Krone BiG X 600_1100 TT Basic 2017 Self-propelled forage harvester Service Tranning Manual 6781_EN

Forage Harvester BiG X

Training

Season 2017

Name:

________________________________

Company:

________________________________

Training date:

__.__. 2017 to __.__. 2017 BiG X 600_1100 TT Basic 2017

Basic_BX_6781_EN

Last update: March 2017 (V006)

© KRONE Training Team, Spelle

Table of content Chapter

page

Download training documentation from Media Centre

1

Media Center / Solution Manager

3

Search term:

__________________

2

Machine Concept

6

Password:

__________________

3

Assistance Systems

29

4

Operation

36

5

Crop Flow

85

6

Field Operation

153

7

Hydraulic System

157

8

Electrics/Electronics

166

9

Systems Technology

188

10

KRONE Diagnostics

270

11

Maintenance

271

WARNING Danger if information is missing or incorrect!

This training document is worded so as to be easily understood. The document therefore does not claim to be complete. Moreover, the information might not always be fully up-to-date as a result of ongoing technological advances.

Consequently, this training document can only provide a basic understanding, and is not intended to replace the actual machine documentation!

• This document may only be used for training purposes!

• When procuring information, only the actual documentation (operating instructions, workshop manual, etc.) may be used!

The machines, what are described in this document, have next to different configurations (options), also small technical differences. The approciate parts, systems, etc. are marked with „*“ in this document.

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

1. KRONE Media Center / Solution Manager KRONE Media Center enables you to download the training documentation for the course you have booked in digital form.

To do this, please use the service login for KRONE Media

1

2

Centerhttp://mediathek.krone.de/

Step 1: - Open KRONE Media Center - Log in via the service login - Enter the search term you got during the training course in field (1) - Display hits (2) Step 2: - Select the document in your required language - Save the file to your PC 3

Step 3:

- Double-click on the file and then enter the password you got during the training course

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

1. KRONE Media Center / Solution Manager KRONE Solution Manager The KRONE Solution Manager (KSM) is a software to display possible error causes and error codes in digital form from the terminal of KRONE machines. For this purpose, open KRONE Media Center and log in via dealer login. To access the KRONE Media Center click the following link:http://mediathek.krone.de/ The user has the option of using KSM online. To do this, click the button “KSM Online” (1). The KSM opens online as a new tab in the explorer.

The KSM can also be used offline. To do this, download the KSM setup file (2) and then execute the exe.file.

To ensure the most and complete error code data are available in the KSM, carry out updates at regular intervals (3).

1 2

3

We recommend downloading the software from the KRONE Software Portal www.krone.de/software/, where you will also find detailed instructions.

4

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

1. KRONE Media Center / Solution Manager KRONE Solution Manager In the Krone Solution Manager, users can search directly for an error number from a machine. The system explains to the user the meaning of the error, the possible causes and rectification measures. This information is based on the information contained in the operating instructions.

If an error cause or rectification measure can be precisely assigned, direct links, e.g., to circuit diagrams, are added.

1

3 2

4

5

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X history

2002 2008

2006 2013

2006 2011

6

BiG X V8 / 650 / V12  First KRONE forage harvesters  Mercedes Benz (V8/V12) technology

engine

BiG X 500  Mercedes Benz (R6) engine technology

BiG X 650-I  Mercedes Benz (V8) engine technology

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X history

2007 2010

BiG X 800 / 1000  Twin engine generation  Mercedes Benz R6 engines

We will deal with these machine types in this training course.

2011 Today

2013 Today 7

BiG X 700 / 850 / 1100 BiG X 600-I / 700-I / 850-I / 1100-I BiG X 600-II / 700-II / 770-II / 850-II / 1100-II  MAN engine technology (V8/V12) BiG X 700-III / 770-III Liebherr engine technology (V8)

BiG X 480 / 530 / 580 / 630  MTU R6 engine technology with exhaust aftertreatment (SCR)

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X 700-1100 Overview of product range 2017 with a crop flow width of 800 mm

Type

Chopping drum

Engine

BiGX 700-2 BiGX 700-3 BiGX 770-2

Fuel tank (l)

Silage additives (l)

Bosch Rexroth

960 (+ 330 option)

300 (option)

MAN V8 V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 36, 40* blades)

Liebherr V8 MAN V8

BiGX 770-3

BiGX 850-2

Traction drive system

Liebherr V8

V-shaped / 11 ° Ø 660 mm; 800 mm 28 blades (20, 36, 40*, 48* blades)

MAN V12

BiGX 1100-2

*40 and *48 chopping drums are standard model (no MaxFlow)

1 The type plate (1) of every BiG X forage harvester indicates whether it is a -2 series machine or a -3 series machine.

8

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Performance data BiG X 700-1100

V 8 engine with 16.16 l engine displacement BiGX 700-2, 770-2 (MAN D 2868 LE 121) BiGX 700-3, 770-3 (Liebherr D 9508 A7 00)

Machine power

----X-Power: heavy-duty (e.g. maize)

use

----Eco Power:

e.g. grass mode

Principle of PowerSplit on BiG X 700/770/850/1100

BiG X 700 Continuous chopping output X-Power: 505 kW / 686 HP Continuous chopping output pick-up: 375 kW / 510 HP BiG X 770 Continuous chopping output X-Power: 536 kW / 729 HP Continuous chopping output Eco-Power: 375 kW / 510 HP V 12 engine with engine displacement of 24.24 l (MAN D 2862 LE) BiG X 850 Continuous chopping output X-Power: 605 kW / 825 HP Continuous chopping output Eco-Power: 468 kW / 636 HP BiG X 1100 Continuous chopping output X-Power: 793 kW / 1,078 HP Continuous chopping output Eco-Power: 468 kW / 636 HP

Liebherr V8 MAN V8 MAN V12 Eco-Power – X-Power Eco-Power is used where you can manage on less machine performance. If you require more power, switch to X-Power on the BiG X 700, 770, 850 and 1100 by pressing a key. Optionally, this switchover can also be made automatically depending on the engine load. This mechanism enables flexibility and reduces diesel consumption. The use of large, powerful forage harvesters is therefore more economical even in weak or highly changeable mowing conditions.

9

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Performance data - Overview Applications of different characteristic curves For BiG X 700/770 only

= Torque = Performance

= Torque = Performance

X-Power full power for: • larger areas • equal yields

ECO-Power for economical...

• uncomplicated conditions • low yields • e. g. small grass swaths

= 10

Fuel saving

=

Maximum throughput t/h

BiG X 600_1100 TT Basic 2017

= Torque = Performance

TRI-Power torque boost for: • large torque reserves • For highly changeable and difficult conditions • small areas • on slopes

=

Relaxed working without much readjustment © KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X maize headers Overview of product range 2017 with a crop flow width of 800 mm (pendulum frame adaptation) Working width (mm)

Operating units

600-2

6,000

circulating collector

vertically folded (2-part)

603

6,000

circulating collector

horizontally folded (3-part)

750-2

7,500

circulating collector

vertically folded (2-part)

753

7,500

circulating collector

horizontally folded (3-part)

903

9,000

circulating collector

horizontally folded (3-part)

1053

10,500

circulating collector

horizontally folded (3-part)

Type

Pendulum frame adaptation

11

Transport position

EasyCollect 1053:

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X maize headers Overview of product range 2017 with a crop flow width of 630 mm (spherical roller adaption) Working width (mm)

Operating units

Transport position

450-2

4,500

circulating collector

vertically folded (2-part)

600-2

6,000

circulating collector

vertically folded (2-part)

750-2

7,500

circulating collector

vertically folded (2-part)

6,000

circulating collector

horizontally folded (3-part)

750-3

7,500

circulating collector

horizontally folded (3-part)

900-3

9,000

circulating collector

horizontally folded (3-part)

Type

600-3 600-3 FP*

EasyCollect 600-3 FP*

Spherical roller adaptation

EasyCollect 450-2:

*Exclusively for Claas Jaguar Series: 491, 492, 493, 494, 496, 497

12

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Grass attachments Pick-up Working width (mm)

Operating units

300

3,000

Uncontrolled pick-up

380

3,800

Uncontrolled pick-up

300 S

3,000

Uncontrolled pick-up

380 S

3,800

Uncontrolled pick-up

Type

Type

EasyFlow 300/380 (pendulum frame adaption with crop flow width of 800 mm)

EasyFlow 300S/380S (spherical roller adaptation with crop flow width of 630 mm) Spherical roller adaptation

Pendulum frame adaptation

13

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program BiG X maize headers Overview of product range 2017 for other choppers

Type 600-3 FP*

Working width (mm)

Operating units

Transport position

6.000

Circulating collector

horizontally folded (3-part)

EasyCollect 600-3 FP* *Only for Claas Jaguar Models: 491, 492, 493, 494, 496, 497

14

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Direct cut header Working width (mm)

Operating units

6200

6,200

Disc mower

620

6,200

Disc mower

Type

XDisc 6200 (pendulum frame adaptation with a crop flow width of 800 mm)

XDisc 620 (spherical roller adaptation with a crop flow width of 630 mm)

Pendulum frame adaptation

Spherical roller adaptation

15

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Overview optional accessories BiG X 2017:

Additional weights

LED working lights for closerange illumination and longdistance illumination

Track system (only for Bosch traction drive)

Silage additives tank 16

Discharge distance adjustment StreamControl

Additional axle

BiG X 600_1100 TT Basic 2017

Mudguard extension

LED ladder lighting

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Overview optional accessories BiG X 2017:

Spout extension 10 rows

Service cart for intake unit

Service wagon for chopping drum

Spout extension 12 rows folding

VariLOC: Pulley gearbox to increase the cutting length range Spout extension 14 rows folding

17

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Machine concept The engine (2) is transverse-mounted on the frame (1). This ensures direct drive with maximum efficiency. As the diesel tank is positioned low down in the frame, the machine has a low centre of gravity, guaranteeing safe working on slopes. The forage harvester is driven fully hydraulically by wheel motors without manual gearbox. This design provides space for a large chopper unit above the front axle. Thanks to the good arrangement of the chopper unit and the placement of the engine behind the rear axle, an optimal weight distribution of 60% : 40% on front and rear axle is obtained.

Pos.

2

Designation

4

1

Frame

2

Engine

3

Fuel tank

4

Planetary gearbox at front

5

Planetary gearbox at rear

6

Auxiliary tank (optional)

7

Silage additives (optional)

3 1

5

4

7

tank

6 18

Graphic_BiG X

3 BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Crop flow

Theoretical crop flow rates/rotational speeds

Optimum design: BiG X 600, 700, 770 2361 rpm -> v = 69 m/s - No power loss thanks to gentle diversion of the crop flow BiG X 850, 1100 2475 rpm -> v = 73 m/s - Smooth crop flow thanks to six pre-compression rollers and individual balancing of the individual unit speeds - High flow speed > 200 km/h at discharge - High pre-compression of the crops with four tension springs and a baling force up to 4,600 kg.

BiG X 600, 700, 770 v = 44 or 50 m/s BiG X 850, 1100 v = 47 or 52 m/s

BiG X 600, 700 ,770 BiG X 850, 1100

2

1188 rpm -> v = 41 m/s 1245 rpm -> v = 43 m/s

- The base with the counterblade adjusts to the wear condition of the blades - Drum base and rear wall are spring-mounted (1), (2) and are able to avoid large forage masses to ensure that the machine runs smoothly.

1 Gutfluss

19

Gutfluss MaxFlow

V = 1 – 5.5 m/s n = 190 – 950 rpm

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Drive of operating units The operating elements are hydraulically and mechanically driven.

From the power take-off gear (1) the force flow is conveyed further to the main drive coupling and to the pumps of the - hydrostatic traction drive - hydrostatic intake drive - hydrostatic header drive - work hydraulics and steering hydraulics.

This drive concept enables the header and intake speeds to be adjusted automatically and steplessly. From the hydraulic motors of the drive train the force continues through the transfer gearbox (2) (change in speed and direction of rotation) and the universal shafts to the header and to the intake.

Pos.

On the BiG X 600, 700, 770, 850 and 1100, the drive train of the intake and header pump is mechanically connected to the main coupling, via which it is activated and deactivated.

Component arrangement BiG X 600 / 700 / 770 / 850 / 1100

Designation Graphic_BiG X

1

Power take-off gear

2

Transfer gearbox

3

Hydraulic motor intake

4

Hydraulic motor header

5

Quick-stop valve

geschlossener Hydraulikkreis

5

1 2

3 4 20

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Drive of operating units Most of the power is consumed by the drive of the operating elements. The drive is conveyed by kraftband directly to the chopping drum and to the discharge accelerator. The discharge accelerator shaft transmits the drive to the right side of the machine where the corn conditioner drive is positioned.

Reversing the intake with chopping drum at a standstill Since the hydraulic pumps for the intake and header on machines equipped with a MAN engine are mechanically connected to the main coupling by the power take-off gear, the main coupling must always be switched on before these drives can be rotated.

If the crop flow is blocked, this means that the header cannot be reversed.

1 Graphic_BiG X

On all machines with Bosch traction drive, the hydraulic cylinder for tensioning the main belt is therefore double-acting.

1. Main coupling

3

2. Kraftband of main drive BiG X 600 / 700 / 770

7-groove

BiG X 850 / 1100

8-groove

3. Kraftband corn conditioner

6-groove

2

If the driver then presses and holds the momentary switch for reversing the intake/header with the main coupling switched off, the belt is slackened, the main coupling is switched on and the pumps are then activated.

As a result, reverse can be selected again even if the crop flow is blocked.

SI_150417073

Optionally 7-groove

7-Rilliger_Corn Conditioner Riemen_DE

21

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Main drive brake All BiG X machines of type 600-2, 700-2/3, 770-2/3, 850-2, 1100-2 have a main drive brake as standard. This means more safety for the driver, and enables braking of the main drive from full rotational speed in less than 10 seconds.

Component overview Pos.

2

Designation

1

Adapter between gearbox and brake saddle

2

Brake disc

3

Brake saddle

4

Wear monitor

5

Hydraulic main coupling

1

5 4

3

Hauptantriebsbremse

22

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Poclain traction drive The traction drive is fully hydraulic and is driven by two axial piston variable displacement pumps and four radial piston engines. Four-wheel drive is included as standard on all models.

Type

Wheel motors

I. Road

II. Field FA

III. Four-wheel

IV. Axle separation

FA: 2-stage RA: 2-stage

0…40 km/h FA: 2/2 -> 1/2

0…19 km/h

0…14 km/h RA: 2/2 -> 1/2

0…11 km/h

FA: 3-stage RA: 2-stage

0…40 km/h FA: 3/3 -> 2/3 -> 1/3

0…31 km/h FA: 3/3 -> 2/3

0…18 km/h RA: 2/2 -> 1/2

0…10 km/h

FA: 3-stage RA: 2-stage

0…40 km/h FA: 3/3 -> 2/3 -> 1/3

0…31 km/h FA: 3/3 -> 2/3

700

850 / 1100

0…18 km/h RA: 2/2 -> 1/2

0…10 km/h

III I

II

Road/field FA

III

Four-wheel

IV

IV

Axle separation Changeover

23

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Bosch Rexroth traction drive The BiG X traction drive with components from Bosch Rexroth consists essentially of a variable displacement pump and four adjusting motors.

