necessary for the regulation of the intake/header drive.

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15. Hydraulics: High-Pressure Circuit Feed Drive M9 : p = 24 – 435 bar

Variable displacement pump

Speed sensor B 26

Hydraulic motor with Flush valve

M

Quick-stop valve

M11 : p = 24 – 435 bar Diagnostic intake drive: The high pressure circuit can be measured on Minimess 9 and 11.

Look at forward and return pressures!

WHB_4.1 High pressure intake_EN

147

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15. Hydraulics: Function of Quick-Stop Valve Quick-stop valve Speed sensor B26 Valve (1) connects feed and return line, so the oil can flow back to the pump.

1 3

Valve (2) closes the return line from the motor, so the motor stops immediately. The short pressure peak is relieved at the cushion valve (3).

2 Hydraulic motor with flush valve

Y 35 becomes grounded.

When metal is detected in the intake, KMC 2 energizes Valve Y 35 (Gnd).

The pressure behind the restrictors in the high pressure circuit can escape to tank Then both main valves (1) and (2) move up to stop the motor 148

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15. Hydraulics: High-Pressure Circuit Front Attachment M10 : p = 24 – 435 bar

Variable displacement pump

Speed sensor B 27

M

Hydraulic motor with flush valve

M12 : p = 24 – 435 bar Diagnostics header drive: The high pressure circuit for the head can be measured on Minimess 10 and 12.

Look at forward and return pressures!

WHB_4.1 High pressure header_EN

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15. Hydraulics: Fan drive BIG X 700 / 850 / 1100 Function: High-pressure measurement connections

- closed circuit drive - pump is controlled in one direction -> fan only rotates in one direction

6

- if the magnetic valve is disconnected, the pump displacement is maximum -> max. roation speed (fail-safe-function) - rotation speed is dependent on the charge air temp (B403), cooling water temp. (B124), and hyd oil temp (B85).

5

1

3 4

2

(1) Fixed displacement motor with flush valve

(4) Charge pressure pump (integrated)

(2) High-pressure relief valve / feed valve

(5) Charge pressure relief valve (25 bar)

(3) Pressure cut-off

(6) High-pressure measuring points

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15. Hydraulics: Brake and Work Hydraulics (Machines with Poclain Travelling Gear) Pump: working hydraulics and steering (1) (twin pump) In 2009 the pumps changed ! Working hydraulic pump is installed directly on main gear box.

(2) high pressure filter (3) relief valve (p = 240 bar) (4) priority valve

1

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15. Hydraulics: Brake and Work Hydraulics (1)

priority valve

(2)

Hydraulic accumulators park and foot brake

(3)

Hydraulic accumulators lifting gear Corn mode only the big accumulator (135 bar active).

Grass mode both accumulators (35 bar and 135 bar are active).

WHB_4.4 Valve block working hydraulics_EN

(4)

Valve block working hydraulics (with LS function) manual override of valve possible

WHB_4.1 Service brake_EN

5

(5)

EHR

(6)

Valve block (pressure release)

(7)

2/2 way valves pendulum frame

(8)

Switch block grass/corn with lifting gear pressure sensor (9)

11 4

7

8

1

2

valve parking brake

(10)

cylinder parking brake

(11)

valve service brake and test port

(12)

wheel motors with drum brakes

6

9 3

12 10

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15. Hydraulics:

Function Accumulator Charging Valve (Machines with Poclain Travelling Gear)

Working hydraulics pump (1) pump stack changed since Y.o.M. 2009! Working hydraulics pump is now situated directly on the main gearbox.

3

Accumulator charging valve < 70 bar

4

High-pressure filter (2) The priority valve supplies both brake circuits (parking brake and foot brake) with oil first (priority).  Brake system has priority over work hydraulics.

Accumulators (3) are installed to maintain a constantly filled brake circuit. Also a pressure balance spool is installed and activated by a control line.

5 Steering

1

153

Motor power take-off gear

2

When a pressure of p = 150 bar is reached at the pressure maintaining valve (4) the balance valve (5) supplies oil to the working hydraulics (port EF). The oil is held in the brake accumulators by the non return valve.

When the pressure in the brake circuit drops under 120 bar, the pressure balance valve shifts to fill up the brake circuit again.

A pressure switch B 18 monitors the pressure on both brake circuits. When the pressure falls under 70 bar an alarm is sent by the Smart Drive.

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15. Hydraulics:

Parking and Foot Brake Circuit (Machines with Poclain Travelling Gear)

The park brake valve Y18 is powered to release the parking brake. The single acting park brake cylinder collapses the tensioning spring to release the brake.

The hand pump (1) is used for emergency release. The shut off valve (2) must be closed to manually release the brake.

Pedal switch B40

WHB_4.1 Service brake_EN

2

Apply the foot brake to measure the brake pressure.

Pressure increases depending on how far the pedal is pressed. When fully depressed, the pressure should be max p≈120 bar. It can be measured at Minimess 8.

1

154

Safety function!!

The brake pedal position sensor B40 recognizes that the brake pedal has been pressed. The brake pressure sensor B16 must measure between p = 70 - 90 bar at the point where the pedal position sensor changes state.

The change point can be adjusted by moving the sensor B40 in the slotted hole.

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15. Hydraulics: Overview of Brake System (Bosch Transmission) Overview of Brake System

6

3 4

5

Components

1 2

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1

Gear pump work hydraulics

2

High pressure filter work hydraulics

3

Accumulator charging valve

4

Pressure accumulator - service brake

5

Pressure accumulator - parking brake

6

Valve foot brake

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15. Hydraulics: Brake System Concept on Bosch Transmission

Brake System Concept (Service Brake) Machine braking / decelleration functions differently, based on how the driver stops the machine: 1. Using the Joystick - Displacement of the drive motors is increased - Pump displacement is controlled by the joystick and supplemented by the engine speed

2. Using the brake pedal - Displacement of the drive motors is increased - Pump displacement is controlled by the joystick and supplemented by the engine speed - High-pressure limiting valves are used (hydraulic energy is converted into heat) - From a specific braking requirement by the driver a multiple disc brake will also be activated (dynamic brake) Brake System Concept (Parking Brake) The parking brake is applied using the same multi-disc brake as the dynamic brake.

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15. Hydraulics: Mechanical Brake in the Wheel Gearbox (Bosch) Function of Brake System Parking brake released, service brake not applied If pressure is applied to port S (Static brake), piston (1) moves to the left against spring tension (2). This releases piston (3) so no force is exerted on brake pack (4).

S

2 1

3

4

3

4

Parking brake released, service brake applied If pressure is applied to port D (Dynamic brake), piston (3) presses against the brake pack (4). This controls the braking effect dependent on the pressure.

D

2 1

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15. Hydraulics: Brake System Bosch, Emergency Mode Manually Releasing the Parking Brake / Towing the Machine 1.

Connect Minimess line from hand pump to test port on parking brake (1)

2.

Switch shut-off valve (2)

3.

Use the hand pump to pressurize the system

4.

Switch off ignition (as a result drive motors have

2

virtually no intake volume) 5.

Maximum distance:

5 miles

6.

Maximum speed:

(6 mph)

1

The engine must be off for towing, rendering the hydraulics inoperable. Do not tow the machine faster than it can be safely controlled by the driver!

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15. Hydraulics: Bosch Brake System, Diagnostics/Venting Measurement Connections Brake System

Port D: D = Dynamic brake (service brake) Pressure: 0…80 bar (depending on position of the brake pedal)

D

Port S: S = Static brake (parking brake) Pressure: 0 bar (parking brake applied) 30 bar (parking brake released)

S

The brake can also be bled via the respective test port!

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15. Hydraulics: Bosch Brake System, Foot Brake Valve Brake valve The brake valve is installed directly under the brake pedal (under the cab). The position of the brake pedal is measured by an angle sensor (B109).

Brake pressure is measured by pressure sensor (B16).

B109

B16

B

FB

N

R B N FB 1 2

= = = = = =

Pressure of the accumulator charging valve Dynamic brake wheel gearbox Tank line Service brake pressure sensor Adjustment screw - initiate braking Adjustment screw - max. brake pressure

R

B16

FB

2

FB

B109

1 B109

160

N

B

R

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N B © KRONE Training Team, Spelle, Germany

R

15. Hydraulics:

Bosch Brake System, Accumulator Charging Valve

Accumulator charging valve The accumulator charging valve is a priority valve which ensures that the pressure accumulators for the parking brake and service brake circuit have been permanently filled. The brake circuits have priority over the work hydraulics.

P = F = B = R = N = R4 = X1 = B110 = X = Y18 = B18

P

B

X1

N

R4

R

Hose from pump Brake pressure sensor (accumulator) Outlet to working hydraulics Out to service brake accumulators / valve Out to tank line Out to Parking brake accumulator Connection manometric switch parking brake Parking brake switch (B110) Out to parking brake in the drive motor Solenoid valve parking brake R

F

X

B P

Y18

B110

N B110

X1

X1

F X Y18

X P R4

R4

B 161

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N

© KRONE Training Team, Spelle, Germany

Y18

Valve block Work hydraulics

Brake system

Bosch Brake System, Function in the Circuit Diagram Pump Work hydraulics

15. Hydraulics:

Function of accumulator charging valve When the engine is running, the pump for the work hydraulics (1) supplies oil to the system.

The accumulators for the parking brake and the foot brake valve are filled via the accumulator charging valve (2).

As soon as both accumulators have been filled to approx. 150 bar, the accumulator charging valve (2) switches over and the work hydraulics are supplied.

The parking brake valve (3) is limited to approx. 30 bar via a pressure-reducing valve (4).

Valve block work hydr.

3

4

1 2

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Valve block Work hydraulics

Brake system

Bosch Brake System, Function in the Circuit Diagram

1

Pump Work hydraulics

15. Hydraulics:

1

Valve block work hydr.

2

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As long as there is no pressure on the parking brake (1), the parking brake is applied. Braking is controlled by spring force.

If the parking brake valve (2) is powered, 30 bar is applied to the parking brake (1) At 30 bar, the brake is released.

Service Brake Function

3

163

Parking Brake Function

An angle sensor is used to monitor the position of the service (foot) brake valve (3). If the driver presses the brake pedal, hydraulic braking is initially actuated via drive motors and drive pump. The more the pedal is depressed, the more the machine is hydraulically braked.

If the pedal is pressed even further, pressure begins to gradually accumulate also in the mechanical brake.

Maximum deceleration is obtained by the combination of mechanical and hydraulic braking.

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15. Hydraulics: Bosch Sensors, Speed Sensor Drive Motor Speed sensor In the case of Big X 700-I, 850-I and 1100-I a speed sensor is installed on the variable motor for each wheel drive.

This speed sensor is used monitor the travel speed, antilock and anti-slip system.

B103 / B104 / B105 / B106 – speed sensor 20 081 687 0

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Pin 1:

+10 volts

Pin 2:

GND

Pin 3:

Frequency signal

Pin 4:

Direction of rotation signal

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15. Hydraulics: Bosch Sensors, Steering Axle Angle Sensor Steering axle angle sensor A steering angle sensor is installed on the left side of the rear axle.

This sensor provides the steering angle to the DRC to control the anti-lock and traction control systems.

After replacing the sensor or working on the steering, recalibrate the steering angle sensor.

Angle sensor Bosch 20 081 488 0 (Bosch R 917 P07 620)

Signal voltage min 0.25 x Uvers (Sensor voltage) Signal voltage max 0.75 x Uvers (Sensor Voltage)

3 2 1

Pin 1:

0 V (earth)

Pin 2:

2.5 V – 7.5 V (steering angle)

Pin 3:

+10 V Uvers=1 0V 0°

2.5V→7.5V

72° (82°)

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15. Hydraulics: Bosch Sensors, Foot Brake Valve Angle Sensor Angle sensor brake pedal An angle sensor is attached to the brake valve to monitor the position of the brake pedal. Current is output to the DRC based on the position of the brake pedal.

The angle sensor works together with the signal of the brake pressure sensor (B16) After working on the brake system, the brake valve must be recalibrated!

2

1

5

B109 – angle-position encoder 20 081 500 0

6 Measuring range:

120°

Supply voltage:

12 volts

Signal:

4 - 20 mA

Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6:

166

GND 12 volts 4 - 20 mA Free Free Free

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3

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4

15. Hydraulics: Bosch Sensors, Brake Pressure Sensor Hydac Pressure Sensor 130 bar – Brake Pressure sensor The sensor uses a 12V power supply. As the pressure (P) at the sensor varies from 0 to 250 bar, the signal voltage changes from 1 V to 5 V. The pressure in the service brake pressure line is determined by the pressure sensor B16. The data is transmitted to the DRC where it is evaluated together with the signal from the brake pedal angle sensor (B109).

P

B16 – pressure sensor 00 302 029 2 Measuring range:

0–130 bar

Supply voltage:

12 volts

Signal voltage:

1–5 volts

1

2

P

U 3

1

2

Pin 1: 12V Pin 2: 0V Pin 3: Signal voltage 1–5V

3

167

Pin 4: not assigned

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15. Hydraulics: Bosch Sensors, Pump Swash Plate Angle Sensor Swash plate angle sensor The swash plate angle sensor monitors the angle of the swash plate. It provides feedback to the DRC to indicate the position of the swash plate and if the swash plate has moved according to demands from the DRC. When the pump is in the neutral position, the potentiometer must be set to 2.5 +/- 0.02 volts.

Forward travel:

Value range approx. 2.5–4.0 volts

Reverse travel:

Value range approx. 2.5–1.0 volts

Pin A:

0 V (earth)

Pin B:

12 V (supply voltage)

Pin C:

approx. 1–4 V

B Setting the swivel angle sensor 1. Start engine and ensure that the pressure in both high-pressure lines is approx. 30 bar (charge pressure) 2. Stop engine 3. Set angle sensor to 2.5 +/- 0.02 volts by turning it (value indicated via Diagnostics terminal).

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C

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A

15. Hydraulics: Bosch Sensors, High-Pressure Sensor Bosch high-pressure sensor 600 bar Two high-pressure sensors are installed. They record the pressure in both high-pressure sides of the closed circuit. They are installed in the drive pump, directly next to the SAE flanges.

B101 / B 102 – pressure sensor 27 007 711 0 Measuring range: Supply voltage: Signal voltage:

169

0–600 bar 10 volts 0.5–4.5 volts

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15. Hydraulics: Bosch Sensors,

Seat Contact Switch

Seat Switch for Self-Propelled Machine – S 69 The seat switch is used as safety equipment with the Bosch transmission. If the seat switch has a fault or is not actuated, the machine cannot be driven.

Observe parameter!

Big X:

33659

Diagnosable switch: 16-pin plug at rear left in the driver's seat

> 333 digits: Seat switch

Manipulations may result in serious or even fatal injuries! Any manipulation is therefore absolutely forbidden!

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< 261 digits: Seat switch < 142 digits: Broken cable > 452 digits: Short circuit

© KRONE Training Team, Spelle, Germany

15. Hydraulics: Drive Control DRC Bosch Transmission Drive Control / Control Unit RC 28-14/30 The DRC (Drive Control) is installed in the console of machines with Bosch transmission.

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15. Hydraulics: Calibrations Bosch Transmission Calibration of the Bosch Travelling Gear Installation and production tolerances as well as component fluctuations cause the values to differ slightly in specific positions. Valves will often have a slightly different behaviour. It is necessary to save these componentspecific properties in the control unit and after each relevant change in the system. The following components must be calibrated for the Bosch transmission:

1

• Brake pedal angle sensor B109 (1) - Signal current with brake pedal not depressed (0 bar) - Signal current with brake pedal fully depressed (80 bar) • Steering angle sensor B107 (2) - Setting the sensor for straight-ahead driving (5.0 +/-0.1 V) - Saving the difference from the setpoint value (offset) - Signal voltage with steering fully left; fully right - Swash plate angle sensor B108 (3) - Setting the sensor when pump is in neutral position (2.50 +/-0.02 V) - Saving the difference from the setpoint value (offset) - Proportional valves pump Y101 + Y102 (4) + (5) - Minimum current (respond threshold) - Maximum current (end of the control range) - Proportional valves drive motors Y103, Y104, Y105, Y106 (e.g. (6)) - Maximum current (respond threshold) - Minimum current (end of the control range) The complete description of the calibration is in the BODAS Manual!

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2

3 4

5

6

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15. Hydraulics: Work Hydraulics Valve Block Individual pressure balances BIG X 500 / 650 / 800 / 1000

Pressure limiting valve: 200 bar

BIG X 700 / 850 / 1100 (until year of manufacture 2010) Observe parameter 33659!