Stepless driving from 0-40 km/h is therefore possible.

A machine with Bosch Rexroth traction drive is identified by planetary gearboxes (1), which are installed in the wheels as an end power take-off on front and rear axles.

Other features are the switches for traction control system (2) + (3), (TC ON/OFF und TC I/II) which are installed in the console.

TC stands for TractionControl. Whenever the machine is restarted, stage I is always activated.

2

3

1 1

24

Mode

Speed

Diesel engine control

Road

0…40 km/h

Automatic

Field

0…25 km/h

Manual

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Bosch Rexroth traction drive:

II

The road/field release switch (1) is used to switch from road travel to field mode and vice versa (only possible when the machine is at standstill!)

I - Road travel II - Field mode In road travel, all functions of the working hydraulics (raise/lower spout etc.) are deactivated. Only driving hydraulics and steering hydraulics are active. The driving speed and engine speed are also dependent on the switch position.

1 I

I.Road mode: The machine is started by front and rear drive motors. Driving speeds: Forward 40 km/h, reverse up to 14 km/h.

II.Field mode: The drive is provided by front and rear drive motors. The drive motors are adjusted steplessly according to conditions Driving speeds: Forward 25 km/h, backward 14km/h

TC Traction Control: TractionControl is active in field travel mode (traction control system). If required, this can be switched on or off. Complete deactivation is not possible to protect the engines from overspeeding.

TractionControl is available in 2 stages: TC I is the traction control system for maize 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 system for grass mode. This mode allows only very little slip (spinning wheels). This ensures that the sward is protected.

The selection of the stages for the traction control system depends on the operating mode (grass/maize) set on the terminal. So the stage can be adjusted to conditions.

25

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Engine cooling The cooling pack (1) is located in front of the engine as viewed from the direction of travel. Cold air is drawn in behind the cabin from above through the cooling pack and discharged to the rear with the heat of the engine.

A conical screen (2) rotates in front of the cooling pack and protects it against contamination.

The exhaust fan (3) cleans the sieve and blows residual dust out of the air filter cartridges. It is driven via main belt.

1

3

1

26

2

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Cooling pack To ensure ease of maintenance, all coolers are arranged on one level.

View of the cooling pack with cooler door open, on left as seen in direction of travel:

Fuel cooler only for BiG X 700-3 and 770-3

BiG X 600 / 700 / 770

BiG X 850 / 1100 Oil cooler

Charge air cooler

Coolant cooler

Charge air cooler

Oil cooler Coolant cooler

27

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

2. Machine Concept / Product Program Fuel tank Main tank The main tank (1) is positioned in the centre, low down in the frame to ensure a low centre of gravity.

BiG X 600 / 700 / 770 / 850 / 1100 = 960 l

2 1

2

Additional tank The additional tank (2) is installed behind the rear axle and can either be used as fuel tank or silage additives tank. The tank capacity depends on the model: BiG X 600 BiG X 700 / 770 BiG X 850 BiG X 1100

= 330l = 330l = 330l = 330l

3

The fill level of the additional tank (2) can be displayed on the working screen (3). Use of the additional tank, and activation and deactivation of the filling level indicator, is programmed from the menu (4). The menu (4) is opened by pressing key (C).

28

BiG X 600_1100 TT Basic 2017

4

C

© KRONE Training Team, Spelle

3. Assistance Systems Overview of ICAN components

ForageCam: Image transfer to transport vehicles driving in parallel

29

CCI. Control Mobile: To use data and fleet management systems

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

3. Assistance Systems Overview of ICAN components

RockProtect: Rock detection

ISOBUS: Steering system

AutoScan: Automatic maturity level detection

NIR moisture measurement

CropControl: Yield recording (data acquisition also possible via Delta or an external ISOBUS terminal)

30

BiG X 600_1100 TT Basic 2017

AutoCalibrate: Automatic calibration of yield recording

© KRONE Training Team, Spelle

3. Assistance Systems RockProtect - Rock detection (optional) RockProtect is a system for detecting fairly large, solid foreign objects. An acceleration sensor (1) on the upper roller gearbox monitors the acceleration of the upper intake rollers. Each foreign object causes the upper intake rollers to accelerate, their height depending on the size of the foreign object. As soon as a threshold, which is specified by the driver, is exceeded, the system activates a quick-stop of the intake and header. As a result, the intake rollers stop so quickly that the foreign object cannot pass through the intake to the chopping blades. This will prevent major damage to the chopping drum and to the following components.

The driver must adjust the setting to the particular working conditions, as changing swaths will also cause the acceleration of the upper roller unit to vary greatly.

1

31

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

3. Assistance Systems CropControl - Yield recording (optional) Inductive path sensor

Pressure sensor

In the cabin:

Alternatively, CropControl can also be operated via the DELTA terminal or via an external ISOBUS terminal.

Functional principle Based on the data of path sensor and pressure sensor (the pressure sensor represents a type of baling force which is exerted by the springs of the intake unit), the harvested volume can initially be specified together with the intake speed. A volume factor is specified by control weighing. The harvested volume is converted to mass by means of the factor specified in this way.

On the operation unit in the cabin it is possible to switch between the display of the total mass (t), the yield (t/ha) and the throughput (t/h). All determined data can be printed out on the associated CAN bus printer.

32

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

3. Assistance Systems Yield-dependent silage additives dosage (only in conjunction with CropControl yield recording) The silage additives can be dosed depending on the crops throughput (l/t) or volume (l/m3). A flow sensor (3) monitors the flow rate of the silage additives.

The desired output quantity can be set on the terminal. The silage additives pump (2) is then activated variably depending on the yield quantity.

On machines without CropControl yield recording, it is also possible to dose the silage additives dependent on time (l/min).

3

1 2 1. Additional tank (depending on year of manufacture in rear of machine) 2. Silage additives pump and filter (depending on year of manufacture in rear of machine) 2 3. Flow sensor (depending on year of manufacture mounted on spout )

3

1 BA_A-1_Int.Siliermittelanlage

33

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

3. Assistance Systems Connection of silage additives devices generally Overview and position of plug connections for connection of silage additives units Plug

Function

Position

XY 60

Silage additives pump (external)

Depending on year of manufacture, above the right front wheel or on the right on the cabin rear wall

XM 16

Silage additives pump (KRONE unit)

Depending on year of manufacture, above the right front wheel and in the rear of the machine (near the engine support), or factory-fitted on the pump

XB 77

Flow sensor

Depending on year of manufacture, on the left on the cabin rear wall or factory-fitted behind the silage additives pump

XB 60

Filling level of additional tank

Depending on year of manufacture, in the bumper at the rear of the machine and on the right on the cabin rear wall, or above the right front wheel

When using an external silage additives unit, it is advisable to connect the pump to plug XY60 XY 60  Pin 1: +12 V automatic mode (1) max. 15 A via fuse 22-F74 XY 60  Pin 2: Ground XY 60  Pin 3: +12 V continuous voltage, max. 15 A via fuse 22-F74

1 XY60

In automatic mode (1) the external pump is only supplied with a voltage of 12 V if the following conditions are met:

2

Furthermore, the lifting unit must be lowered to the working position (2).

34

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

3. Assistance Systems Moisture measurement with NIR sensor (optional) The NIR sensor supplies precise data on the moisture of the crops. This recorded data can be assigned to the harvested area in the customer counter. The sensor is protected by highly wear-resistant materials and can therefore be used universally for any crops (no warranty claims will be valid in the event of damage by foreign bodies). The moisture content is measured on the spout of the BiG X. The continuous crop flow at this point is the basis for reliable data recording. The sensor is easy to install and is safely protected from damage by a cover.

Functional principle A Near Infra Red light beam is transmitted to the chopping crops. NIR light has the exact wavelength to excite the water molecules. NIR light can be reflected only by the water molecules in the crops (the other molecules absorb the light). The difference between transmitted and reflected light is measured. The moisture content and thus the dry matter content can be calculated from this difference.

The sensor is automatically calibrated internally at fixed intervals.

To optimise the accuracy of the NIR sensor, field calibration can be performed when using the sensor for the first time. Field calibration must be performed by trained service personnel.

150469025-Allgemein-BIGX-Feldkalibrierung_NIRSensor__Be.pdf

NIR sensor in the back of the spout 35

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Operating elements in the cabin

Pos.

1

3

2

6 5

Designation

1

Automatic climate control/ISO compartment for radio installation 12 V

2

Roof panel

3

Two free compartments, e.g. for radio etc. 12V

4

Reversing monitor (option)

5

Front wiper

6

Lateral wiper

7

Steering column

8

Cooling box (under passenger seat)

9

Terminal

10

Control lever

11

Operation console

4 9

9 10 7 11

8

36

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Switch group roof console

2 Pos.

3

1

6

4 5a 5

Designation

1

Working lights on the side of the cabin

2

Working lights cabin roof

3

Working lights on front at bottom

4

Rear working lights

5

Transport lights I - Parking light II - Dipped beam

7 8 12

11 10 9

2

5a

Top headlight for 3-part EasyCollect

6

Mirror adjustment (right outside mirror only)

7

Warning beacons

8

Hazard lights

9

Windshield wiper

10

Windshield washer

11

LED spotlight joystick light

12

Working lights spout

5a 1

5 3

1

3

12

11 4 37

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Automatic climate control and radio

Pos.

38

Designation

1

ISO compartment for radio (12 V)

2

Key to switch automatic climate control on and off

3

Key to switch air conditioning mode on and off

4

Key to increase the desired cabin temperature.

Alternatively: Manual settings “up”

5

Key to reduce the desired cabin temperature. Alternatively: Manual settings “down”

6

Key to switch REHEAT mode on and off (demoisturising the cabin air).

7

Key to toggle blower speed between manual/automatic

8

Covered key to switch the temperature display to ° Fahrenheit

1

3

4

2

5

BiG X 600_1100 TT Basic 2017

6

7

8

© KRONE Training Team, Spelle

4. Operation Operation console

3

4 5 5 2

6 Pos.

1

39

7

BiG X 600_1100 TT Basic 2017

Designation

1

Release switches release buttons

2

Warning lights

3

Key module

4

Emergency stop switch

5

12 V sockets

6

Cigarette lighter

7

Ignition key © KRONE Training Team, Spelle

and

4. Operation Warning lights and connections

Engine failure/oil pressure warning light Warning light (1) lights up when a disturbance occurs in the diesel engine. In this case, switch off the engine immediately and repair the fault.

1

2

Coolant temperature warning light too high The coolant temperature too high warning light (2) lights up when the coolant temperature in the engine has risen above 102°C. Switch off the engine as quickly as possible in order to avoid major engine damage.

3

Charging warning light The charging warning light (3) lights up if the output voltage of the alternator is not sufficient to charge the batteries.

Diagnostics socket (4) CAN bus interface.

5

USB port (5) The USB port can be used to save the data from the customer counter to a USB flash drive.

Connection ISOBUS (6) Additional CAN bus interface

Connection (7)

7

4

12 V connection for cooling box

6 Connection (8) ISOBUS In-Cab socket (e.g. for ISOBUS steering system)

40

8

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Emergency stop switch When the quick-stop switch (1) or (2) is pressed, the traction drive is deactivated and the machine stops. All work functions are stopped.

To activate the machine, turn the actuated quick-stop switch (1) and (2) slightly to the right to its initial position.

1

Ignition lock The ignition lock (3) has four positions: 0 - Off I - Electrical circuit for electronics is switched on II - The ignition is switched on III - Engine start

2 I

0 3 41

BiG X 600_1100 TT Basic 2017

II III

© KRONE Training Team, Spelle

4. Operation Console button Function keys with LED:

1

3

2

4

5

6

7

8

11

12

15

16

9

10

13

14

9 Pos. 1

Designation Discharge distance adjustment StreamControl (optional)

2

Discharge distance adjustment StreamControl (optional)

3

Main drive on

4

Main drive off

5

Swivel pendulum frame to the left

6

Swivel pendulum frame to the right

10

8

7

7-8

Red hydraulic connections (fold in/out maize header; raise/lower crop press roller unit)

9-10

9-10. Hydraulic connections blue (plant divider of EasyCollect, fold in/fold out guide wheels of pick-up)

11 12-16

Discharge accelerator rear panel (spring-mounted), standard Auxiliary hydraulics (option)

Press keys 7+8 or 9+10 simultaneously to depressurise both hydraulic circuits!

42

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Poclain – Driving modes/traction drive

1 On Traction drive release switch When the traction drive release switch (1) is actuated, the traction drive is released.

The traction drive release switch must be switched off for the following functions: - Engine start - Manual operation on the platform Road mode • Traction drive release switch (1) switched on • The road/field release switch (2) is in the “road” position When starting up, the front hydraulic motors run at high displacement – i.e. at maximum torque. The displacement is reduced in stages when the machine has reached a certain speed.

BiG X 700 – approx. 11 km/h, BiG X 850/1100 (700 optional) – two stages approx. 10 and approx. 20 km/h. Maximum speed 40 km/h.

The engine speed automatically adapts to the travelling speed (automotive running) 43

Changeover

BiG X 600_1100 TT Basic 2017

2 Off

© KRONE Training Team, Spelle

4. Operation Poclain – Mountain mode

2

1

On

3

Off

Press

• Traction drive release switch (1) switched on • The road/field release switch (2) is in the “road” position • Mountain mode is activated and deactivated with the axle separation momentary switch (3) when the machine is at a standstill.

In mountain mode, the engine speed is also adapted automotively to the driving speed, although when starting up it is already slightly higher. The machine reacts promptly.

44

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© KRONE Training Team, Spelle

4. Operation Poclain – Field mode (only the front wheel motors active)

2

3 1

On

3

On

Off

• Traction drive release switch (1) switched on • Road/field release switch (2) is in the “Field” position (changeover only possible when the machine is at standstill) • Four-wheel drive switch (3) switched off In this case, the front hydraulic motors on the BiG X 700 always run at a high displacement, i.e. at maximum traction.

On the BiG X 850/1100 (700 optional) the motors run in the first two stages. (Reduction 3/3 to 2/3) Maximum driving speeds: BiG X 700 – 19 km/h, BiG X 850/1100 (700 optional) – 31 km/h.

45

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© KRONE Training Team, Spelle

4. Operation Poclain – Four-wheel drive

2 1

3 ON

ON

ON

• Traction drive release switch (1) switched on • Road/field release switch (2) is in the “Field” position • Four-wheel drive switch (3) switched on The four-wheel drive can only be switched at a standstill!