Electronic lifting gear control valve Y32 / Y33

Valve front attachment 2 (red)

Intermediate plate / pressure limiting valve

Y26 / Y27

Raise / lower discharge chute

Automatic steering

Y24 / Y25

Y39 / Y40

Discharge chute flap Grinding Device

Y22 / Y23

Y30 / Y31

Rotate discharge chute Pendulum frame

Y20 / Y21

Y37 / Y 38

Connection plate

Valve front attachment 1 (blue) Y28 / Y29

LS pressure limiting valve: 220 bar 173

T

LS

P WHB_4.4 Valve block working hydraulics_EN

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15. Hydraulics: Work Hydraulics Valve Block BIG X 700 / 850 / 1100 (from year of manufacture 2011)

Individual pressure balances

Pressure limiting valve: 235 bar

(6) Valve, front attachment 1 (blue)

(11) Electronic lifting gear control valve

Y28 / Y29

Y32 / Y33 (10) Intermediate plate / pressure limiting valve

(5) Valve, front attachment 2 (red) Y26 / Y27

(9) Automatic steering (4) Raise / lower discharge chute

Y39 / Y40

Y24 / Y25

(8) Grinding device (3) Discharge chute flap

Y30 / Y31

Y22 / Y23

(7) Pendulum frame Y37 / Y 38

(2) Rotate discharge chute Y20 / Y21

(1) Connection plate Observe parameter 33659!

T 174

LS P

LS pressure limiting valve: 210 bar

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WHB_4.4 Valve block working hydraulics_EN

© KRONE Training Team, Spelle, Germany

15. Hydraulics: Work Hydraulics Valve Block Function of Valve Block with Individual Pressure Balances for Parallel Actuation As long as no directional control valve is actuated, the pressure in the total LS line (Y) is the same as in the return line (T).

m 2 >> m 1

The different loads are applied up to the respective directional control valve.

When a directional control valve is actuated, the respective load pressure is set in the LS line of the respective valve up to the directional control valve.

The directional control valves (1) ensure that the maximum load pressure is always applied to the input pressure balance (2).

The individual load of the respective consumer is always applied to installed individual pressure balances (3).

The maximum load pressure plus the control differential pressure is set in the pump line (P).

The individual pressure balances (3) used ensure that only the load pressure plus the control differential pressure required at this valve is applied in the supply line to the respective directional control valve.

As a result, exactly the required control differential pressure is exerted on each directional control valve. The flow control function of each valve is therefore guaranteed.

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15. Hydraulics: Work Hydraulics Valve Block Connection plate 3

4

1

2

(1) Spring LS pressure (3 bar) (2) Control line (LS) (3) Pressure limiting valve LS pressure

Bosch_Repair manual

(4) Pressure balance 176

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15. Hydraulics: Work Hydraulics Valve Block 5/3-way valve plate

(1) Magnetic coil (3.5–3.75 Ω) (2) Return spring (3) Valve slide

1

2 3

1

(1) Magnetic coil (2) Return spring (3) Valve slide The valve spools are precision machined to match the valve body.

The valve spool is not replaceable.

Emergency manual operation: Every valve can be operated manually.

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15. Hydraulics: Work Hydraulics Valve Block 5/3-direction control valve with hydraulic unlockable non-return valve

The non-return valves can be replaced individually. They are available as a spare part.

Locking block (1):

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15. Hydraulics: Work Hydraulics Valve Block Divider plate with PRV (Pressure Relief Valve

An additional PRV is mounted directly at the gear pump.

If there is a problem where the maximum pressure is not reached, the PRVs or the gear pump could be the reason.

The LS-PRV in the divider plate should also be tested!

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15. Hydraulics: Work Hydraulics - Lifting Gear Maize / maintenance

(1) EMR valve Y 32 – lifting valve Y 33 – lowering valve (2) accumulator control valve unit (3) 3-direction valve grass / corn (4) shutt off safety valve (5) pressure sensor

Grass

4 3

4

1

5

2

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15. Hydraulics: Work Hydraulics - Lifting Gear

1

2

5

Lifting gear cylinder

4 3

6

4

(1) Pressure level

2

(2) Lifting spool

3

(3) Lowering valve insert (4) Check valve (5) Lifting set unit

1

(6) Lowering set unit

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15. Hydraulics: Work Hydraulics - Lifting Gear EMR – Electronic Mowing table Control Grass / Maize

Pressure sensor B49 (1): The pressure sensor (1) constantly measures the pressure in the line.

The signal goes to the EHR. Correct calibration is important for error free lifting gear regulation. from the EMR

2 1

Y34

Y53

3

182

Function valve Y34 (2): The valve is energized so it is always open and is independent of the grass/corn valve. If the machine is on rough ground the lifting gear is cushioned by the accumulators. The function of the valve is necessary only with operation of the lifting gear, in order to achieve a direct function in the hydraulic system the valve closes 3 secs and opens automatically.

Function valve Y53 (3): The function of the valve Y53 is to shut off the small accumulator in corn mode because the corn head is too heavy for the small accumulator. In grass mode Y53 is energized so the grass head (lighter) is cushioned by the small accumulator.

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15. Hydraulics: Work Hydraulics – Throttle Non-Return Valves Restrictor for adjusting the speed chute flap lift chute flap lower

chute lift chute lower

sharpening cylinder retract sharpening cylinder extend

2/2 –way lock valves for locking the pendulum frame

2 / 2-way seat valve

Y38

Y37

Actuation of locking valves occurs at the same time as main valve in the valve block!

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15. Hydraulics: Work Hydraulics – Option 14-Row Extension The extension is folded via the "Raise DC" (Y24) and "Lower DC" (Y25) valves.

The folding system is connected parallel to the lifting cylinder of the DC. As soon as the extension is folded, lock valve Y76 is actuated in addition to Y24 or Y25.

The lowering brake valve ensures an even folding process.

The speed of the folding process can be set for each direction on the throttle nonreturn valves.

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15. Hydraulics: Work Hydraulics Diagnostics Check the maximum pressure in the work hydraulics: The lifting gear/intake must be fully lowered to the ground. Close both shut-off valves on the lifting cylinders.

Field switches must be switched on and the engine should be at low idle speed. Operate the manual header lift switch on the Joystick. The pressure can be measured at the following connections at p = 200 bar.

for machines until year of manufacture 2007:

WHB_4.1 Pressure working hydraulics_EN

Test port at the PRV after the working hydraulic pump, if available (up to year 2009)

alternatively for all machines: Test port in the lift line (after EHR), if fitted (since 2008, series since 2009)

Pressure measurement on the couplers for the pendulum frame cylinder or for the front attachment

Test port at the valve block input (before EHR), if fitted (since 2008, series since 2009) 185

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15. Hydraulics: Steering, Overview (1) Pump steering hydraulics pump has changed after Y.o.M. 2009. The pump for steering hydraulics is now installed as the outside pump!

(2) High-pressure filter (3) Steering orbitol

3

(4) Steering cylinder (5) Valve autopilot

7

(6) 2/2-way seat valves autopilot (7) Test point

1 5 2 6

4

WHB_4.1 Steering_EN

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15. Hydraulics: Steering from automatic steering valve

Y67

If steering is not actuated, the oil is returned to the tank

Y66

2 3

As the steering wheel is rotated, a pressure develops in the lines to the steering axle. The maximum pressure can be measured at minimess 9. Rotate the steering wheel completely right or left and hold. When the wheels contact the stop, a max pressure of 200 bar should be measured at low idle. The pressure relief valve (2) is in the orbitrol. The shock valves (3) are for the safety of the orbitrol and open with a pressure of p = 250 bar.

WHB_4.1 Steering_EN

Measurepoint Minimess 9

1

Motor power take-off gear

Autopilot: The steering of the machine is taken over by the auto pilot valve. The lock valves Y67/Y68 open at the same time, as soon as one of the main valves Y39/Y40 are operated.

Pump steering hydraulics (1)

Autopilot Disconnection: If the autopilot is activated and the steering wheel is turned, the pressure sensor B63 senses a rise in pressure and the autopilot is deactivated by the controller.

pump arrangement changed from year of manufacture 2009.

Steering pump is now the outside pump!

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15. Hydraulics: Rear Axle Suspension

The rear axle suspension is self contained. The hydraulic pre-loading of the suspension can be adapted with the help of the hand pump according to the weight and the rear ballast.  between rear axle (1) and main frame (2) a distance of A = 30 - 40 mm (1-1.5 in) should be present. The pressure in the system must be set accordingly.

Pressure gauge Hydraulic cylinder Accumulator

2 a

Hydraulic accumulator 1.4 l / 60 bar Connect Minimess line from port to the hand pump

1

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15. Hydraulics: Additional Axle, Overview (Optional)

(1) Accumulator charging valve additional axle (2) Valve block additional axle (3) Pressure limiting valve

3

Additional axle

2

(4) Axle with lifting cylinders

1 NOT STANDARD IN USA!!!

4

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15. Hydraulics: Additional Axle (Optional) Description of function additional axle: Additional axle function is active in corn mode only!

Lowering of the additional axle (valve Y81) Raising of the additional axle (valve Y80) The lowering of the additional axle is switched cyclically, i.e. the interval duration and duty cycle can be specified by parameters.

The axle is lowered only in road mode from a speed >10 km/h. In field mode and when backing up, the additional axle is automatically raised.

At the same time the pressure sensor B80 monitors the pressure in the system. If the pressure is below the minimum pressure to set via parameters, valve Y81 opens until the maximum pressure is reached. This must also be specified via parameters.

Pressure limiting valve (1) set to 90 bar.

The additional accumulator charging valve (2) with integrated pressure balances ensures that the required oil volume is always available for the additional axle.

1

Standard settings parameters comp. current list in the Downloadcenter.

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15. Hydraulics: Drive Molasses Pump (Optional) NOT STANDARD IN USA!!

1

2

3 Hydraulic Connection for Molasses Pump - Additional gear-type pump (1) on the main gearbox - Valve block (2) for single-acting function at the back of the machine - Couplings (3) for pressure line and zero-pressure return line 191

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15. Hydraulics:

1 x Double-Acting Control Unit (Optional)

NOT STANDARD IN USA!!

1

2

Double-Acting Control Unit - Additional gear pump (1) driven by the main gearbox - Bosch 4/3-way valve SB 12 (2) - Bosch series SB 12 connection plate 192

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15. Hydraulics:

2 x Double-Acting Control Unit (Optional)

NOT STANDARD IN USA!!

4

1

2

Two double-acting control units 3

- Additional gear pump (1) driven from the main gearbox - Valve block (2) from Hydac with two 4/3-way valves - High-pressure filter (3) - Additional hydraulic oil tank (4) 193

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15. Hydraulics:

Additional Option Compressed-Air Braking System

Brake connections wheel motors

2

3 Valve parking brake

9 4

1

8 5

7 Accumulator charging valve

Return line

6

Hydraulics

Pneumatics

(1) Foot brake valve

(6) Pressure control valve 7.3 bar

(2) Brake pressure sensor B16 (0–130 bar)

(7) Compressed-air compressor

(3) Actuating cylinder parking brake

(8) Air filter

(4) 3/2-way valve compressed-air brake

(9) Connections compressed-air brake trailer

(5) Compressed-air storage tank 194

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15. Hydraulics:

Additional Option Compressed-Air Braking System Compressed-air supply from the storage tank

Signal from parking brake valve Actuating cylinder parking brake

To the trailer connection coupling (supply line) 3/2-way valve Signal from brake valve

(Trailer brake valve)

To the trailer connection coupling (brake line)

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15. Hydraulics: Cooling Circuit / Leakage Oil - Overall View BIG X 500 / 650 / 800 / 1000

Manifold (1) Manifold (2) Oil cooler (3) Tank with suctionreturn filter (4)

Manifold : Four leakage oil lines, which come from the driving pumps, are mounted at manifold.

The total housing pressure can be measured at minimess 20. With warm oil it should be approx. 2.5 bar and should not exceed 4 bar (36-58 psi) when the oil is cold.

4 WHB_5.1 Case pressure_EN

3

Housing pressure Front Axle Pump

2

1

Manifold

2

Housing pressure Rear Axle Pump

Housing pressure Header Pump

1 Minimess 20 196

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Housing pressure Intake Pump © KRONE Training Team, Spelle, Germany

15. Hydraulics: Filter BIG X 650 / 800 / 1000 Return line valve block 2-fold (changeover / main clutch) Return line combination valve (pilot valves) Leakage oil front wheel motors Return line brake hydraulics

Bypass cooler

Leak oil rear wheel motors

Housing pressure transmission and intake / head

Return line work hydraulics

Suction lines intake / head

Suction lines transmission

Suction lines Work hydraulics

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15. Hydraulics: Cooling Circuit / Leakage Oil - Overall View BIG X 700 / 850 / 1100

(1) Tank

2

3

(2) Suction return filter (3) Tank return filter (4) Cooler

3 2 1

4

• the leak oil from the wheel motors (red hoses) goes to a separate tankreturn-filter • there is no collector for leak oil • flushing oil from transmission, intake and header drive by-passes the cooler.

Parallel to the cooler there is a bypass to protect the cooler from extremely high pressure.

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15. Hydraulics: Filter BIG X 700 / 850 / 1100 Leakage oil shift valve, quick-stop valve, motors intake drive and header, fan drive;

Return line steering valve, work hydraulics, additional axle

5 7

Charge pressure circuit transmission

4

Leakage oil wheel motors at front Leakage oil rear wheel motors

6

Leakage oil pumps, transmission, intake and header

1 2

3

inlet line charge pressure pumps transmission, intake, header and cooler fan drive

(1) Suction return filter

(4) Rotary screen drive

(2) Tank return filter

(5) Cooler

(3) Pressure sensor

(6) Pressure switch

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(7) Temperature sensor (installed directly on the suction return filter)

© KRONE Training Team, Spelle, Germany

15. Hydraulics: Suction return filter Suction-return filter: The suction return filter integrates the return filter for the open hydraulic system and the suction filter for the closed hydraulic system in a common filter.

This filter can be used whenever the quantity of the filter return oil is larger than that of the suction side.

The surplus volume causes the pressure retaining valve to generate a pre-tension on the suction lines of the feed pumps which improves the cold start behaviour of the charge pumps and reduces the risk of cavitation.

Re-suction valve Pressure retaining valve

Pressure limiting valve

Return suction filter E 198-458 (BiG X 650 / 800 / 1000) Pressure limiting valve: 2.5 +0.3/-0.1 bar Pressure retaining valve: 0.5 +0.1/-0.1 bar Filter element 2.5 bar differential pressure Flow from inside to outside

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15. Hydraulics: High-pressure filter BIG X 500 / 650 / 800 / 1000 BIG X 500, 650, 800, 1000 Work and steering hydraulics High-pressure filters are installed in the pressure lines after the work and steering pumps.

They are located near the left rear wheel.

Charge pressure line High pressure filters are installed in the lines between the charge pressure pumps and the main pumps. In the charge pressure lines of the transmission and intake/header pumps

Leakage oil line of front wheel motors High-pressure filters are installed in the leakage oil line of the front wheel motors These are near the radiator.

The high-pressure filters are maintenance-free, but can be opened for diagnostics! Observe installation direction!

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15. Hydraulics: High-pressure filter BIG X 700 / 850 / 1100 high pressure mirco filter for steering and work circuits - with contamination indicator - change the filters when changing the hydraullic oil or if the indicator singals contamination.

- bypass-function with contaminated filter

High-pressure filters are not required in the charge pressure circuits for the BIG X700, 850 and 1100!

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15. Hydraulics: Error Messages and Accessories Pressure switch suction return filter When the return line pressure rises above 2 bar a warning symbol is displayed in the terminal.

Pressure sensor tank return filter wheel motors - When the pressure in the leak oil return line is above 1.5 bar for longer than 6 seconds, an error-message “leak oil filter dirty“ is displayed - When the pressure in the leak oil return line is above 2 bar for longer than 5 seconds, an error-message “check wheel motors“ is displayed Level switch When the oil level in the tank is too low a warning symbol is displayed in the terminal.

Breather filter When using the breather filters with the double check valves the interchange of outside air is minimized so this reduces dirt and humidity in the tank. A small pressure of 0.2 bar is created in the tank, this also improves the suction of the pumps.

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15. Hydraulics: Maintenance Oil maintenance : 500h Tank capacity: BIG X 500 BIG X 650 BIG X 800/ 1000 BIG X 700 / 850 / 1100

90 L (23.8 gal) 90 L (23.8 gal) 120 L (31.7 gal) 120 L (31.7 gal)

When changing the hydraulic oil, always change the hydraulic filter cartridges.

Hydraulic oil change: With the 500 h hydraulic oil service the hydraulic oil should be discharged from the tank over the quick coupler with a hose into a suitable container. Change the filters at this time!

To drain the oil completely out of the system, remove the leak oil pipe off of the intake and header motors.

Bleed the system completely before start-up. (Wheel motors and pumps)!

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15. Hydraulics: Maintenance Bosch Wheel Gearbox Maintenance Planetary Gearbox Front Planetaries Oil level check • Oil level must reach inspection screw (1) in the position shown.

Oil change • Remove filler plug (2) to release pressure from the planetary • Remove drain plug (3).

• Allow oil to drain.

• Reinstall drain plug (3).

• Fill with oil. Oil level must reach inspection bore (1).

• Reinstall the filler plug (2).