In this case, the front hydraulic motors on the BiG X 700 always run at a high displacement, i.e. at maximum traction.

On the BiG X 850/1100 (700 optional), the motors run in the first two stages (reduction from 3/3 to 2/3).

On all models the rear hydraulic motors are switched to half volume when the following speed is reached: BiG X 700 – approx. 9 km/h, BiG X 850/1100 – approx. 13 km/h.

Maximum driving speeds: BiG X 700 – 14 km/h, BiG X 850/1100 (700 optional) – 18 km/h.

46

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Poclain – Axle separation

1 ON

3 ON

4 Press

2 ON

• Traction drive release switch (1) switched on • Road/field release switch (2) is in “Field” position • Four-wheel drive switch (3) switched on • Pressing the axle separation key (4) switches the axle separation on or off.

Switching the axle separation is possible at driving speeds below 11 km/h (BiG X 700) or 10 km/h (BiG X 850/1100 optionally BiG X 700), also corresponding to the maximum driving speeds. In this case, the front and rear hydraulic motors on all models always run at a high displacement – that is, at maximum traction.

47

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Poclain – Traction drive parking brake The parking brake is engaged at “ignition off” or when the parking brake release switch (1) is switched on. The machine is held by spring force and released at “ignition on”, provided there is sufficient pressure in the hydraulic accumulator. The spring force forces the brake shoes of the front wheel motors apart – the parking brake is active.

With the ignition on and the parking brake switch (1) off, and provided there is sufficient pressure in the hydraulic accumulator, the springs are pulled together and the parking brake is released.

1

48

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Bosch – Switches and warning lights

Pos.

49

Function

1

Road field/field mode release switch

2

Intake/header release switch

3

Parking brake (momentary switch)

4

Traction drive release switch

5a

TractionControl on/off

5b

Traction Control (maize/grass)

9 1

stage

I

/

2

3 11

II

6

Automatic steering release switch

7

Maintenance release switch (Grinding blades/ counterblade adjustment)

8

Engine failure indicator lamp (for BiG X 600/700/770//850/1100: Oil pressure and serious engine fault)

9

Coolant temperature indicator lamp too high

10

Charging warning light

10

4

5a

BiG X 600_1100 TT Basic 2017

5b

7

© KRONE Training Team, Spelle

8

4. Operation Bosch – Operation traction drive/driving modes

ON I. Road mode: - Traction drive release switch (1) switched on The machine is started by front and rear drive motors.

Driving speeds: Forward 40 km/h, reverse up to 14 km/h.

II. Field mode: - Road/field release switch in field position + traction drive release switch (1) switched on The drive is provided by front and rear drive motors. The drive motors are adjusted steplessly according to conditions.

Driving speeds: Forward 25 km/h, reverse 14 km/h.

1

2

3

Press

Press

TC Traction Control ON / OFF: - Actuate momentary switch (2) until the required icon is indicated on the display TractionControl is active in field travel mode (traction control system). If required, this can be switched on or off. Complete deactivation is not possible to protect the engines from overspeeding.

Traction Control stage I: - Actuate momentary switch (3) until the required icon appears on the display TC I is the traction control system for maize mode. This mode allows increased slip (spinning wheels). This is required to ensure adequate forward drive even under difficult conditions.

Traction Control stage II: - Actuate momentary switch (3) until the required icon appears on the display TC II is the traction control system for grass mode. This mode allows only very little slip (spinning wheels). This ensures that the sward is protected.

The selection of the stages for the traction control system depends on the operating mode (grass/maize) set on the terminal. So the stage can be adjusted to conditions.

Animation TC

50

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© KRONE Training Team, Spelle

4. Operation Bosch – Traction drive parking brake The parking brake is automatically applied when the machine is at standstill and no driver is on the seat.

If the momentary switch (1) is pressed while driving, the machine automatically brakes. As soon as the machine is at a standstill, the parking brake is applied.

Automatic start-up:

If the driver is sitting on the seat, the traction drive release switch is switched on and the joystick is actuated, the parking brake is automatically released.

To release the parking brake at a standstill, the service brake pedal must be depressed all the way and then the momentary switch (1) must be pressed.

1

51

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© KRONE Training Team, Spelle

4. Operation Autopilot release switch Pressing the autopilot release switch (1) releases the “automatic steering” function. The autopilot can be switched on by means of control lever, when the switch (2) is in the field mode, traction drive release switch (3) is switched on and autopilot release switch (1) is activated. Furthermore the machine must move forward (> 0.7 km/h).

If the machine features a diagnosable seat switch, it is used from software version 200814613 as a connection condition instead of the door switch.

3 1

ON

2

52

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Maintenance release switch Pressing the maintenance release switch (1) releases all maintenance functions (manual operation on the left platform) and opens the Maintenance menu (2) (menu level 3-2). To enable manual operation (5) on the platform, the road/field release switch (3) must also be set to field mode and the traction drive release switch (4) must be switched off.

3

4

ON

Off

1

5

2

53

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4. Operation Manual operation platform

1

9

2

3

4

5

7

6

Pos.

8

Designation

1

Approach counterblade on right

2

Move away from counterblade on right

3

Approach counterblade on left

4

Move away from counterblade on left

5

Close grinding flap

6

Open grinding flap

7

Start grinding cycle in automatic mode

8

Move grinding stone manually

9

Reverse header/intake

If one momentary switch on the manual operation is enables, the LED lights up.

10

11

Grinding blades The following conditions must be met in order to execute the “grind blades” function: • Engine running • Traction drive release switch (10) switched off • The road/field (11) release switch is in the “Field” position • “Maintenance” switch (12) is switched on • Main drive (13) switched on

Off 13

For grinding, the header/lifting unit must be placed on the ground.

54

ON

BiG X 600_1100 TT Basic 2017

12

ON ON © KRONE Training Team, Spelle

4. Operation “Grinding Blades” menu

1 1. Display engine speed The engine speed is set as standard to 1100 rpm.

2. Display for conditions not met (yellow) 3. Warning icons 4. Cycle switch 5. Display for grinding flap position The grinding flap can be opened and closed manually using the keys 3 and 4 of the terminal or using the keys (T) on the manual operation.

The grinding flap is automatically opened when the maintenance switch is turned on and closed when it is turned off.

6. Grinding stone position display If the grinding stone position is not detected, the automatic grinding process cannot be started.

7. Number of executed grinding cycles 8. Setpoint value for grinding cycles to be carried out.

9. Status display for electric motors Counterblade adjustment 10. Menu parameter counterblade adjustment 11. Start automatic grinding 12. Start manual grinding

4 5 2

When the maximum number of cycles has been reached, automatic grinding is no longer possible. Press key 1 to reset the cycle counter to the start value.

55

BiG X 600_1100 TT Basic 2017

3 6

8

7

10

9 T

11

12

© KRONE Training Team, Spelle

11

4. Operation Grinding cycle counter

2

3

One proximity switch on the right and one on the left-hand side detect each end of the grinding path. The grinding cycles are also counted via theses pulses. After a number of grinding cycles specified by parameters has been counted, the driver receives an information message in the terminal and automatic grinding is no longer possible.

1

In the maintenance menu of the terminal, there is a field containing a grinding cycle counter (1), a bargraph showing the number of cycles still possible (2) and a key for resetting the counter (3).

After the grinding stone has been reset or replaced, the cycle counter on the terminal must always be reset!

56

Parameter

Designation

Meaning

33590

Total counter grinding cycles

Current status of grinding cycle counter (for information only)

33657

Grinding stone adjuster

Number of adjusting ratchets per grinding cycle

34014

Grinding stone adjuster number of teeth

Number of teeth of star wheel

34023

Number of grinding cycles until information is displayed

Number of total grinding cycles until the information message indicating that grinding stone must be reset. (default value calculated from 34014 and 33657)

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation Reversing header/intake Pressing the intake/header release switch (3) releases the hydraulic drive of the intake rollers and the corresponding header (safety function). The pumps are actuated only with the release switch on.

The following conditions must be fulfilled to perform the “reverse header/intake” (R) function: • Engine running • Traction drive release switch (1) off • The road/field release switch (2) is in the “field” position • Intake/header release switch (3) switched on • Main coupling running (4)

In the case of machines with Bosch traction drive, first the main belt is slackened and the main coupling is automatically connected as soon as the “reverse intake/header” function is implemented when the drum is at a standstill!

2

ON

3

ON

1

Off Moving back the counterblade To activate counterblade adjustment (G), the following conditions must be met: • Traction drive release switch (1) switched off • The road/field release switch (2) is in the “field” position • "Maintenance" switch (3) switched on

4

G

R 57

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation External operation Raising/lowering lifting unit 1. Raise lifting unit 2. Lower lifting unit The execution of function “Raise/lower lifting unit” is possible on both sides.

To raise/lower the lifting unit by the external manual operation unit, the following conditions must be met: • Traction drive release switch (3) off • Road/field release switch (4) switched on

3

1

2

Off

4

ON

58

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation KRONE control lever Pos. 1

Function Lifting unit multi-way button top: Lower lifting unit manually bottom: Raise lifting unit manually left: Lower lifting unit automatically right: Raise lifting unit automatically

2

Start/stop intake/header

3

Reverse intake/header

4

Memory keys M1 / M 2 – freely configurable (menu level 1-10)

5

Activate autopilot

6

Reverse/lower spout

7

Spout multi-way button top: Spout flap up bottom: Spout flap down left: Rotate spout to the left right: Turn spout to the right

8

Spout rotating speed

9

free

10

Lifting unit adjustment memory key

11

Warning light traction drive on

16

Increase engine speed (in stages)

59

17

Switch from idling speed to rated speed and vice versa

18

Reduce engine speed (in stages)

19

Traction drive activation key

20

Acceleration ramp switch

21

Activation button on small cross lever for saving two chop lengths and folding spout extension

22

X-Power / Tri-Power (only BiGX700/770) / Eco-Power switching

3

9

16

10 11

17

8

18

4 5

2

19

1

6 7

21

20

22 BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation KRONE control lever A - Acceleration (for forward travel) Deceleration (for reverse travel) Start traction drive with activation key pressed (19) B - Control lever central position C - Acceleration (for reverse travel) Deceleration (for forward travel) Start traction drive with activation key pressed (19) D - Deceleration to 0 km/h Fast reversing with pressed activation key (19) (only possible in field mode) E - Control lever central position F - Switch on cruise control (only when travelling forward) Save current speed for cruise control – Press the key (19) and the control lever in the direction (F).

Tilt control lever twice to the right in field mode to activate the “ConstantPower” load limit control.

G - Retrieve chop length value 1 (to the left) When the key 21 is pressed and the joystick is moved beyond the pressure point, the chop length set in the info centre is saved under value 1.

H - Central position J - Retrieve chop length value 2 (to the right) When the key 21 is pressed and the joystick is moved beyond the pressure point, the chop length set in the info centre is saved under value 2.

K - Lower spout (joystick movement via pressure point) - Fold in spout extension (with key 21 pressed) L - Central position M - Raise spout (joystick movement via pressure point) - Fold out spout extension (with key 21 pressed) 60

F E D

19

C B A

M L

J H

K

BiG X 600_1100 TT Basic 2017

G 21

© KRONE Training Team, Spelle

4. Operation KRONE - Display lighting Info centre: 1.

2.

3.

4.

5.

-

Display Keys from 1 to 8 Keys A,B,C.D. Rotary potentiometer Menu key

+

1

2

Keys 1-8 (2) Keys 1-8 are used to activate the softkeys located in the right column. For the assignment of the keys, see the graphic. If there is no softkey next to the key, the key is without function.

In the working menu the keys are used to quickly adjust the values for the working width, header speed, chop length and header working height.

3 4 5

Keys A-D (3) Keys A-D are used to activate the softkeys located in the line just above them. For the assignment of the keys, see the graphic. If there is no softkey above the key, the key has no function.

Rotary potentiometer (4) The rotary potentiometer has two functions: 1. The rotary potentiometer can be turned to change settings and to select the desired menu in the menu level.

2. Pressing the rotary potentiometer activates and saves the settings.

Menu key (5) You can use the key next to the rotary potentiometer to open or close the menu level, or to go to the previous menu level. Holding the button down slightly longer takes you back to the working screen.

61

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4. Operation 2 1

1

3

4

I – Status line: 1.

2.

3.

4.

Time/date, fuel consumption, rotational speed of chopping drum, acreage output, Throughput, yield, moisture of the crops (NIR sensor) / field is freely configurable (menu level 1-7-5) Number of active errors Status of central lubrication and compressed air valve for cleaning intake and grinding device Beige field - idle state Green field – lubrication interval/blow-out active Red field - error central lubrication/blow-off valve Pendulum frame position

• Pendulum frame free. Pendulum frame position as shown.

• Pendulum frame position unknown because pendulum frame sensor defective or not calibrated, or intake not mounted.

• - Pendulum frame locked. Pendulum frame position as shown.

62

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© KRONE Training Team, Spelle

4. Operation II – Information area for engine data 1. Engine speed Road mode: 0 – 1,700 rpm Field mode: 0 – 1,950 rpm on MAN / 0 - 2,100 on Mercedes Benz 2. Machine performance or or 3. Engine load as % 4. Coolant temperature display. If the coolant temperature is in critical range, the background of the temperature display changes to red 5. Filling level fuel tank 6. Engine warning light (red = serious error, switch off engine)

6 1

2 3

4

63

5

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation III – Info area for traction drive (Poclain) 1. Driving speed Road mode: Field mode:

0 - 40 km/h 0 - 19 km/h (BiG X 700) 0 - 31 km/h (BiG X 850-1100 700

4 8.0

optional) 2. Direction of travel

1

Forward travel Neutral (standstill) Reverse travel

3

3. Acceleration ramp 1 - Lowest acceleration ramp 4 - Highest acceleration ramp 4. Cruise control, ConstantPower status The number behind the icon indicates the stored cruise control speed in km/h. When cruise control is active the icon is green.

When ConstantPower is active, the icon changes to 5. Travel mode:

5

• Front wheel drive

64

2

• Four-wheel-drive

• Parking brake applied

• Quick-stop console actuated

• Axle separation

• Limp mode (emergency mode)

• Quick-stop manual operation actuated

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation III – Info area for traction drive (Bosch) 1. Driving speed Road mode: Field mode: 2. Direction of travel

0 - 40 km/h 0 - 25 km/h

4 8.0

Forward travel

1

Neutral (standstill) Reverse travel 3. Acceleration ramp 1 - Lowest acceleration ramp 4 - Highest acceleration ramp 4. Cruise control, ConstantPower status The number behind the icon indicates the stored cruise control speed in km/h. When cruise control is active the icon is green.

When ConstantPower is active, the icon changes to

3

2

5. Travel mode: if the TC icon has a green background, TractionControl is active • TractionControl on/off

•

5 TractionControl stage I for maize

• TractionControl stage II for grass 65

• Parking brake is applied • Limp mode (emergency mode)

BiG X 600_1100 TT Basic 2017

• Quick-stop console actuated • Quick-stop manual operation actuated

© KRONE Training Team, Spelle

4. Operation III – Info area for traction drive 6. Autopilot status display (adjusted when centre scanning is programmed) - Autopilot active, the row tracer left or right is evaluated

4

- Autopilot active, both row tracers are evaluated

1

- Autopilot active, spout side row tracers are evaluated

- Autopilot active, row tracers of side opposite spout being evaluated

3

2

7. Status of lifting unit control - Lifting unit bearing pressure control active

- Lifting unit distance control (ground contour) active

7

6 2 - Lifting unit position control active

8.

66

- ISOBUS autopilot active (GPS steering)

BiG X 600_1100 TT Basic 2017

8 © KRONE Training Team, Spelle

4. Operation IV – Setting and display for work functions The value in the window can be altered using the rotary potentiometer or the keys next to it. The left key (-) reduces the value and the right key (+) increases the value. А. Working width and operating mode The working width setting is needed to calculate the area. This area shows the icon for the selected header and the programmed working width or number of rows.

If the header is not working to full capacity across the entire width, the value in the window must be reduced in order to obtain a correct area measurement. Activating the key on the control lever (Raise lifting unit up to top) causes the system to switch back to the permanently set value.

When using the pick-up, the working width of the rotor rake is set.

The set operating mode is indicated by the header icon:

A

B

C

- Pick-up (grass)

- EasyCollect (maize)

D

X-Disc (whole crop silage)

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+

4. Operation IV – Setting and display for work functions

-

В. Header In field mode and with the release switch intake/header switched on, the header menu area shows the status of the header, the metal detection status, the actual header rotation speed and the setpoint speed.

The header speed can be changed during operation.

A

Status of header Uncoloured icon - header not active, red icon - error, green icon - header OK and active.

B

Header forward inactive/active Header reverse inactive/active Status of metal detection and RockProtect system (optional)

C

Metal detection inactive Error in the metal detection or RockProtect system Error in both systems, metal detection and RockProtect Metal detected in intake

68

D

Rock detected

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

+

4. Operation IV – Setting and display for work functions

-

C. Chop length The chop length is determined by the rotational speed of the intake rollers and the number of blades used. In field mode the chop length menu field shows the current chop length and the status of the“AutoScan” system.

Depending on the number of blades set and installed chopping drum, the chop length can be set between 2.0 mm (minimum) to 58 mm (maximum).

The chop length can be adjusted using the keys (5) – (6) or using the rotary potentiometer.

Two different chop lengths (value 1 / value 2) can be saved and called via the small joystick.

When the “AutoScan” system is active, the icon (S) is coloured green. When AutoScan is active the display indicates the current chop length. The “AutoScan” system is switched off as soon as the chop length is changed manually.

A

B

S

C

D

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+

4. Operation IV – Setting and display for work functions

-

D. Working height In field mode, the working height menu field shows the actual height (I) of the lifting unit in cm and the corresponding preset ground pressure or height (II).

Display for set value (II):

A

- Setpoint ground pressure as percentage of header dead weight.

It is adjustable between -5 % (header sways above the ground) to a maximum of 70 % (header presses on to the ground with 70 % of its dead weight).

- Preset height as a percentage of glide skid sensors control travel with ground contour programmed. Adjustable between min. 10 % and max. 90 % to ensure the header has adequate pendulum travel.

B

- Target height in cm with set lifting unit position control.

The working height can be altered during operation using the keys 7 - 8 or the rotary potentiometer.

The setpoint ground pressure or the setpoint height can also be saved via the control lever.

C

I

D

II 70

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+

4. Operation V – Setting and display for functions, menu access 1.

2.

3.

4.

Gap adjustment corn conditioner Counter menu Menu and status display for silage additives unit. Filling level of additional tank (T).

General Machine Settings menu.

When the “maize” or “XDisc” mode is set, the field (1) shows the current actual value of the corn conditioner gap. The distance is changed via rotary potentiometer.

The respective menus are accessed by pressing the keys (В), (С) or (D). (quick accesses)

1

71

2

3

X

4

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

4. Operation EasyCollect header When using EasyCollect with sensing skids, lifting unit distance control (d) must be selected in “General Machine Settings” menu.

d

Recommendation: Header speed (U) approx. 380 - 420 rpm as basic speed

U

α

EasyCollect header When using EasyCollect without sensing skids, select lifting unit position control (α) in the “General Machine Settings” menu.

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4. Operation Pick-up EasyFlow: When using EasyFlow, select “Lifting unit ground pressure control” (Р) in the “General Machine Settings” menu.

The setpoint value (A) for work with EasyFlow should be between 2030 % depending on the operating conditions.

The header speed (U) must be set according to the chop length or can be operated dynamically at the driving speed.

Recommendation: 400 - 420 rpm as basic speed.

P

Direct cut header XDisc:

U

When using XDisc, select the bearing pressure control (Р) in the “General Machine Settings” menu. In exceptional cases (stony conditions) the machine can be driven in lifting unit position mode (α) .

Setpoint value (А) for operation with XDisc: ~ 5-10% The header speed (U) is set to maximum speed 700 rpm.

A

U

A 73

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© KRONE Training Team, Spelle

4. Operation Joystick memory keys: The keys M1 and M2 of the joystick can be freely configured.

In the supplied condition, the keys M1 and M2 on the joystick are not assigned with functions.

In this case the “Joystick memory keys” settings mask can be selected from the working screen via menu item 1-10 or by pressing button D. The following functions can be assigned to the joystick memory keys:

M1

M2

- Plant divider (only in maize)/raise/lower holding-down clamp (only in grass)

- Increase/reduce working width ± - Retrieve saved chop lengths (from small cross actuating lever) 1 or 2 1/2 - Increase / reduce header speed ± - Rotate pendulum frame left/right

- StreamControl discharge distance adjustment (optional) ±

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4. Operation AutoScan settings

2

(standard)

3

The “AutoScan” system regulates the chop length within an adjustable range dependent on the degree of maturity of the crop being harvested by the EasyCollect. The AutoScan sensor is located in the central tip of the EasyCollect.

10 7

8

9

6

1.

Setting of min./max. chop length

2.

Graphical representation of the settings

3.

Setting degree of maturity sensor available/not available

4.

AutoScan status

4

5

6. at

“AutoScan Setting” menu in the machine settings area 1-2 Currently determined degree of maturity. If the display remains 50 %, valid maturity is not detected by the sensor.

7.

Current chop length

8.

Current position on the characteristic curve in the range of operation

Automatic adjustment of chop length active Manual adjustment of chop length active 5.

1

9.

Min. chop length set by the driver. The associated degree of maturity can be changed in AutoScan expert mode (DEF = 33 %).

Activation of automatic chop length adjustment via “D” key 10. Max. chop length set by the driver. The associated degree of maturity can be changed in AutoScan expert mode (DEF = 67 %).

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4. Operation Settings ConstantPower – Load limit control (optional) The ConstantPower load limit control controls the forward speed of the machine depending on the diesel engine load and provides constant machine load at a lower fuel consumption.

4

Software requirements for ConstantPower: Terminal: KMC3: SmartDrive (Poclain) DRC (Bosch)

1

2

5

min. 150 200 104-08 min. 150 200 103-08 above A16939C (e.g. A22823H, A33789C.H86, ) all software versions

6 3

Activation ConstantPower: Tilt joystick 2x to the right (only possible in field mode) 1.

2.

1750

Speed reduction setting dependent on speed (key “1”) e. g.: 10%  2,000 rpm – 10% = 1,800 rpm Speed reduction setting dependent on load (key “2”) e. g.: 80% 

3.

Setting of min./max. speed.

ConstantPower controls forward speed only until min./max. limits are reached.

4.

Actual engine speed 5.

Actual engine load 6.

Diesel engine rated speed On the BiG X 1100, ConstantPower can only be adjusted depending on rotational speed (1).

Recommended “target speed” - BiG X 700/770/850:1,700–1,750 rpm - BiG X 1100: 1,750 - 1,800 rpm

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4. Operation PowerSplit (optional) BiG X 700/770/850/1100 Eco-Power – X-Power Eco-Power is used where you can manage on less machine performance. If you require more power, switch to X-Power on the BiG X 700, 770, 850 and 1100 at the press of a key (1). Optionally this switch can also be made automatically depending on engine load. This mechanism enables flexibility and reduces diesel consumption. The use of large, powerful forage harvesters is therefore more economical even in weak or highly changeable mowing conditions.

The PowerSplit function can be set via the configuration mask (1-4) on the machine terminal.

1

BiG X 700 / 770 Tri-Power The BiG X 700 and BiG X 770 can also be switched to Tri-Power at the press of a key (1).

On older machines this option can only be activated by KRONE Service.

BiG X 600 The BiG X 600 only has X-Power mode

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4. Operation Various setting options for automatic switching between Eco and X-Power

 Current power mode  Continuous switching (recommendation for maize mode) starts 100 rpm below the preset speed  Switchover here at 1,755 rpm +100 rpm (value adjustable)  Options for setting the power mode active after restarting the machine

 Current power mode  Jump switching (recommendation for grass mode)  Switching here at 1,850 rpm (value adjustable)  Options for setting the power mode active after restarting the machine

 Current power mode  Switching between Eco and X-Power is deactivated. However the switch can still be toggled manually at the press of the key  Options for setting the power mode active after restarting the machine

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4. Operation Auto PowerSplit Example graphical representation of switching response when specified abrupt or steady.

Do not select switching point too low!

Recommendation BiG X 700 / 770 / 850: 1,700 – 1,750 rpm BiG X 1100: 1,750 – 1,800 rpm

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4. Operation RockProtect - Rock detection (optional)

Setting the sensitivity from 0-100% by the driver. Due to different conditions (variable or irregular swath shape), it may be necessary to adjust the sensitivity several times a day. To ensure that the system works properly, the sensitivity must be adjusted to the given conditions. To do this, adjust parameter 27500 according to the graphics.

The default factory setting is 50 %

Sensitivity 0%

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100%

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4. Operation Discharge distance adjustment StreamControl Machines from the 2016 year of manufacture feature an optional discharge distance adjustment. The discharge distance of the crops can be adjusted from the cabin by a swivelling flap on the rear panel. The electric motor (1) is controlled by the M1/M2 momentary switches on the control lever and on the control panel in the side console. The current position of the flap is displayed on the terminal.

The electric motor (1) can set three different positions.

Short / medium / long discharge distance

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1

© KRONE Training Team, Spelle

4. Operation 1. Settings 2. Counters

3. Calibrations

4. Diagnostics 5. Close sub-menu

1-1-22

1-1-25

1-1-26

4-4-4

4-4-5

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4. Operation Relieving the tension on the main belt To rotate the chopping drums manually, on machines with a main belt brake (1) the main drive belt (2) tension must first be relieved. To do so, switch the diesel engine off and operate the two valves (3) in parallel by emergency manual operation until the clamping cylinder (4) has retracted. The hydraulic accumulator (5) must be charged with charge pressure for the purpose. This is done automatically when the diesel engine is briefly started and then switched off again beforehand. When the clamping cylinder (4) has retracted, the chopping drum can be rotated manually to the desired working position and then locked with the locking bolt (6).

1

2

WARNING • Always wear protective gloves when working on the chopping drum.

• Sharp-edged components pose a hazard when working on the chopping drum!

• When working on the chopping drum, always secure it against turning with the locking bolt (6).

5

3 4

6

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4. Operation Brake hydraulics – Manual release of parking brake/machine towing 1.

2.

3.

4.

5.

6.

7.

8.

Connect Minimess line from hand pump to measurement connection on parking brake (1) Reverse the stop cock (2) Pressurise the system by using hand pump Switch off ignition (as a result drive motors have virtually no displacement) Maximum distance: 8 km Maximum speed: (10 km/h) Before removing the connecting hose, open the drain valve on the hand pump to relieve the system pressure.

The function of the brake is restored by removing the connecting hose and turning the lever of the stop cock (3) back to (I) (open). Fit a protective cap on the screw coupling.

2

1

WARNING Uncontrollability of the machine by towing it too quickly For towing the machine, it is necessary for the ignition to be off so that the wheel motors have no displacement. The steering hydraulics are then depressurised. So the machine may only be towed at a speed such that the driver can always control it safely!

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I

3

© KRONE Training Team, Spelle

5. Crop Flow Intake: Design The intake consists of six rollers. The lower roller unit is fixed and the upper roller unit is spring-mounted. The level of the spring force is 4.6 t, which then exerts a pre-compression pressure of 1.6 kg/cm² on the crops. The length of the intake is 820 mm. The upper front (1) and the lower roller (4) are made of stainless steel to enable metal detection. They are equipped with replaceable strips (9). The metal detection is installed in the roller (4).

8 6

5 Pos.

3

2

1

7

The wear strips for the bottom feed roller (10) are available as an accessories kit.

85

4

Designation

1

Intake roller top front

2

Pre-compression roller top middle

3

Pre-compression roller top rear

4

Intake roller bottom front

5

Pre-compression roller bottom middle

6

Flat roller bottom rear

7

Bearing plate lower roller unit

8

Bearing arm upper roller unit

9

Toothed bars (can be rotated for grass/maize)

10

Wear strips (optional at bottom)

BiG X 600_1100 TT Basic 2017

9

10

© KRONE Training Team, Spelle

5. Crop Flow Intake: Design

Pos.

1

Designation

1

Top feed rollers

2

Middle compression roller

3

Rear compression roller

4

Bearing arm upper roller unit

5

Rocker arm left

6

Supporting axle for feed roller

7

Upper roller gearbox

8

Supporting axle for compression roller

9

Supporting axle compression roller

10

Rocker arm right

4 2

3

for

6 7 8

9

middle

10 rear

5

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5. Crop Flow Intake: Metal detection In the magnetic bath (1) there are electric coils (2) which generate a forward-directed magnetic field (3). If a material passes through the magnetic field (3) which causes a change in the magnetic field, a signal is generated and the intake is stopped by the quick-stop function. At the same time the header drive is shut down.

3

3

2

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1

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5. Crop Flow Intake: Bearing for roller unit top left (from BiG X Bosch YOM 2012) The upper rollers are mounted on fixed axles (4) on the left-hand side. The axles are connected with one another by a bearing arm (2) which is guided from behind by a rocker arm (1). Both is then pulled down by tension springs. The bearings are supplied with grease by the central lubrication.