Rear Planetaries Oil level check • Oil level must be 40 mm (1 9/16“) below opening (1) in the position shown Oil change • Remove filler plug (1) to release pressure from the planetary • Rotate wheel to move drain plug (2) into lowest position and remove.

• Allow oil to drain.

• Reinstall drain plug (2).

• Rotate the wheel upward 30 ° (to position shown).

• Fill with oil. Oil level must reach approx. 40 mm below the wheel centre.

• Screw the oil filler plug (1) back in again.

Perform all work while the Planetaries are warm!

Only "swd SYNKROL 5 FM (SAE 85W90)" may be used as Planetary oil!

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15. Hydraulics: Start-up  Fill hydraulic tank with Krone recommended hydraulic oil!! (Keep it Clean!!)  Start bleeding the system at the wheel motors and check oil level in the tank.  Bleed the variable displacement pump on the top of housing.  Check charge pressure at all charge pressure points with a 60 bar gauge during start-up.  Start engine and run at idle speed without load.  Check charge pressure. Within 30 seconds the charge pressure of all pumps must have reached 24 ±3 bar.

 Check the level in the hydraulic tank to ensure it is full.  Slowly engage the intake/header and check that charge pressure remains stable. With stable charge pressure drive the machine and check all pressures are in order.

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15. Hydraulics: Start-up Bleeding the Wheel Motors Front wheel motors, allen bolt on side.

BiG X 650/700/800/850/1000/1100 Rear wheel motors, allen bolt on the top

Front wheel motors, allen bolt on the top

BiG X 500

Rear wheel motors, allen bolt on side

the 207

The static pressure is adequate to force the air out of system. It is not necessary to start the motor.

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15. Hydraulics: Start-up

Bleeding the pump To bleed of the pumps loosen the hydraulic hoses on the top of the pumps to let the air out of the system.

BiG X 800/1000

The static pressure is enough to let the air out of the system. The engine doesn't have to be started.

BiG X 500 / 650 / 700 / 850 / 1100

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15. Hydraulics: Gearbox cooling BIG X 800 / 1000 2

3

from the radiator WHB_4.6 Getriebeölkühlung_DE

to the radiator

1

4

(1) Gear pump (2) Pressure switch (3) Nozzle

Always change filter when changing the gearbox oil (1000 h / annually)

(4) Filter

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15. Hydraulics: Gearbox oil cooling BIG 700 / 850 / 1100 4 WHB_4.6 Getriebeölkühlung_DE

3

from the radiator

1 2 to the radiator

(1) Gear pump

5

(2) Integrated pressure relief valve (3) Pressure switch

Always change filter when changing the gearbox oil (1000 h / annually)

(4) Nozzle (5) Filter 210

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Contents The table of contents shows which function / component is on the diagram and where it can be found. At the top is a list of the machines. Also in addition a list of the components by either function or component name and a wiring diagram legend (description).

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16. Electrical System/Electronics:

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Layout of Wiring Diagram

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Layout of Wiring Diagram The wiring diagram is presented on several pages. Each page is named and numbered according to its functions. To be able to better locate components, etc. on the circuit diagram, the page is divided into 8 sections or columns (current paths). These are marked in the upper and lower margins.

1. Designation of wiring diagram 2. Name of the sheet according to function 3. Current page number 4. Total number of pages of the wiring diagram.

5. Current path 1

2

3 4 5

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16. Electrical System/Electronics:

Layout of Wiring Diagram

1

colored field For a better understanding of the wiring diagram, the electronic components are marked with colored fields. For example: 1. green – relay board cabin (A4) 2. yellow – cabin 3. grey – roof console 4. blue – steering column (A18)

3

2

1

4

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Change The areas marked with a letter indicate that something there has been changed.

Changes with the same letters were plotted at the same time.

The marked changes are briefly described and dated in this field. The more detailed descriptions are in the appendix.

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Continuation arrow (1) This arrow indicates that the electric potential (or wire) continues on to another page. The number placed adjacent to the tip of the arrow identifies the page number (before the dot) and the circuit path (behind the dot) where the circuit continues to. Example: Page 109, circuit path 1 Potential designation (name) (2) This provides the continuation arrow with a name that can also be found on the referenced page. In some cases there are standardised short designations which are also used here as follows: 15. Ignition stage 2 (+12V switched) 30: Permanent positive (+12V) 31: Ground 49: Input flash encoder 49a: Output flash encoder 50: Starting 54: Brake light 56a: Full beam, full beam control 56b: Dipped beam 58: Background lighting 58R: Clearance lamp right 58L: Clearance lamp left 61: Charge indicator C2: Flash encoder for 2nd pilot lamp R: Flashing lamp Right L: Flashing lamp Left 75: Ignition stage 1 (+12V switched, turned off during starting) Additional KRONE designations: E: Electronics L: Power Wire designation and wire colour (3) Each wire is labelled with its designation. The designation (3) can also be found on the circuit diagram. Example: Yellow lead with black label PLD 1 15

1

2

3

Wire colors BX 500 / 650 / 800 / 1000: Power supply CAN high Signal line / switch circuit CAN low Earth (white) 216

Wire designation BX 700 / 850 / 1100: RT = red  Power supply

BL = blue  CAN high

GE = yellow  Signal line / switched

GN = green  CAN low

WS = white  Ground

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16. Electrical System/Electronics:

Layout of Wiring Diagram

11. Plug Number

Diagram Layout

X... Plug (connector) 1X... Smart Drive (A 1) 2X... KMC 2 (A 2)

Plug

3X... KMC 3 (A 3) 4X... cab circuit board (A4) 5X... Autopilot (A 5) 6X... DIOM (A 6) 9X... EMR (A 9)

a – Male contact b - Female contact

11X... Manual operation (A 11) 14X... Terminal (A14) 15X... Joystick (A 15) 16X... CU (A 16) 17X... Potential distributor circuit board (A 17) 19X... EasyControl (A 19)

B49 - Component

One plug is identified with X. The number before the x describes the affiliation with the module, the number after – the affiliation with a component or the number of the plug. The small letter "a" indicates male contacts and "b" indicates female contacts. The number by itself is the contact number. A letter may also stand for certain plugs.

In addition to the actual plug designation, there may be another designation in brackets. This is the plug designation for components which could be transferred from the "old" generation of machines, as they are identical in design but are labelled according to the "old" system.

20X... Console (A 20) 22X... Console relay circuit board (A 22) 217

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Input – Output Job Computer 1 1. Function of input and output.

2. Computer designation and location (e.g. page 81 path 5) 3. Designation from the input (I) or output (O) Abbreviations for the designation DIG - digital ANA - analogue G - earth/ground GND - earth/ground FRQ - frequency HFRQ - high frequency PWM - pulse width modulation LA - load output HB - half bridge (on output (+), (-) or no signal is switched) STR - strand MULTI - multi-function (analogue and digital signals are possible) STROM - current measurement SS - switching voltage

2 3 4 5

5 4

CAN H CAN L

3 2

- CAN High - CAN Low

4. Connector (e.g. plug X3 pin 12) 5. Module description

1

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16. Electrical System/Electronics:

Layout of Wiring Diagram

Job Computer - Complete Overview The complete overview describes all input and all outputs according to function. The representations (X1) and (X2) indicate the pin assignment of the plugs on the job computer.

2

1 Supply voltages, Power Supply of Electronics: The marked area (1) indicates the 4 supply voltages for the computer or the power supply for the electronics. It shows which supply voltage is used for which outputs of the computer (e.g.: Supply PWM_LA 5-8 = load outputs 5-8). For diagnostic purposes the respective LED is also shown and can be used to determine if the voltage is present at the computer (LD 37, 39, 40, 41).

3

Inputs: This area (2) shows all inputs to the computer. Inputs are usually sensors.

Outputs: The area (3) shows all outputs from the computer. Outputs are electromagnetic valves or electric motors.

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16. Electrical System / Electronics: Design Sensors Actuators

KMC 4

A35

120Ω

A40

~150Ω

Buttons LED

Sensors

A10

Actuators

A11

Optional

A1

Sensors

120Ω

120Ω

CAN 2

Smart Drive/ DRC

Actuators

A2

KMC 2

120Ω

Actuators

switched!

A6

Actuators

Sensors

KMC 3 DIOM EMR

A5

Sensors Actuators

A3 120Ω

Autopilot

CAN 1

CAN 3

A9

Joystick

A15

120Ω Control unit (BEK)

CAN MB, MFR (MAN), ADM 2 (MB)

Switch Actuators 220

A16

A14

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A7

CAN MAN

A8

© KRONE Training Team, Spelle, Germany

Sensors

Actuators

16. Electrical System / Electronics:

Component Overview of Console

Console BIG X 500 / 650 / 800 / 1000

Console BiG X 700 / 850 / 1100

A16 A14

A16

A14 A33 A31

A22 A22 A6 A5 A8

A7

A2 A17 A3

A1 A3 A2

A5 A6 A12 A7

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A1 © KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics: Component Overview of Console Console BiG X 700_1 / 850_1 / 1100_1 A14

A16

A17

A5

A22 A3

A2

A2 A3

222

A6

A7

A1

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A19

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics:

Fundamentals of CAN Bus

12 V GND

A1

A2

A3

A4 CAN high

R1

R2 CAN low

The CAN bus is a network where different controllers (here: A1-A4) can exchange data.

All controllers are connected to two lines which transmit the data in digital form.

A voltage signal, which contains the data, is transmitted in the opposite direction on both wires.

To prevent the messages from being "reflected" at the ends of the bus wires, two terminating resistors are used in each CAN bus system.

Each controller can only be an active user on the CAN bus when the power supply is available.

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16. Electrical System / Electronics: CAN BUS CAN BUS – Distributor Circuit Board

CAN 3 (A 33)

(only for BiG X 500 / 650 / 800 / 1000) Controller Area Network Responsibilities: Distributes the CAN BUS (CAN 1 and CAN 3) to the individual computers in the machine/console. CAN 2 is an exception, it goes directly to the rear panel of the cab! (to the hand controller, metal detector etc).

Models with the new console (BiG X 700/850/1100) do not have a CAN BUS distributor circuit board. The wiring is basically the same, although the wire connections are in the cable harness.

The terminating resistors are designed as external resistors and are situated in the cable harness in the console.

A33

A31

CAN 1 (A 31) CAN BUS Overview

A31

Blue wire: CAN HIGH

A33

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Green wire: CAN LOW

Blue:

CAN 1

Green:

CAN 2

Red:

CAN 3

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics:

CAN 1 (BX 500/650/800/1000)

CAN 1 – Design and Diagnostics CAN 1 120Ω

120Ω

A2 KMC 2 A1 SD

A31

A6

120Ω

DIOM

A5

R

AP CAN high CAN low

A15

Control unit console

KMC 3

A14

A16

A3

120Ω

Measure resistance between CAN high and CAN low. Measurement points on A 31 are arbitrary.

Diagnostics The total resistance in CAN 1 can be measured on the CAN BUS distribution board.

Always measure without voltage!

Terminating Resistors The two CAN BUS wires (CAN high / CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for CAN 1 are integrated in the job computers KMC 2 and KMC 3.

120 Ω ║120 Ω  60 Ω total resistance STLP_CAN 1_DE

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16. Electrical System / Electronics:

CAN 3 (BX 500/650/800/1000)

CAN 3 – Design and Diagnostics CAN 3 120Ω EMR

A33

120Ω

R

A9 ADM 2

A8

120Ω ADM 1

A7

Measure resistance between CAN high and CAN low. Measurement points on A 33 are arbitrary.

Diagnostics

CAN high CAN low KMC 3

A14

A3

120Ω

The total resistance in the CAN 3 can be measured on the CAN BUS distribution board.

Always measure without voltage!

Terminating Resistors The two CAN BUS wires (CAN high / CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for CAN 3 are integrated in the job computer KMC 3 and in the cable harness next to the EMR.

120 Ω ║120 Ω  60 Ω total resistance STLP_CAN 3_DE

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16. Electrical System / Electronics:

CAN 1 BUS (BX 700/850/1100)

CAN 1 – Design and Diagnostics CAN 1

120Ω

120Ω A2 KMC 2 A1

1

SD/DRC

2

A6

120Ω

DIOM

A5

R AP CAN high CAN low

Control unit console

A15

A14

Diagnostics

120Ω

A16

Measure resistance between CAN high and CAN low.

KMC 3

The individual terminating resistors or the cable connections can be tested by removing a resistor and then measuring the resistance in the open plug connection.

Always measure without voltage!

A3

Terminating Resistors The two CAN BUS wires (CAN high / CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for CAN 1 are located as external resistors in the console (next to the control unit console (1) and in the front part of the console (2)).

 120 Ω terminating resistor

120 Ω ║120 Ω

STLP_CAN 1_MAN_DE

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 60 Ω total resistance

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics:

CAN 3 BUS (BX 700/850/1100)

CAN 3 BUS – Design and Diagnostics CAN 3 120Ω EMR

120Ω

2

A9

1

MFR

120Ω MFR

R A7 CAN high

Diagnostics

120Ω

CAN low

Resistance measurement between CAN high and CAN low.

KMC 3

A14

The individual terminating resistors or the cable connections can be tested by removing a resistor and then measuring the resistance in the open plug connection.

Always measure without voltage!

A3

Terminating Resistors

 120 Ω terminating resistor

The two CAN BUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for the CAN 3 are located as external resistors in the cable harness (in the front part of the console (1) and next to the EMR (2)).

120 Ω ║120 Ω

STLP_CAN 3_MAN_DE

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 60 Ω total resistance

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics: CAN BUS CAN 2 – Design

AutoScan

120Ω

A40

Resistor located in KMC 2

CAN 2

120Ω

A2 KMC 2 120Ω

Without AutoScan: Resistor connected in KMC 2

A55

~150Ω

120Ω

With AutoScan: Resistor disconnected in KMC 2

optional

A11

120 Ω ║~150 Ω

CAN high CAN low Rock Protect (Option)

A35

A10

 ~ 66 Ω total resistance

Crop Control (Option) KMC 4

~150Ω

Terminating Resistors The two CAN BUS wires (CAN high / CAN low) are terminated with a 120 - 150 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors of CAN 2 are integrated in job computer KMC 2 and in the metal detector or in the AutoScan sensor depending on whether AutoScan is installed ot not.

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STLP_CAN 2_DE

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics: CAN BUS CAN 2 – Diagnostics

Measuring resistance in CAN 2 As CAN 2 is routed directly from KMC 2 to the rear wall of the cab. Diagnostics of the closed circuit is very difficult. It is recommended to disconnect CAN 2 in an easily accessible location and measure the terminating resistors individually. e.g. on the feed drive plug 25X12.

A2 KMC 2 120Ω

Resistor connected in the KMC 2

A55

AutoScan

STLP_KMC 2_DE

120Ω

A40

AutoScan attached: Terminating resistor of 120 Ω in the AutoScan sensor can be measured at plug 25X12.

optional

AutoScan not attached: The 120 Ω terminating resistor in KMC 2 cannot be measured at plug 25X12, because the resistor is only connected when powered. It is necessary to bridge the relay to "simulate" the connection (compare wiring diagram).

A11

Rock Protect (Option)

A10

A35

Crop Control (Option)

25X12 KMC 4

~150Ω

R

R

~ 150 Ω 25X12 Pin A + B 230

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Bridge: 22X5b PIN 10 + 13 © KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics: KMC 2 B25 B26

Supply voltages 12V V1_KMC2 V2_KMC2 V3_KMC2 Supply 12V V4_KMC2

Header right(folded out) Intake speed

Earth 12V supply

Intake forward

Y5 Intake reverse

Y6 Header forward

Y7

Header speed

B27

Header reverse

Y8

Chute middle position

B28

Chute rotation left Chute down position

B29

Y20

KMC 2

A2

Chute rotation right

Y21

Chute rotation pulses

B30

Chute flipper raise Header left (folded out)

120Ω *

B55 B58

A10 B91

Chute flipper lower

Y23 Chute Raise

B60

M12

switched!

Cutting drum speed Level additional tank

M12

Y22

120Ω

Y24

Supply Sensors

Chute Lower

CAN 1

Central lube status

CAN 2

Accumulator grass / corn

Y53

Central lube Fault

KMC 2 (KRONE machine controller 2, 16-bit job computer)

Metal detection

Tasks

Pressure leakage oil filter

Control of the work hydraulics such as feed drive, front attachment and discharge chute

231

Y25

Chute Fold 1 Chute Fold 2 (not used!)

* Terminating resistor can be found in the controller BiG X 500/650/800/1000, on BiG X 700/850/1100 the resistor is located in the harness of the console as an Run down alarm external component.