1

2

3 Pos.

Designation

1

Rocker arm left

2

Left bearing arm

3

Radial spherical plain bearing

4

Fixed axle

5

Fixed sleeve

6

Spherical roller bearing

7

Labyrinth seal

88

5

5

5 7

7 6

7 6

4

6 4

BiG X 600_1100 TT Basic 2017

4

© KRONE Training Team, Spelle

5. Crop Flow Intake: Roller gearbox top right (from BiG X Bosch YOM 2012) The upper rollers are mounted on the right-hand side on fixed axles (1). The two front axles are externally attached in the gearbox housing (2) by means of clamping elements (3). The rear axle is mounted in the gearbox and is attached by a profile sleeve (4) in a rocker arm (5) that guides the entire gearbox. The rollers are driven by profile flanges (6) which are inserted in the gearbox.

Pos.

Designation

1

Fixed axles

2

Gearbox housing

3

Clamping element

4

Profile sleeve

5

Rocker arm right

6

Profile flanges

6

6

6

1 5

2 1 3

1

3

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5. Crop Flow Intake: Bearing rear compression roller at top Pos.

Designation

1

Profile sleeve

2

Gearwheel on hollow shaft

3

Grooved ball bearing

90

1 4

4

Radial shaft sealing ring

5

Quad-ring

3

6

Lamellar ring

2

7

Reducing ring with O-ring seal

8

Fixed axle

9

Bushing

10

Cover disc with thread

11

Taper roller bearing

12

Radial shaft sealing ring

13

Labyrinth seal

14

Ring seal

6

8

5

9

14 13

10 11

4

12

7

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Intake: Bearing roller unit bottom right The journals (1) of the lower rollers are mounted via pendulum roller bearing (2) in a bearing plate (3). The bearings are supplied with grease by the central lubrication. The front roller is additionally equipped with a continuous fixed axle (4) to which the metal detection is attached. The shaft sealing rings (5) are installed in a way that allows grease to escape from the bearing, while providing external protection to the bearing against dirt and moisture.

Pos.

91

Designation

1

Journal

2

Spherical roller bearing

3

Bearing plate

4

Fixed axle

5

Shaft sealing rings

6

O-ring seal

7

Clamp on axle for metal detection

1

1

4

3

5

2 2

5

5 6

6

BiG X 600_1100 TT Basic 2017

5

2 6

7

© KRONE Training Team, Spelle

5. Crop Flow Intake: Bearing lower roller gearbox (left)

1

3

2 5 4

Pos.

92

Designation

1

2x taper roller bearings

2

Radial shaft sealing ring

3

O-ring seal

4

Gearbox sealing flange

5

3x fastening screws

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Intake: Intake drive The intake is driven by the hydraulic motor by means of universal shaft on the lower intake roller gearbox (2). From there the force is distributed on to the lower intake and pre-compression rollers and by means of the double joint (BiG X 600/700/770/850/1100) on to the transfer gearbox (3). From the transfer gearbox the drive shaft (4) drives the upper roller gearbox (5) on the right side of the machine. The possibility to infinitely vary the speed of the intake from the cabin enables the chop length to be infinitely adjusted manually or automatically.

3

5 4 6

2 Since YOM 2011, the intakes on the BiG X 600 / 700 / 770 / 850 / 1100 are fitted with a modified drive.

Owing to the new layout of the rear springs, there is a new bottom roller gearbox (2).

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

93

Pos.

1

Designation

1

Input shaft of lower roller gearbox

2

Lower roller gearbox

3

Transfer gearbox

4

Universal shaft

5

Upper roller gearbox

6

Double joint

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Intake: Settings The upper roller unit is pulled down by means of four springs. The springs must be pretensioned equally right and left. When the crops run through the intake, the upper roller unit is lifted against the spring force.

h v

Spring length h = 450 mm

Spring length v = 416 mm

The front springs (v) cannot be adjusted on a BiG X with Bosch traction drive!

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5. Crop Flow Intake: Settings scraper and flat roller

2

The scraper (1) is set at a minimum distance from the flat roller (3) (0 – 0.3 mm).

The distance (A) between the roller shell of the pre-compression roller (2) and the scraper (1) should be uniformly about 3-8 mm on the right and left. The setting is made by spacer plates (6) under the rubber elements.

It is also very important that the setting is not below (D) 24 mm. The scraper (1) should be replaced then at the latest. .

A D 1

Under no circumstances must a collecting edge (5) be created between the scraper (1) and counterblade (4).

This must be checked before every season!

4

6

Fig. Intake unit from YOM 2017

3 1

5 A scraper with a height (D) of 30 mm is factory-fitted. If problems are encountered with a machine (collecting edge), there is a scraper with a height (D) of 335mm.

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5. Crop Flow Chopping drum

WARNING Risk of injury from sharp chopping blades The extremely sharp chopping blades may cause serious injuries!

• Wear suitable gloves when installing chopping blades!

• Secure drum to prevent it from unintentional rotating!

WARNING Risk of injury from improperly attached chopping blades Improperly attached blades and mounting parts may become detached and be uncontrollably ejected at high speed.

• Use original KRONE spare parts only!

• Clean all parts and contact surfaces before assembly!

• Observe tightening torques!

• Whenever a blade is changed, use new blade screws!

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5. Crop Flow Chopping drum - Overview BiG X 600 / 700 / 770 / 850 / 1100

Chopping drum

*

Standard design

BiG X 600 / 700 / 770 = 1,200 rpm BiG X 850 / 1100 = 1,250 rpm

Rotational speed (rpm)

660 / 800

Diameter / width, (mm) Number of blades

20

28

36

*40 / *48

Cutting length range, (mm)

5.0 – 31

4.0 - 22

3.0 – 17

2.5 – 15 / 2.0 - 12

Cuts / min.

12,000 12,500

16,800 17,500

24,000 25,000

30,000

Field of application

Overseas markets use with lucerne Use with grass

Universal use

Universal application and biogas products High throughput despite short chop length due to more cuts / min.

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Biogas products, Cutting length recommendation for optimum machine function: 2 - max. 10 mm. © KRONE Training Team, Spelle

5. Crop Flow Chopping drum – VariLOC VariLOC is a gearbox which is installed in the pulley of the chopping drum.

• Possibility to change the drum speed (1,250 rpm or 800 rpm) in a few minutes using a standard tool (open-end wrench).

• Drum do not need to be replaced and blades must not be repositioned.

• Release when reducing the drum speed (800 rpm) • For use in maize mode Exclusively for MaxFlow drum with 28 and 36 blades and complete number of blades Chopping drum

min. LOC [mm]

max. LOC [mm]

Cutting length range [mm]

MaxFlow 28

4

22

17

MaxFlow 28 with VariLOC

-

30

26

MaxFlow 36

3

17

14

MaxFlow 36 with VariLOC

-

24

21

98

Increase of cutting length range

+53%

+50%

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Chopping drum – VariLOC If you drive with activated VariLOC (1), the machine must be informed via parameter 34025.

Only then is the chop length (2) displayed correctly on the terminal.

The information message 578 “Check switch position of VariLOC gearbox!” appears when the main coupling is switched on and the chopping drum speed does not match the parameter setting or when the grinding process is started and the chopping drum speed does not match the parameter setting.

2 1

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5. Crop Flow Chopping drum – MaxFlow On all BiG X 600, 700, 770, 850, 1100 machines from the 2016 year of manufacture a MaxFlow drum with 28 blades is fitted as standard.

The chopping drum consists of a solid drum pipe (1) with welded-on blade carriers. A special arrangement of the blade carriers means that the blades (2) and the counterblade (3) form a cutting angle of 11°. This causes a cut which is pulled towards the middle, thereby ensuring a perfect chop quality with a low power requirement.

If conditions require different chop lengths, there are drums available with different numbers of blades (20, 28 and 36 blades) to cover these different chop length ranges.

It is also possible to replace half of the blades with so-called blind blades and then move the possible chopping length range.

2

3

11 °

2 1

Number of blades

100

Cutting length range

20

5…31 mm

28

4…22 mm

36

3…17 mm

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Chopping drum - MaxFlow: Installing and setting the chopping blades The retaining screws of the chopping blades (1) must be tightened with a torque of 280 Nm.

2 1

WARNING Risk of injury from improperly attached chopping blades • Whenever a blade is changed, use new screws.

• Sharp tools – risk of injury!

• Always wear gloves when working on the chopping drum.

Easy adjustment of the blades to the counterblade An eccentric bolt can be inserted into two boreholes (2) in the blade supports as an adjustment aid.

The eccentric bolt enables quick and precise adjustment of the blades to the counterblade.

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5. Crop Flow Chopping drum - MaxFlow: Bearing The bearing of the chopping drum is located on both sides in flange bearing housings (1) screwed to the outside of the drum housing. Doublerow spherical roller bearings (2) are used as rolling bearings. The flange-mounted bearing housings are mounted with a slide bush (3) in a frame bearing block which is installed permanently in the frame. These slide bearings form the pivot point of the lifting unit. On the left side the flanged shaft of the drum is longer and protrudes out of the housing where the pulley (4) for driving the drum is fitted.

From the 2016 year of manufacture, the speed sensor (5) for the chopping drum is located in the bearing block on the right as seen in the direction of travel, and no longer on the left as seen in the direction of travel on the pulley (4).

3

2

2

3

4 3

1

5

102

Machine type

Kraftband

600, 700, 770

7-groove

850, 1100

8-groove

2

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Chopping drum – MaxFlow: Readjusting the chopping blade (maize mode) In maize mode it is not essential to adjust the blades. The counterblade adjustment mechanism (1) can be adjusted so as to be able to make full use of the coating (2) without “pulling” the blades.

When new, the coating (2) of a blade is 19 mm thick. (b)

2 b 1

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5. Crop Flow Chopping drum – MaxFlow: Readjusting the chopping blades (grass operation)

Pos.

Designation

1

Blade carrier

2

Blade

3

Screw bar

4

Drum body

F

Feed space

3

1

4

2

b

F

The machine operates with particularly good discharge capacity when the maximum feed space (F) on the chopping drum is used.

To avoid crop flow blockages in grass mode, the blades should be adjusted when the dimension (b) falls below approximately 10-12 mm.

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5. Crop Flow Chopping drum – MaxFlow: Readjusting the chopping blades 1. Grind the blades (1) of the chopping drum.

2. Using the electric motors, by manual operation on the platform, move the counterblade (2) away from the chopping drum on both sides.

3. Align the counterblade (2) parallel to the ground blade backs on the counterblade support.

4. Keep the dimension (a) between the counterblade (2) and the chopping drum (4) to max. 89 mm.

5. Unscrew all hexagon head screws (3).

6. Adjust the blades to the counterblade.

7. Tighten all hexagon head screws (3) with a torque wrench (tightening torque 280 Nm).

8. Loosen the locking (5) of the chopping drum, turn the chopping drum one row of blades further and lock again.

9. Readjust the next row of blades.

10. Continue in this way until all rows of blades on the chopping drum are adjusted evenly.

11. Loosen the locking of the chopping drum.

12. Adjust the grinding stone until there is a gap of about 0.5 mm between blade back and grinding stone.

13. Grind chopping blades.

14. Adjust the counterblade.

WARNING Risk of injury from sharp chopping blades • Sharp tools – risk of injury.

• Always wear gloves when working on the chopping drum.

105

2 a 4

1

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5. Crop Flow Chopping drum – MaxFlow: Replacing the chopping blades To avoid imbalances in the chopping drum, the chopping blades (2) must always be replaced in pairs. The two blades that go together are offset by 180° to each other on the chopping drum. The same applies to the screw bars (3).

If dirty chopping blades are fitted, there is a risk of the chopping blades becoming detached from the chopping drum.

There are left and right blades (2) and left and right side screw bars (3). These must not be mounted incorrectly.

WARNING Risk of injury from improperly attached chopping blades Always wear protective gloves when working on the chopping drum.

Clean all components before installing them.

Whenever a blade is changed, use new screws.

1

1

2

2

Pos.

Designation

1

Blade carrier

2

Blade

3

Screw bar

3

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5. Crop Flow Chopping drum – MaxFlow: Replacing the chopping blades 1. Lock the chopping drum in the desired working position with the locking bolt (1).

2. Fully loosen the hexagon head screws (2) and dismount the blade (3) with the screw bar (4).

3. Clean the screw bar (4) and the contact surface on the blade carrier (5).

4. Insert a new chopping blade (3) with the existing screw bar (4) and hand-tighten with new screws.

5. Align the chopping blade (3) exactly to the counterblade using the eccentric bolt (6).

6. Use a torque wrench (280 Nm) to tighten the chopping blade (3).

1

4 6 2

3

5

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5. Crop Flow Standard chopping drum

2

The chopping drum has a closed body on which the blades are arranged in a V-shape, offset at 11° to the counterblade. The bearing journals (1) are attached to the drum body with screws. The chopping drum is driven via kraftband (2). The composite V-belt pulley and the bearing journal diameter vary depending on the model. The chopping blades (3) are screwed in place by five hexagon head screws which are tightened with 280 Nm.

3

11 °

If conditions require different chop lengths, there are drums available with different numbers of blades (20, 28, 40 and 48 blades) to cover these different chop length ranges.

It is also possible to replace half of the blades with socalled blind blades and then move the possible chopping length range.

1

Number of blades Standard 20

5…31 mm

Standard 28

4…22 mm

Biogas 40

2.5…15 mm

Super Biogas 48

WARNING Risk of injury from improperly attached chopping blades Whenever a blade is changed, use new screws.

108

Cutting length range

2…12 mm

Machine type

Kraftband

600, 700, 770

7-groove

850, 1100

8-groove

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

5. Crop Flow Standard chopping drum: Readjusting chopping blade (maize mode and grass mode) When the remaining coating (b) is only 10-12 mm, the chopping blades should be readjusted.

b

1. Grind the blades of the chopping drum.

2. Using the electric motors, by manual operation on the platform, move the counterblade (3) away from the chopping drum on both sides.

3. Align the counterblade (3) parallel to the ground blade backs on the counterblade support.

4. Keep to dimension between the counterblade (3) and the chopping drum (5) of max. 80-82 mm.

5. Unscrew all hexagon head screws (2).

6. Adjust the blades to the counterblade.

7. Tighten all hexagon head screws (2) with the torque wrench (tightening torque 280 Nm).

8. Loosen the locking of the chopping drum, turn the chopping drum one row of blades further and lock again.

9. Adjust the next row of blades.

10. Continue in this way until all rows of blades on the chopping drum are adjusted evenly.

11. Loosen the locking of the chopping drum.

13. Set grinding stone until there is a gap of 0.5 mm between blade back and grinding stone.

14. Attach the intake housing and fold it in.

15. Grind chopping blades.

16. Adjust the counterblade.

5

2

WARNING Risk of injury from sharp chopping blades Always wear gloves when working on the chopping drum.

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3 BiG X 600_1100 TT Basic 2017

3 © KRONE Training Team, Spelle

5. Crop Flow Standard chopping drum: Replacing the chopping blades To avoid imbalances in the chopping drum, chopping blades must always be replaced in pairs. The two blades that go together are offset by 180° to each other on the chopping drum.

If dirty chopping blade, blade supporting surfaces and pressure plates (4) are screwed on, there is a risk of the chopping blades becoming detached from the chopping drum. Clean all parts before installing them.

1. Unscrew the hexagon head screws (2) and (3).

2. Dismount the chopping blade (1) towards the front.

3. Clean blade mounting surface and pressure plate (4).

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

5. Insert new chopping blade and screw it hand-tight by using new screws on the blade mounting surface and pressure plate (4).

6. Align the chopping blade exactly to the counterblade and tighten with a torque wrench (280 Nm).

WARNING Risk of injury from improperly attached chopping blades • When installing the chopping blades (1), observe the installation direction of the threaded bars (5). The area (a) with the rounded corners must be positioned on the chopping drum (6), the area (b) must be turned away from the chopping drum (6). Mount the wider surface of the threaded bars facing upwards towards the blade carrier!

• Whenever a blade is changed, use new screws.

• For safety reasons, replace the pressure plates (4) with new ones once a year.

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5. Crop Flow Chopping drum - Chopping drum bearing BiG X 700 left (floating bearing)

Pos.

111

Designation

1

Slide ring

2

Retaining ring I 160x4

3

Seal ring protection

4

Shaft sealing ring A 130x160x12

5

Bearing 22216 E

6

Thrust ring 80.1x95.2x15

7

Bearing housing left

8

Shaft sealing ring A 105x130x12

9

Intermediate ring

10

Retaining ring 130x4

11

Flange left

10

9

6

4

3

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5. Crop Flow Chopping drum - Chopping drum bearing BiG X 700 right (fixed bearing)

Pos. 1

Designation Retaining ring 130x4

1

2

Cover Rd. 150x30

3

O-ring seal 130x4

4

Retaining ring A 75x2.5

5

Support disc Rd.85/75x5

6

Spherical roller bearing 22215 E

7

Bearing housing right

8

Shaft sealing ring A 85x110x12

9

Intermediate washer Rd.

2

3

4

5

9

10

7 6 8

109.9/95x3 10

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5. Crop Flow Chopper unit – Turning or replacing counterblade

WARNING Risk of injury from improperly attached counterblade Install the counterblade on the cleaned supporting surface only. The mounting surface must be flat. Rework or replace the mounting surface as necessary. When turning the counterblade, clean its underside.

1. Grind the blades on the chopping drum.

2. Using the electric motors, by manual operation on the platform, move the counterblade (1) away from the chopping drum on both sides.

3. Unscrew hexagon head screws (2), detent edged washers (3) and discs (4).

4. Loosen spring assembly (5) on one side so that the counterblade support is tension-free.

Then retighten the spring assembly again with a torque of 75 Nm. 5. Pull counterblade (1) forwards out of the supports.

6. Clean skid surface area and bottom side of counterblade.

7. Turn counterblade or mount new counterblade.

350 Nm !

!

210 Nm

Mounting new counterblade ! = Loctite (medium-strength 1. Place the new counterblade (6) on the counterblade support and attach hand-tight in the middle at bottom using hexagon head screw (2), detent edged washers (3) and discs (4).

2. Align counterblade (6) parallel to the ground blade backs on the counterblade support (m).

3. Move the electric motors so that the outer hexagon head screws (2) with detent edged washers (3) and discs (4) can be screwed in tension-free through the draw shackle (7). m 4. Tighten all three screw connections of the counterblade with the specified torque (see fig.).

2

7

1

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3

4

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6

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5. Crop Flow Chopper unit – Modified counterblade adjustment from YOM 2014 On all machines from the 2014 year of manufacture, and on the last machines from 2013, a modified counterblade adjustment is fitted.

The bolts (1) form the lower pivot point; the lever (2) is firmly screwed with the counterblade support (3). The adjustment is made via the electric motor unit at the pivot point (4), which moves the threaded piece (5) via a threaded spindle. The threaded piece is mounted so as to be rotatable in the lever (2).

A holding brake (6) pretensioned by disc springs cushions vibration on the complete adjuster unit.

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5. Crop Flow Chopper unit – Counterblade adjustment from YOM 2014 The distance from the blades to the counterblade (7) can be adjusted via anvil (6) on which the counterblade is fastened. The anvil (6) turns in the plain bearings at the pivot point (1). When the momentary switches (9) are pressed, the counterblade is adjusted by means of the adjusting motor units (5). A sensitive and direct adjustment of the counterblade is possible as there are fewer pivot points (1),(3),(4), and two of those pivot points (1),(4) are pre-tensioned via springs (8),(9). The pre-tensioned pivots cause fewer vibrations to occur, which protects the bearings.

The attachment of the anvil is pre-tensioned as before by means of the disc spring assemblies and crown nuts. The pretension is reached if a tightening torque of 65 – 75 Nm is reached on the crown nuts.

9 5

4 Pos.

115

Designation

8

1

Pivot point of anvil

2

Holding brake (no pivot point!)

3

Pivot point of threaded piece on the threaded spindle

SI_150385506Gegenschneidenverstellung_ DE

3

2 7

4

Pivot point of adjusting motor braked

5

Adjusting motor unit

6

Anvil with screwed adjusting lever

7

Counterblade (bolted to anvil)

8

Disc spring for electric motor pretension

9

Anvil disc springs

6 9

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5. Crop Flow Chopper unit – Counterblade adjustment from YOM 2014 Tightening torques: 1. Nut for anvil on chopping drum 65-75 Nm 2. Screw centred in counterblade on anvil 210 Nm 3. Screw outside counterblade on anvil 350 Nm 4. Screw parking brake on chopping drum 85 Nm 5. Screw adjusting lever on anvil 210 Nm 6. Crown nut adjustment unit on chopping drum 40 Nm 7. Gap covering on anvil 49 Nm 8. Adjustment limit on adjusting lever 25 Nm Installation counterblade adjustment To ensure that counterblade adjustment functions properly, it is very important that it is mounted tension-free. To do this, observe the following procedure: 1. First the anvil is mounted and then it is tightened with nuts 1.

2. In the next step, the counterblade is mounted and tightened with the screws at position 2 and 3.

3. Then the adjusting lever is pre-assembled, meaning the adjusting motor unit is connected to the adjusting lever so the lever can then be mounted.

4. Now the screw of the holding brake right + left (4) are tightened with the prescribed torque.

5. Then the screw connections for the adjusting lever on right and left are attached to the anvil (5).

6. Finally the crown nuts of the adjusting motor units are tightened with torque.

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5. Crop Flow Chopper unit – Counterblade adjustment

WARNING Risk of injury from improperly attached chopping blades and counterblade If the blades for the counterblade adjustment from the 2014 year of manufacture (1) are pulled out or completely replaced, the counterblade must be moved down far enough so that the dimension (a) does not exceed the permitted value.

Chopping drum standard dimension a = max. 82mm.

Chopping drum MaxFlow dimension a = max. 89 mm.

a

2 a 4

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5. Crop Flow Chopper unit – General information on setting the chopping blades to the counterblade Dull chopping blades and too great a distance between the chopping blade and the counterblade will result in an unnecessarily high requirement of force, poor chop quality and high wear and tear on the cutting elements.

Sharpening is only beneficial if the counterblade is reset as well. As the maize blades sharpen themselves very effectively, there is no need to “sharpen them until they shine” at every grinding interval. In maize mode it is recommended to readjust only the counterblade several times a day between the grinding processes without having ground it beforehand. In doing so, the sharpness of the blades must be monitored continuously. On grass blades, short grinding intervals with a brief grinding duration and appropriate adjustment of the counterblade are better than long grinding intervals with long grinding times.

1. To relieve the machine, lower the header by actuating the key (1) until it is fully contacting the ground.

1

2. Move maintenance release switch to “ON” position.

The maintenance menu appears on the info centre display.

3. Set the number of grinding cycles in compliance with the above points!

4. The engine speed is automatically adjusted at the start of the grinding process depending on software and setting (number of blades).

Readjusting the counterblade When the grinding process is complete, the counterblade must be re-adjusted while the chopping drum is running.

5. Very briefly press alternately the “Move counterblade right to chopping drum” key and the “Move counterblade left to chopping drum” key.

6. If there is a noise when readjusting one side (right/left) (blades striking the counterblade!), release the key immediately and very briefly press the appropriate key “Move counterblade away from chopping drum”.

7. Readjust the counterblade on the other side using the same procedure.

After the counterblade has been blocked, the chopping drum must run without making any noise.

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5. Crop Flow Chopper unit – General information on setting the chopping blades to the counterblade If the header unit is not completely on the ground in maintenance mode, the driver receives a notification. If the driver confirms the notification yet still grinds the blade and adjusts the counterblade, the notification is entered in the event list (1). The event list (1) cannot be deleted.

1

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5. Crop Flow Chopper unit – Blades and counterblade Blades and counterblade must be adjusted to the requirements and conditions for the particular application.

Grass blade (G)

Strong blade back for optimum resistance to smaller stones

Maize blade (M) edge Blind blade

Flatter blade back for optimum cut and self-sharpening effect of the cutting Blade carrier cover plates (dummy blades) must be used for operation with half the number of chopping blades.

Universal counterblade grass (1)

Coating on the edges without protrusion for maximum resistance even to small stones

Counterblade maize special (2)

Slightly protruding coating on the edges, additional coating of the surface for best cut and maximum service life

Grass universal (HDG 550)

1

120

M

G

Maize special (HDGT)

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5. Crop Flow Chopper unit – Standard chopping drum cutting blades There are two types of blades: (A) – Grass blade and (B) - Maize blade. The shape of the blades is different. Both blades are available in the standard design and in the HD design. The HD blade has a thicker hardening layer, thereby increasing the lifetime. The standard blades are fitted as standard and are better suited for stony conditions. Blades must always be changed in pairs, set at an 180° offset on the drum, so as to avoid imbalance and vibration. To reach longer chop lengths in the grass, it is possible to operate the chopping drum with half the number of blades. The removed blades are replaced by dummy blades (3) and (4) in order to protect the drum body from damage and wear.

“Standard”

1

6

7

“Special“

5

2 4

A

B

3

6 7 5

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5. Crop Flow Chopping blade – The most important factors influencing wear and fuel consumption The influence of the counterblades The counterblade is subjected to the greatest stress during harvesting and is largely responsible for the cutting quality. The different crop and usage conditions result in different wear patterns on the cutting components. These wear patterns form the basis for selecting the most suitable quality and version of the counterblade.

“Smooth surface“ – no significant impacts of foreign bodies.

“Crater-shaped surface” - numerous impacts of foreign bodies and deformations in the surface.  A harder counterblade version would be the wrong choice here!

The influence of the cutting gap setting In addition to the correct assembly of the counterblade, it is extremely important to set the cutting gap between the blade and counterblade precisely, not only for harvesting maize, but also for harvesting grass. The drive must constantly check that the counterblade is perfectly set along its entire length. It has been shown that operating with an wider cutting gap consumes significantly more energy. Simply making continuous adjustments to the cutting gap from time to time will already result in noticeably smooth running and improved cutting quality. Continuously setting the cutting gap is much more important than grinding the blades intensively. At the same time, however, any contact between the chopping blades and the counterblade during operation must be avoided at all costs!

The consequence of the blades coming into contact with the counterblade!

The coating on the reverse will break off due to vibrations!

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5. Crop Flow Chopping blade – The most important factors influencing wear and fuel consumption The influence of the chopping blade – Self-sharpening effect When original counterblades and chopping blades are used for maize harvest, a self-sharpening effect is achieved due to high-quality coatings. This means that the basic material wears out faster than the coating on the cutting edge! The coating forms a sharp cutting edge - the so-called “mouse tooth”! The self-sharpening effect is clearly visible. On original parts, it can be easily felt with your fingernail. Too frequent and too intensive grinding will needlessly grind away the expensive coating and the self-sharpening effect. All too often, the quality advantage, difference in performance and added value of original parts is not exploited due to incorrect handling.

Well-developed “mouth tooth” on the maize blade!

It must look like this!!

The self-sharpening effect is clearly visible on the back of the blade!

Too frequent and too intensive grinding will needlessly grind away the expensive coating and the self-sharpening effect!!

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5. Crop Flow Chopper unit – Drum base On the BiG X 600 / 700 / 770 / 850 / 1100 machines of the 2011 year of manufacture the springs of the drum base have been rearranged.

The default setting (distance from blade to drum base = 6 mm) as well as the setting dimension of the springs (46 mm) remains unaffected (refer to the previous page).

6mm

With these drum bases a husk comb can also be screwed directly on to the drum base.

VariStream_1

Holes for screwing on the husk comb

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5. Crop Flow Chopper unit – Grinding stone unit The blades are ground by a cylindrical grinding stone, which moves horizontally back and forth across the drum as it rotates forwards. The grinding stone is held in the grinding slide by a clamping device (1). This clamping device is located in a threaded sleeve (2). The height of the grinding stone is set using this threaded sleeve. The grinding slide is moved by a synchronized hydraulic cylinder (3). For each grinding cycle, the adjusting ratchet (4) turns the star wheel (5) by one tooth and the grinding stone is moved a little further towards the drum. An adjustment ratchet can be mounted on both sides as an option.

The visible thread length of the threaded sleeve (A) should be at least 5 mm. If necessary, readjust the grinding stone.

SI_150388056

6 4 9

The grinding flap (9) is opened as soon as the maintenance switch is turned on. Otherwise, it is closed via a hydraulic cylinder (6). When the diesel engine is switched off, the grinding flap always opens. The throttle check valves (7) next to the valve block are used to set the speed of the synchronised cylinder (3).

The grinding slide is guided at the rear with a fixed bearing on a rail. From the 2012 year of manufacture, a spring-loaded fixed bearing (8) is additionally installed from the top.

8

5

A 7

The speed of the grinding stone should be set so that the grinding stone takes approx. 8 sec. to move from one side to the other. Based on experience, we also recommend using an adjustment ratchet (4).

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5. Crop Flow Chopper unit - grinding stone design

1

Grinding stone

2

Threaded sleeve

3

Clamping ring

5

4

Intermediate ring

4

5

Support disc

6

Sleeve

7

Gearwheel (z = 36)

6

max.

Designation

100 mm

Md = 180+10 Nm

Pos.

6 2

1

5

5 1

3 4 Note the position of the bevelled edges!

Bevelled edge faces down!

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5. Crop Flow Replacing/resetting grinding stone The grinding stone must be replaced as soon as dimension “X” exceeds 100 mm!

To do this, loosen pawl (9) first and turn the detent pin (8) by 90° to let it engage later on.

Unscrew the adjustment wheel (7) together with threaded sleeve (2) until the detent pin engages in the threaded sleeve. Unscrew the adjustment wheel from the threaded sleeve.