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Y76 Y77 K10

16. Electrical System / Electronics: KMC 3 Suction return filter

B20 Sharpening stone left

B36 Sharpening stone right

Earth 12V supply

Supply voltages 12V V1_KMC3 V2_KMC3 V3_KMC3 Supply 12V V4_KMC3

B37 KP gap

Main clutch Header fold / crop roller raise Header unfold / crop roller lower

Y26 Y27

Crop divider / EF wheels

B42

Y28 Crop divider / EF wheels

Hydraulic oil level

B43

Y29

KMC 3

A3 Fuel level

Sharpening stone right

Air filter restriction

Sharpening stone left

Y30

B44 B46

120Ω *

Y31

120Ω * Pendulum frame 1 lock

Pendulum frame position

Y54

B52 Sharpening cover (USA)

B59 Main gearbox oil pressure

B70 Innoculant flow

B77 Pendulum frame left up

B87 Pendulum frame right up

B88 B85

Y12

Hydraulic oil temperature

232

Pendulum frame 2 lock

Supply Sensors

CAN 1

CAN 3

Y55

* Terminating resistor for BiG X 500/650/800/1000 is in the computer.

For BiG X 700/850/1100 the resistor is external in the cable harness next to the computer!

KMC 3 (KRONE machine controller 3, 16-bit job computer) Tasks Control computer for the complete system, also controls the display, the counterblade, the grinding, silage agent and the monitoring of the Smart Drive (toggle signal / life signal / safety output)

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Shear bar left

M9 Whear bar right

M10 KP gap

M11 Innoculant pump

M16 Smart Drive release

© KRONE Training Team, Spelle, Germany

GAL

16. Electrical System / Electronics: DIOM Additional hydraulics 1 up

Y51 Y52

Earth 12V supply

Supply 12V

Additional hydraulics 1 down Terminating resistor CAN2-KMC2

Clutch 2nd engine

Y56

K15 Additional hydraulics 2 up

Y61 Y62

Additional hydraulics 2 down

Metal detector signal (horn)

A6

K18 Output Molasses pump

DIOM

K28 Battery changeover 12V/24V

Sharpening flap closed

Y65 Steering Lock left

Y66

K39 K41

Release intake / header

GAL

Steering lock right

Y67 Cleaning valve

Y73 Pressure release head quick couplers

CAN 1

Y75 Valve hydraulic fan drive

Y82 Tasks Clutch 2nd engine (BiG X 800/1000), additional hydraulics (optional), 12/24 V changeover relay, sharpening flap, cleaning valve, steering lock (autopilot), silage agent pump, valve hydraulic fan drive (only for BiG X 700 / 850 / 1100) 233

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A6

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16. Electrical System / Electronics: Smart Drive Transmission front axle reverse

High pressure

Poclain travelling gear

B13 Hyd. oil temperature

Earth 12V supply

B14

Supply 12V

Brake pressure

Transmission front axle forwards Transmission rear axle reverse

Brake accum. pressure

Shift valve rear axle

Y11 4-wheel drive

Feedback sensor Pump rear

Y13 Shift valve front axle

B39

Smart Drive

Parking brake pressure

Supply Sensors

Shift valve front axle (3speed) Stop valve pump front axle

K20.1 Stop valve pump rear axle

FG travelling gear

K43.1

Auto lubrication

Wheel speed

CAN 1

B90

Back-up light / horn Brake light

A1

Life signal (toggle)

Tasks The Smart Drive controls and monitors the drive hydraulics

234

Y4

Y10

A1

Feedback sensor Pump front

Brake pedal switch

Y3

Axle separation

B18

B40

Y2

Transmission rear axle forwards

B16

B38

Y1

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Y14 Y68 Y69 Y70 M12 K29 K30 KMC3

16. Electrical System / Electronics:

BODAS Control Unit DRC

Bosch Travelling Gear Transmission release

S3

Supply Earth

Seat switch

S 69

Supply 12V

High pressure MA forward

B101 High pressure MB reverse

Back-up signal

B102 Brake accumulator pressure

K29

A1

B18

Brake lightd

K30

Parking brake pressure

Pump forwards

B110

Y101

Brake pressure

Pump reverse

Brake pedal angle

Hydraulic motor, front left

B16 B109

Pump swash plate angle

B108

Y102 Y103

Supply sensors

Hydraulic motor, front right

Y104

Steering angle Hydraulic motor, rear left

B107

Y105

Speed, front left

B103 Speed, front right

B104 Speed, rear left

Hydraulic motor, rear right

CAN 1

CAN 3

Control unit Bosch RC28 -14/30

B105 Speed, rear right

B106 235

Tasks The BODAS control unit controls and monitors the drive hydraulics

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Y106

16. Electrical System / Electronics: Autopilot Earth 12V supply

Supply 12V

A5

Row tracer right

B61 Autopilot

Steering wheel pressure

B63 B64

Steering valve left

Y39

Angle sensor Steering axle

Supply Sensors

Steering valve right

Y40

Row tracer left

B65

CAN 1 A5 Tasks After activation of the autopilot the computer evaluates all sensors in the system and transfers the information.

The autopilot can then control the machine.

All parameters concerning autopilot are saved in the controller. To adjust them, the controller needs to be powered.

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16. Electrical System / Electronics: EMR EHR / EMR (electronic lifting gear control or electronic mowing unit control) Tasks The EHR / EMR evaluates the information of all sensors relevant to the lifting gear (pressure sensor, header contour, position sensor) and controls the height of the front attachment or the position of the pendulum frame

CAN 3

Distance sensor left

B47

A9

Distance sensor right

Y32

B48 Pressure lifting gear

B49

Raise lifting gear

Supply Sensors

EMR

Lifting gear accumulator

Y34

Lower lifting gear

Y33

Pendulum frame left

Y37

Position lifting gear

B50

Pendulum frame right

Y38 Earth 12V supply 237

Supply 12V

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© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics:

Control unit console

Task The console control unit (BEK) receives the input signals from the panel switches and buttons. The panel switches are connected directly to the control unit console. The "commands" are transmitted via the CAN BUS.Road/field release switch Ground Supply 12V S1

S2 S3

Autopilot release switch Travelling gear release switch Intake / head release switch

A16

Control unit console

S4 S5 S6 S7

Maintenance release switch

Buzzer

U3 4-wheel drive release switch

(Starter cut-off relay)

25K2

Axle separation release switch Activation moisture meter Parking brake

S9 Door switch

Supply Switch

CAN 1

S68 Seat switch

S69 Quick stop console

S90 S91

Quick stop manual operation

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16. Electrical System / Electronics: A14

Easy Touch and Joystick

"Easy Touch" Info Center Machine monitoring, adjustments, and diagnostics.

Power supply

A15

CAN 3 CAN 1 Joystick Controls the functions of the driving hydraulics and work hydraulics. Data communication via CAN BUS. Joystick with own software!

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16. Electrical System / Electronics: Engine Control MB ADM 2 (adaption module version 2) Tasks Forms the interface between KRONE-BUS system and Mercedes-BUS system.

A7

A8

MR (engine control) Tasks Regulates the engine (engine parameters, power, sensors and actuators)

CAN MB ADM 2

Power supply

Star quad cable for data transmission between ADM 2 and MR via MERCEDES CAN BUS Diagnostics sockets diesel engine 1 + 2

240

CAN 3

MR Engine control

Before welding on the machine, remove both engine control plugs and disconnect battery main switch!

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16. Electrical System / Electronics: MFR/EDC MFR (engine control computer) Interface between KRONE-BUS-system and MAN-BUS-system.

EDC (Electronic Diesel Control) The EDC control unit controls the injection quantity, the point of injection and activate the starter. The optimal injection quantity and point of injection are calculated to ensure optimum combustion in all engine operating states.

The control unit evaluates the sensor signals and then calculates the activation signals for the injectors.

The control unit (software/hardware) can be used for a maximum of six cylinders. A second control unit is needed to operating a V-engine. The two control units communicate via CAN and operate in “master/slave” mode.

Before Y.o.M. 2012:

CAN MAN

A7

MFR

Power supply

CAN 3

EDC engine control units: 1. Master: cylinders 1-6 in direction of travel at rear

2

2. Slave: cylinders 6-8 (12) in direction of travel at front

After Y.o.M. 2012:

Before welding on the machine, remove both EDC plugs and disconnect battery main switch!

1 EDC (master / slave)

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16. Electrical System / Electronics:

Potential Distributor Circuit Board

Potential distributor circuit board

A17 Tasks: Combines all supply voltages and ground wires from the sensors and valves in the machine, as well as the combination of the ground wires for the job computers.

A17

Console BIG X 500 / 650 / 800 / 1000

A17

17X1

17X11

17X12 17X8

17X3

17X20

17X7 17X2

17X13

17X4 17X9

17X14

17X10 17X6

17X 17

17X15

17X16

17X18

17X19

Console BiG X 700 / 850 / 1100 242

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17X21

17X5

16. Electrical System / Electronics:

Console and Cab Circuit Board

Installation position BX V8/V12/500/650/800/1000

Tasks The console circuit board (A22) provides fuses and power for all work functions (supply voltages) of the job computers / controllers.