The clamping of the grinding stone is thus released. Set the new grinding stone to a distance of 3 mm to the blades using a suitable tool. When installing a new grinding stone, mind the correct position of clamping rings, thrust rings and intermediate rings. After adjusting (resetting) a grinding stone which has already been used, check dimension “X”. The adjustment wheel (7) is tightened to 180+10 Nm. Pull detent pin and rotate it by 90° (parking position). Fasten the pawl (9) again and close the grinding device side guard.

Reset grinding cycle counter!

3 2

x

WARNING Risk of injury from improperly attached grinding stone After adjusting or replacing the grinding stone, always retighten the grinding stone with 180 Nm after the first grinding cycle.

1

127

Pos.

Designation

1

Detent pin

2

Pawl

3

Gearwheel (Z = 36)

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5. Crop Flow There are 2 different clamping ring versions. If the machine is fitted with an adjustment ratchet (1), you should fit transparent/light brown (2) clamping rings.

If the relevant machine is equipped with two adjustment ratchets (1), you should fit black clamping rings (3) (softer).

On machines from the 2015 year of manufacture, the colour of the clamping rings has changed (2) from transparent/light brown to dark brown (5).

WARNING

1

Risk of injury from improperly attached grinding stone After you have adjusted or replaced the grinding stone, you must always retighten the grinding stone with 180 Nm after the first grinding cycle.

The intermediate ring (4) is not fitted in every machine.

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5. Crop Flow Chopper unit - General information Blade sharpening does not do any good unless the counterblade is readjusted afterwards.

Grass blades: Short grinding intervals, grinding briefly each time, and with appropriate adjustment of the counterblade, are better than long grinding intervals followed by lengthy grinding!

Maize blades: As the maize blades have a highly efficient selfsharpening function, it is not necessary to 'grind' them fully at every grinding interval.

WARNING Risk of injury due to flying sparks Do not grind blades with the intake removed.

Correct and precise setting of the counterblade is important for optimal utilisation of the self-sharpening effect of the blades.

Please follow the instructions on the following pages precisely!

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5. Crop Flow Chopper unit – Removal The chopper unit can be removed on the wagon (1) manufactured for this purpose. The trailer features an integrated height adjuster (2).

For the post-harvest inspection and to ensure optimum cleaning of the machine, the chopper unit should be removed.

The chopping drum mounting trailer is available as an option for the machine.

2 1

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5. Crop Flow Corn conditioner – Design and drive

L

The operating units are designed as serrated rollers. The rollers are mounted by means of pendulum roller bearings (L) and rotate to each other at different speeds. The bearing housings of the rear roller (3) on the right and left are firmly mounted and have a fixed installation position.

The bearing housing (4) of the front rollers swivel around the axle (X) and are held in the working position by means of the springs (5) and the wedge (6). Therefore the distance between the rollers can be adjusted by moving the wedge (6). The adjustment is made from the cabin by the lever (8) and the electric motor (7).

From the 2011 year of manufacture, the BiG X 600/700/770/850/1100 machines are fitted with lubricatable deflection rolls on the corn conditioner.

X 4

8 3

6

1 5

2 7 9 1

2

131

The corn conditioner is driven by a 6-groove kraftband which is tensioned by a hydraulic cylinder. The speed difference of the rollers is 20% as standard. Optionally the speed difference can be increased to 30% or 40%.

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5. Crop Flow Corn conditioner – Bearing right (floating bearing) Pos.

Designation

1

Retaining ring 110x4

2

Support disc S 90x110x3.5

3

Shim ring 90x110x0.1

11

10

9

6

4

3

2

1

9 8

Shim ring 90x110x0.5 4

O-ring seal 110x3

5

Ring Rd. 120x23

6

Shaft sealing ring B2 SL

5 7

80x10/12

132

7

Bearing 22212 ES

8

Bearing housing right

9

Retaining ring I 100x3

10

Shaft sealing ring BA 70x100x10

11

Supporting disc S 80x100x3.5

12

Roller

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5. Crop Flow Corn conditioner – Bearing left (fixed bearing) Pos.

Designation

1

Retaining ring 110x4

2

Support disc S 90x110x3.5

3

Shim ring 90x110x0.1

1

2

3

5

6

7

Shim ring 90x110x0.5 4

Cover lh. Rd. 120x23

5

O-ring seal 110x3

6

Retaining ring A 60x2

7

Support disc S 60x75x3

8

Shim ring 60x75x0.3

8 10

11 13

11

12

4 9

Shim ring 60x75x0.5

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9

Bearing 22212 ES

10

Bearing housing left

11

Retaining ring I 100x3

12

Shaft sealing ring BA 70x100x10

13

Support disc S 80x100x3.5

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5. Crop Flow Corn conditioner - accessories kit: Differential speeds To optimise corn conditioning in the corn conditioner, it is possible to increase the speed difference of the rollers. Three differential speed variants are possible. They are set by replacing the drive pulleys and are available for all toothed roller shells. 20% differential speed is the standard version.

Deflection roll (1)

Speed difference

Ø mm 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

S 3

2 20020768.0

20020767.0

1

A

Spare parts numbers marked in blue refer to corn conditioners with lubricatable deflection rolls. Before converting, check carefully whether the deflection roll can be lubricated or not!

If is found after converting to another differential speed that the belt is catching in area (A), or the path of the clamping cylinder (S) is not adequate to tension the belt, the deflection roll (1) can be replaced by a deflection roll with diameter 204 mm.

The distance of the belt at the narrowest point (A) must be at least 6 mm!

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5. Crop Flow Corn conditioner rollers

1

The rollers are made from 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 chrome-plated 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.

1. Rollers with 123 teeth: Optimum equipment for maize silage with a chop length of more than 18 mm. This ensures maximum throughput allied to optimum grain working and long chop lengths. These rollers are usually used in combination with the 20-chopping drum. A roller with chrome plating and a saw tooth profile is optionally available.

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

3. Rollers with 166 teeth: Fine toothing with saw tooth profile are very well suited for grain whole crop silage.

Small grains are reliably worked as a result. The rollers should be used in conjunction with 28, 40 or 48 blade drums.

4. Disc rollers: 4 On account of its V-shaped friction gaps the disc conditioner has a friction surface 2.3 times larger 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.

1.

5

2.

3.

Roller Z = 123 “standard” straight teeth Roller Z = 123 HD, saw tooth profile Roller Z = 144 “standard” straight teeth Roller Z = 144 HD, saw tooth profile Roller Z = 166 saw tooth profile New for chop lengths from 20mm. Rollers with 105 teeth

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2

3

5. Crop Flow Corn conditioner – Basic setting

A

If the corn conditioner is dismantled, the minimum gap between the rollers must be set subsequently. Furthermore the minimum distance may have to be readjusted if the rollers are worn. The minimum distance of the rollers should be set by turning the turnbuckle (2).

In this process, the lever (3) must be positioned 12 mm in front of its mechanical stop (A) (housing). The minimum distance (X) of the rollers should now be 0.5 mm (roller-CC) or 3 mm (disc-CC) (set, if necessary). The two hexagonal nuts (4) represent the mechanical safety stop to prevent the rollers coming into contact with one another in the event of incorrect calibration.

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

3

2

4

1

Y X= 3mm

X Distance (X) with mechanical limit = 0.5 mm Dimension Y = 93 mm

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5. Crop Flow Corn conditioner – Corn conditioner motor for adjusting the gap

Parameter 33607 (service): 1

1

Dunker motor

137

Engine type

Corn conditioner version

Wedge (1)

Pulses per 0.1 mm (parameter 33600)

Valeo (old type)

Roller conditioner, standard

219 297 2

33

Dunker

Roller conditioner, standard

219 297 2

58

Valeo (old type)

Roller conditioner, reinforced springs

20 029 728 0

39

Dunker

Roller conditioner, reinforced springs

20 029 728 0

69

Dunker

Disc conditioner

20 029 201 0

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5. Crop Flow Corn conditioner – General information On account of the different adjustment kinematics between the roller conditioner and disc conditioner, the conditioner type is specified by a parameter setting on the terminal. The disc conditioner housing is different compared to a roller conditioner housing.

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

4

Y 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 fit-in key (F). An Oring seal between the segments (R) prevents the ingress of silage effluent. Individual discs can be replaced if damaged or highly worn. If all disc segments have to be replaced, the housing, the shafts etc. can be reused. When fitting the discs, ensure that the direction of rotation is correct!

A

2

3

R Direction of rotation (identical for all discs!)

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S

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5. Crop Flow Corn conditioner – Assembly/setting Installation of adjustable shaft The adjustable disc shaft must be completely installed, i.e. the shaft with the pre-assembled bearing housings (1) is attached to the housing via the pivot bolts (2). The couplers (8) must also be installed, however without a spring for the time being.

1. Installation of fixed shaft The fixed disc shaft must be installed with the completely installed bearing housings (4) in the housing. Tighten the fastening nuts on the bearing housings only until they make contact but do not yet tighten them firmly.

2. Axial alignment of the fixed shaft The fixed shaft can be moved in the oblong holes. This is necessary to set an equal distance between the disc elements. After that, the screws on the fixed bearing side must be tightened completely.

3. Alignment floating bearing of fixed shaft To ensure that the position of the bearing housing for the floating bearing is in line with the shaft, the bearing housing must be aligned. In doing so, a dimension of 95 +/-2 mm from shaft end to bearing cover must be set. Now the floating bearing housing can be screwed on the corn conditioner housing.

4. Parallel alignment of the disc shafts to each other The distance between the rollers must be set the same as for the corn conditioner with rollers using the adjusting levers (5), the coupling rods (6) and the wedge (7). In this process, the distance between adjusting lever (5) and housing must be set at point A to 15 mm. The distance between the rollers must be 3 mm at the tip. The spring dimension Y must be 92 mm (spring length only).

5. Setting the mechanical minimum distance Finally the mechanical stop for the minimum distance must be set via both nuts (8). To do this, screw one nut against the housing and then lock with the other nut.

1

8 7

Y

A

4

2

95 ±2 mm

6

5

3 mm

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5. Crop Flow Conversion corn conditioner – Grass channel In grass mode the corn conditioner is removed and replaced by the grass channel (1). When removing the corn conditioner using the electric cable winch and deflection roll (3), the corn conditioner is placed on the wagon (2) supplied.

Before removal, the cable must be disconnected from the adjusting motor (6) and the central lubrication line (5). The procedure is detailed in the operating instructions.

5

2

6

BA_7.5.7 Umbau Graskanal_Corn conditioner_DE

3 1 4

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5. Crop Flow Discharge accelerator The function of the discharge accelerator is to accelerate the crops from corn conditioner or the chopping drum and to convey the crops into the spout. The diameter of the discharge accelerator is 560 mm. At a speed of 2,188 rpm, we obtain a theoretical crop flow rate of 64 m/s. The discharge accelerator is mounted on spherical roller bearings. The rear wall is springmounted and it is able to prevent large forage masses.

4

2 F

(F) – Direction of travel (3) – Pendulum roller bearing fixed (4) – Pendulum roller bearing floating (5) – Rear wall (6) – Suspension of rear wall

1

6 3

5

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5. Crop Flow Discharge accelerator - right bearing (floating bearing) Pos.

142

Designation

1

Screw M 20x1.5x70

2

Cap

3

Clamping ring

4

Fit-in key A 18x11x70

5

Pulley Rd. 300

6

Clamping ring

7

Race

8

Cover

9

Shaft sealing ring AS 70x100x10

10

Spherical roller bearing 22312 U 15-VS

11

Bearing housing right

12

Shaft sealing ring A 80x110x10

13

Cover

14

Race

14 13 12 11 10

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8

7

6

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4

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2

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1

5. Crop Flow Discharge accelerator - left bearing (fixed bearing) Pos.

Designation

1

Screw M 20x1.5x70

2

Cap

3

Clamping ring

4

Pulley Rd. 268

5

Fit-in key A 18x11x110

6

Clamping ring

7

Shim ring 60x75x2.0

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15

Shim ring 60x75x1.0

143

8

Race 60x70x27.5

9

Shaft sealing ring AS 70x110x10

10

Cover

11

Spherical roller bearing 22312 U 15

12

Shaft sealing ring A 80x110x10

13

Supporting ring

14

Race

15

Bearing housing left

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5. Crop Flow Discharge accelerator – Discharge distance adjustment StreamControl Short discharge distance: The crop has little contact with the paddles of the discharge accelerator  Normal chopping process, forage transport wagon runs adjacent to the forage harvester.

Low power requirement on discharge accelerator = higher throughput Medium / long discharge distance: The crops have more contact or is in full contact with the paddles of the discharge accelerator  Harvesting, forage transport wagon runs behind forage harvester. High discharge capacity for easy filling of the trailer.

Short discharge distance

144

Medium / long discharge distance

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5. Crop Flow Discharge accelerator – Rear wall setting for VariStream

K

Grass mode

R

G

W

1. Adjust the rear wall (R) top using the rubber buffers (G) so that there is a 15 mm jump edge (S) between the rear wall (R) and channel support (K).

2. Set the gap (A) from the rear wall (R) to the discharge scoops (W) to 2-3 mm using stop screws on the grass channel.

3. The tension rods of the spring must be adjusted so that there is a maximum spring path of 10 - 12 mm via the step in the drawbar. As a result, there should be no collecting edge even when the rear wall is fully deflected.

4. Finally, to rule out faults manually pull back the rear wall all the way again and ensure that there is no collecting edge.

A

S

10mm Setting screw grass channel This crop flow variant can be recognized by the quick release fasteners on the side of the rear wall of the discharge accelerator.

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5. Crop Flow Discharge accelerator – Rear wall setting for VariStream Maize mode 1. Using the setting screw on the corn conditioner, set a gap of 60 mm between the corn conditioner screw link and discharge accelerator housing.

2. Set the gap (A) from the rear wall (R) to the discharge scoops (W) to 4-6 mm using the rubber buffer (G).

3. Set the tension rods of the springs so that the rear wall can be pulled far enough back so that there is no collecting edge (max. 10 mm) between the rear wall and channel support.

4. Finally, to rule out faults manually pull back the rear wall all the way again and ensure that there is no collecting edge.

60 mm

Setting screw corn conditioner

R Channel support

G

W

Rubber buffer

A Rear wall 10mm

If a higher discharge capacity is required, the distance (A) between the discharge scoops (W) and the rear wall (R) can be reduced up to 2 mm.

If HD wear plates are used on the rear wall, it may be necessary to install an additional distance sheet between the rear wall and the wear plate (20 221 005 0).

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5. Crop Flow Spout – Rotation The spout can be rotated through 210° by the hydraulic motor (1). The speed sensor in the gearbox indicates the position of the spout. Two proximity switches monitor the centring and top/bottom positioning of the spout.