The GAL logic module (G) integrated on the circuit board controls the individual supply voltages for the various job computers (see wiring diagram)

Cab circuit board

A22

A4

G

Consol circuit board

243

Installation position BX 700/850/1100

A22

Cab circuit board

Tasks The cab circuit board (A4) protects e.g. the "VEHICLE" electronics (light, window washer, brake light ...)

The fuses for ignition stage 1 and ignition stage 2 are also located on the cab circuit board.

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16. Electrical System / Electronics: Supply Voltage Logic + 12 volts Road / field release switch

22F78 Voltage V3 KMC3

Quick stop switch 22K32 Maintenance release switch

22LD34

IN9

IN7

IN13

GAL logic -IC1

OUT 6

F12

KMC 3

LD40

PWM_LA8

Console Relay board LD31

-A22

Valve grinding stone on left

-A3

Y31

0 Volts Both job computers (KMC2 + KMC3) have separate load and electronic power inputs. The load inputs supply power for the output circuit of the job computers. The load inputs come from the relay board and are switched there depending on the different inputs (release switch, etc.) from the GAL logic.

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16. Electrical System / Electronics:

245

Overview of Job Computer

(1) ● LD 27 – LD 29

LEDs Supply Voltages

(2) ● F2, F6, F12, F13

Internal fuses load voltages V1 – V4

(3) ● LD 37 – LD 41

LEDs load voltages V1 – V4

(4) ● LD 1 – LD 12 and LD 30 – LD 36

LEDs outputs

(5) ● LD 13 – LD 26

LEDs inputs

(6) ● LD 38

Life LED (status of the job computer)

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16. Electrical System / Electronics: GAL Inputs GAL Logic Module Tasks GAL logic module specifies which input conditions are required for the individual supply voltages (see wiring diagram) The inputs can be checked via light-emitting diodes (LD xxx).

Inputs

LD xxx

GAL

Console relay circuit board 246

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16. Electrical System / Electronics: GAL Outputs GAL Logic Module Tasks

GAL

If the GAL-logic component has the necessary input signals it switches the relay for the output signal with MOS-FET. The conditions for the respective output signals are described in the table (T). Supply voltages V1-V4 for KMC2 and KMC3 as well as the power supply for Smart drive, autopilot and DIOM are then switched by the relays. Respective supply voltages are secured by a fuse and can be examined by means of the light emitting diodes LD designation in the table (T).

T

Designation in the table (T) "0" – 0 V "1" – 12V "0/1" – 0V or 12V

Statement if LED is lit: - input conditions fulfilled - Relay switched - Fuse ok Supply voltage is ok at the relay board

LD

MOS-FET

Console relay circuit board 247

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16. Electrical System / Electronics: Statement if LED is lit: - Relay board including GAL logic and fuse are in working order - Cable and connections to KMC are OK

Diagnostics via LED on the KMC

V1 V2

Relay board console

V3 V4

V4 V3 V1 V2 Inputs: e.g. sensors and switches 248

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Outputs: e.g. valves

16. Electrical System / Electronics:

Diagnostics via LED on the KMC

Overview of LEDs on the circuit diagram and on the computer Inputs: green / orange Outputs: red

- Bottom connection indicates: Output - Computer: KMC 2 - Function: Raise DC - Supply voltage for this function: V 4 - LED indicator used: LD 1 Statement if LD 1 is lit as soon as function is actuated - Supply voltage is applied - Required logic has been met - Job computer is working

4 x 4 = 16 outputs

Statement if LD 25 is lit or goes out as soon as sensor or switch changes its status: - Sensor or switch in working order - Cable and plug connections up to KMC in working order 249

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- Top connection indicates: Input - Computer: KMC 2 - Function: Chute lower position - LED indicator used: LD 25

© KRONE Training Team, Spelle, Germany

16. Electrical System / Electronics:

Safety Outputs KMC

Smart Drive Release Voltage Module:

KMC 3

(Output LA_1)

Diagnostic LEDs:

22LD102

(Console circuit board)

LD2

(KMC 3)

Switch-on conditions: When engine stops:

KMC 3 active

When engine is running:

KMC 3 active and toggle signal* from SmartDrive is received

*Toggle signal: Life signal (frequency approx. 3 Hz) of the Smart Drive, check via 22LD116

Release voltage Intake/Header Module:

DIOM

(Output DIG_OUT_10)

Diagnostic LEDs:

22LD112

(Console circuit board)

Switch-on conditions: -> Release switch road / field ON -> Release switch Intake / Header ON -> Release switch maintenance OFF -> Main clutch ON -> Intake / Header must be reversed

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17. Software: KRONE Download Center

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Download Center The KRONE Download Center is necessary to update the software on all KRONE control units. You need to have a PC with USB port. The connection between PC and machine is done by the diagnostic socket (A) in the console.

The complete package for updating software on all KRONE machines (incl. setup-CD, all necessary wires and registered PCANdongle) can be ordered through parts with P/N: 27 006 523 0. When ordering, please include the name and birthday of the person who will be using the tools on the order.

1. CD with Software „KRONE Download Center“ 2. PCAN-USB Dongel 3. Diagnostic cable 4. Cable with adapters 5. Smart Drive diagnostic cable (Y-piece) 251

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SI_150369998 Components software update_EN

KRONE Download Center_DE

© KRONE Training Team, Spelle, Germany

17. Software: Phases

WHB_7.10.2_ Phases_DE

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SmartDrive – Software Update and Diagnostics To program the Smart Drive computer it is necessary to have the PHASES software from Poclain Hydraulics. The software is included in the KRONE Download Center CD and can be installed from the CD (1).

The cable (2) is the connection between PC and Smart Drive for updating software and diagnostics.

It is necessary to have a notebook equipped with a serial port or to use a USB to serial port adapter (3).

The Smart Drive diagnostic cable (y-piece) and the USB adapter can be ordered through KRONE parts: SmartDrive diagnostic cable (Y-piece): 27002462.0 USB - serial adapter: 27004132.0

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17. Software: Software Update Guidelines 1. Download the latest machine software

www.krone.de/software

Installation starts automatically after downloading the machine software from the KRONE Download Center

Machine software, software information service technician,

Software information in detail (password required)

Smart Drive parameters (password required)

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17. Software: Software Update Guidelines 2. Establish a connection

3. Download software

4. Compare software versions

Machine

Download Center

5. Follow instructions in the Download Center

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17. Software: Software Update Guidelines 6. Determine, compare and, if required, update SmartDrive software version and parameter set

Software

Depending on machine features, continue with step 7a or 7b!

7a = Machines with Poclain travelling gear 7b = Machines with Bosch travelling gear 7a. Connect SmartDrive

USB adapter only if there is no serial interface!

Send program file

8a. Download software Make correct selection!!

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17. Software: Software Update Guidelines Send parameter file

9a. Download parameter set

Make correct selection!!

10a. Determine wheel circumferences

11a. Enter wheel circumferences Parameters at the "Service" level: 22001 and 22002

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17. Software: Software Update Guidelines Machines with Bosch Transmission 7b. Establish connection

8b. DRC (BODAS control unit) Determine, compare and, if required, update software version and parameter set

Software

BODAS parameter

9b. Save parameter of the DRC on PC

Parameter

Save files on the PC exactly according to the instructions!

Data will be required again after the download!

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17. Software: Software Update Guidelines Software

10b. Download software (flash control unit)

11b. When the software has been successfully downloaded, the machine-specific parameters must be transmitted back into the DRC.

Parameter

Use of the Bosch BODAS software is described in a separate manual. The sequence and the procedure for updating the software are described in detail in the manual.

DRC flash instruction_EN

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17. Software: Replacing Job Computer / Configuration Parameters and settings to be checked after replacing a job computer When specific job computers have been replaced, various settings or calibrations are required depending on the job computer. In some cases there are parameter settings which require the input of codes/passwords. Other cases require calibrations be made. The attached list is an overview of those actions which are to be implemented depending on the individual controls (depending on the machine configuration).

Before replacing any job computer, find out about the actions involved and ensure that you can also implement these properly!

Caution: In some cases it is absolutely essential to telephone KRONE customer service !

Incorrect configurations may cause a machine breakdown or the loss of the operating licence!

The hardcopy list is in the appendix to the training document.

Parameter check Machine configuration_DE

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17. Software: Parameter Settings

Parameter_Service

Parameters must be set if: - A job computer is replaced (e.g. KMC) - Software is updated (as specified in customer service info) - Settings have been changed 260

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