Automatic function of the spout: • At end position: Switch off drive • Reverse spout • Automatically lower the spout to transport position

1

Spout – Start-up safety mechanism BiG X 600, 700, 850, 1100 The spout is fitted with a start-up safety mechanism. The spring assembly holder (3) is connected to a bearing ring by screws (4). The spring hanger (7) is screwed on the slewing ring (5) by means of the screws (6). The disc spring package (8) pushes the cam (9) into the spring hanger (7) and thus represents a connection between drive and spout. If the spout encounters an obstacle, the spring-operated cam is pushed back and the connection is broken. The spout is able to swing freely.

7 X

Setting for start-up safety mechanism spring assembly (8): X = 70 +3 mm.

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6

5

3 8

4

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5. Crop Flow Spout – Start-up safety mechanism from BiG X 600-2, 700-2, 770-2, 850-2, 1100-2 The start-up safety mechanism functions via a spring-loaded roll (1) which is permanently connected to the two internal plates (2) and (3). The counterpiece to this is a moulded part (4) which is connected to the spur ring (5).

Setting start-up safety mechanism To have the appropriate release force, the spring (6) must be set to a length (X). It is also important that there is always a small gap (0.5 mm) between the washer (7) and the block (8) to ensure that the spring force is supported above by the roll and not below by the screw head.

2

1

X

3

5 6

4

7 8 148

Spout version

Setting dimension (X)

Standard

124 mm

10- and 12-row extension

121 mm

14-row extension

118 mm

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5. Crop Flow Spout – Versions BiG X 600-2, 700-2, 770-2, 850-2, 1100-2 Spout The spout consists of a standard base (1) which can be extended with different end pieces. Rigid (2) and hydraulic hinged end pieces are available (3) for the end pieces.

The base is available in standard and HD variants. The HD variant differs in that it has a back plate (4) and a deflector plate (5), both made of a higher-grade material.

4

3

5

2

149

1

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5. Crop Flow Recommendation and possibilities for long cut Method of chopping maize at which the cutting length is increased.

Present BiG X machines with chopping drum with 40 blades and corn conditioner with 144 teeth: • Chopping drum with half set of blades: Cutting length range 5-29 mm • Corn conditioner use up to a cutting length of max. 15 mmstrong springs (1) as an option and flat wedges (2) as a repair kit • Order number spare parts storage: 200241071 Speed change on corn conditioner from 20 % to 30 % • Order number spare parts storage: 200271460 deflection roll • Order number spare parts storage: 200207670 Pulley roller front

1 Present BiG X with a chopping drum with 28 blades and corn conditioner with 144 teeth: • Chopping drum with full or half set of bladesCutting length full set of blades: 4-21mm Cutting length half set of blades: 8-42mm • Corn conditioner use up to a cutting length of max. 15 mmstrong springs (1) as an option and flat wedges (2) as a repair kit • Order number spare parts storage: 200241071 2 Speed change on corn conditioner from 20 % to 30 % • Order number spare parts storage: 200271460 deflection roll • Order number spare parts storage: 200207670 Pulley roller front

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5. Crop Flow Recommendation long cut To guarantee optimum harvest results for the long-cut method, KRONE recommends using the following chopper units and corn conditioners

Chopper unit with 20 or 28 maize blades and corn conditioner with 105/123 teeth HD, speed difference of 30%, saw tooth profile/or for premium conditioning corn conditioner with discs • Chopping drum with 20 blades: Cutting length range 5-29 mm Order number spare parts storage: 204211251 • Chopping drum with 28 blades: Cutting length range 4-22mm Order number spare parts storage: 204211261 • Corn conditioner 105/123 teeth HD, speed difference 30%, saw tooth profile, use for cutting lengths >15mm Order number spare parts storage: 204250970 • Corn conditioner with discs for 2.5x larger friction surface in order to cover all applications Order number spare part storage: 202202442 For forage harvesters which are already fitted with a MaxFlow chopping drum with 28 or 36 blades, it is possible to install a VariLOC pulley gearbox in order to extend the cutting length range.

• VariLOC pulley gearbox (exclusively for MaxFlow chopping drum with 28 and 36 blades) Order number spare parts storage: 204251570

MaxFlow drum with 20 or 28 blades Corn conditioner 105/123 HD Incl. speed difference of 30 % 151

Corn conditioner with discs

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Pulley gearbox VariLOC

© KRONE Training Team, Spelle

5. Crop Flow Recommendation long cut

1 2 3 4 5 6 7

7

At a speed difference of 30% and high throughput rate (BiG X 850, 1100), the 6-groove belt drive of the corn conditioner may be heavily loaded. Therefore it is recommended to retrofit a 7-groove belt drive (7).

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6. Field Operation Maintenance openings crop flow For maintenance purposes or for eliminating crop blockages there are different access options which are easy and quick to open.

WARNING Risk of injury from sharp chopping blades SI_150461043 KRONE makes chopper safer

The extremely sharp chopping blades may cause serious injuries!

• Wear suitable gloves when installing chopping blades!

• Secure component to prevent it from unintentionally rotating!

DANGER Risk of injury from coasting components!

Even when the drives or the diesel engine have been switched off, parts may still be moving in the crop flow. Rotating parts are occasionally difficult to detect.

• Never work on the crop flow while the machine is running!

• After switching off the diesel engine, wait and ensure that all components have stopped before working on the crop flow!

• Never start the diesel engine until all maintenance openings have been properly closed!

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6. Field Operation Overview settings grass operation

RockProtect Sensitivity

Drum Number of blades

Silage additives unit Automatic mode

Rotational speed EasyFlow 400-450 rpm

Rear wall accelerator Distance 2-4 StreamControl

of

discharge mm

and

Drum base Distance 6 mm

Lifting unit Bearing pressure control (P mode) 20-30 %

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6. Field Operation Overview of settings for whole crop silage mode

RockProtect Sensitivity

Silage additives unit Automatic mode

Drum Number of blades

Rotational speed XDisc 700 rpm

Rear wall of accelerator

discharge

Distance 2-4 StreamControl

mm

and

Drum base Distance 6 mm

Lifting unit Bearing mode) 5-10 %

155

pressure

control

(P

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6. Field Operation Overview settings maize operation Silage unit

additives

Automatic mode

Activation AutoScan

Drum Number of blades

Rotational EasyCollect 380-420 rpm

Rear wall of accelerator

discharge

Distance 2-4 StreamControl

mm

and

Drum base Distance 6 mm

156

Lifting unit Distance control (d) mode 1090 %

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speed

7. Hydraulics Brake and working hydraulics circuit – Pressure supply Pos.

4

Designation

1

Triple pump

2

High-pressure filter

3

Pressure limiting valve (p = 240 bar)

4

Accumulator charging valve

3 1

2

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7. Hydraulics Brake and working hydraulics - Component overview Pos.

8

1

Accumulator charging valve

2

Hydraulic accumulator parking brake and service

brake 3

Hydraulic accumulator lifting unit (vibration damping)

4

Working hydraulics valve block (with oil circulation function)

5

LUC (electronic lifting unit control)

6

2/2 directional seat valves pendulum frame

7

Lifting unit accumulator connection block

8

Gearbox for rotating the spout

9

Service brake valve and measurement connection

10

Wheel motor with integrated brake

11

Grinding device cylinder

12

Pendulum frame cylinder

5 9

4

7

6

11

10 1 158

2

3

Designation

12 BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

7. Hydraulics Working hydraulics – Control block Bosch SB12 Pos.

Designation

OEI

01

LUC -Valve

Y32/Y33

02

Intermediate plate with PLV and ext. LS

03

Autopilot

Y39/Y40

04

Grinding device

Y31/Y30

05

Pendulum frame

Y37/Y38

06

EF: Guide wheels EC: Plant divider

Y28/Y29

07

EF: Holding-down clampY26/Y27 EC: Folding

08

Lift/lower spout

Y24/Y25

09

Spout-Flap

Y22/Y23

10

Rotate spout

Y20/Y21

10

11

Intermediate plate with shuttle valve*

11

12

Input plate

12

*Component was modified or added for 2014 year of manufacture.

Valve blocks from spare parts have the same status as from 2014.

External LS line for raising lifting unit*

1 1

2 6

2 3 4

5

3 7

6

4 7

8

8

9 10

5 9

11 12 Return line “T” Intake “P” 159

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7. Hydraulics Working hydraulics – Valve block

Individual pressure balances Pressure limiting valve: 230 bar

WHB_4.4 Ventilblock Arbeitshydraulik_DE

From the 2014 year of manufacture, an external LS line is installed for the lifting unit to guarantee reliable functionality of the lifting unit.

Valve blocks from spare parts storage have the same status from 2014.

LS PLV: 210 bar 160

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7. Hydraulics Spout – Throttle valves for adjusting speed

Raise spout flap Lower spout flap

Lift/lower spout

Grinding cylinder off Grinding cylinder on

2/2 directional seat valves to lock the pendulum frame

Actuation of both seat valves always parallel to the main valve in the valve block!

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7. Hydraulics Working hydraulics - Valve block connection plate

4

3

1 2 M M

3

4 (1) Spring LS pressure (3 bar) (2) Control line (LS) (3) Pressure limiting valve LS pressure (4) Pressure balance

1 162

Bosch_Reparaturanleitung

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7. Hydraulics Working hydraulics – 5/3 directional valve plate valve block

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

2 3

(1)

Magnetic coil

(2)

Return spring

(3)

Valve slide

1

The slides are paired with the plate during production. Therefore, it is not permitted to replace valve slides among different valves!

Emergency manual operation: Each valve can be actuated manually.

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7. Hydraulics Working hydraulics – Valve block: Intermediate plate with PLV

Up to YOM 2013

From YOM 2014 on In addition to this pressure limiting valve, there is an additional pressure limiting valve directly on the gearwheel pump.

Accordingly, if the maximum pressure is not reached in the working hydraulics, the cause may not be the pump but one of these two pressure limiting valves.

Also the LS pressure limiting valve in the inlet plate must be considered!

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7. Hydraulics Working Hydraulics – Checking the maximum pressure in the work hydraulics Initially the lifting unit/header must be placed completely on the ground. Close both stop cocks on the lifting cylinders. Switch on the road/field release switch and leave diesel engine idling. Actuate the joystick key for “Raise lifting unit manually”. The pressure of p = 200 / 210 bar can now be measured on the following connections.

Alternatively for all machines: Pressure measurement on the plug-in connectors for the pendulum frame cylinder or for header

Measurement connection in the lift line (after lifting unit control), if fitted (since 2008, series since 2009)

Measurement connection at the valve block input (before lifting unit control), if fitted (since 2008, series since 2009) Additional LS measurement connection (from series 2014)

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8. Electrics/Electronics Circuit diagram - Table of contents

Contents You can see from the table of contents which functions are illustrated on the particular circuit diagram page and where the components are.

In the appendix, you can find labels for some components that are designed to help identify components more quickly and easily.

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8. Electrics/Electronics Layout of circuit diagram The circuit diagram is displayed on several pages. Each page is named and numbered according to its function.

To make it easier to identify parts etc. on the circuit diagram, each page is split into a grid. This grid is also used for cross references, which indicate the point in the circuit diagram at which an interrupted circuit path is continued.

1. Designation of the circuit diagram 2. Designation of sheet according to function 3. Current page number 4. Total number of pages of circuit diagram 5. Circuit path

167

D6

D7

D8

E6

E7

E8

F6

F7

F8

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8. Electrics/Electronics 1 Coloured field To better clarify the assignment of the individual switching parts of the different colours have been used.

For example on the hydraulic diagram: 1. Green – cabin circuit board (A4) 2. Yellow - cabin 3. Grey - roof panel 4. Turquoise – steering column (A18)

3

2

1

4 168

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8. Electrics/Electronics Cancellation arrow (1) This arrow indicates that the electrical potential is continued on another page.

The figure placed adjacent to the tip of the arrow identifies the page number (before the dot) and the circuit path (behind the dot) where the potential leads to. Example: Page 109, circuit path 1 Potential designation (name) (2) This provides the cancellation arrow with a “name” that can also be found on the referenced page. In some cases there are also standardised short designations which are used here as follows: 15: Ignition stage 2 (+12 V switched) 30: Permanent positive (+12 V) 31: Ground 49: Input flash encoder 49a: Output flash encoder 50: Starting up 54: Brake light 56a: Full beam, full beam control 56b: Dipped beam 58: Background lighting 58R: Side marker lamp right 58L: Side marker lamp left 61: Charge indicator C2: Flash encoder 2.

Warning light R: Direction indicator lamp right L: Direction indicator lamp left 75: Ignition stage 1 (+12 V 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 hydraulic diagram. Example: Yellow wire with black label PLD1 15 Wire colours BX 500/650/800/1000: Power supply CAN high Signal line / switch circuit CAN low Ground (white) 169

1

2

3

Wire designation BX 600/700/770/850/1100: RT = red  Power supply BL = blue  CAN high GE = yellow  Signal line/switch circuit GN = green  CAN low WS = white  ground

BiG X 600_1100 TT Basic 2017

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8. Electrics/Electronics 11. Plug number

X...

Contact number

Plug

1X... SmartDrive (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... LUC (A 9)

a – Pin contact b - Socket contact

11X... Manual operation (A 11) 14X... Terminal (A14) 15X... Joystick (A 15)

One plug is designated with X. The number before the x describes the affiliation with the component, the number behind – the affiliation with a part or the number of the plug. The small letter "a" indicates male contacts and "b" indicates female contacts. The single number 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 parts which could be transferred from the “old” generation of machines, as they are identical in design but are labelled according to the “old” system.

16X... CUC (A 16) 17X... Potential distributor circuit board (A 17)

B49 - Part

19X... EasyControl (A 19) 20X... Console (A 20) 22X... Console relay circuit board (A 22) 170

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8. Electrics/Electronics KMC 4

Sensors Actuators

A35

~150Ω

Keys

120Ω

A37 A10

LED

A40

A11

Option

A1

Sensors

120Ω

120Ω

CAN 2

Sensors

KMC 2

Actuators

Actuators A2

DRC/SmartDrive

120Ω

A6

Actuators

Sensors

switched!

KMC 3

Actuators

DIOM LUC

A5

Sensors Actuators

A3 120Ω

Autopilot

CAN 1

CAN 3

A9

Joystick

120Ω

A15 MFR (MAN), ADM 2 (MB)

Switch

171

Actuators EDC (MAN), PLD (MB)

CAN MB, CUC

Actuators

Sensors

A16

A14

A7

BiG X 600_1100 TT Basic 2017

CAN MAN

A8 © KRONE Training Team, Spelle

8. Electrics/Electronics Console BiG X 700, 850, 1100 (Poclain traction drive)

A14

A16

A22

A17

A1 A3 A2 A6

A5 A7

For part designations, see circuit diagram!

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8. Electrics/Electronics Console BiG X 600, 700, 770, 850, 1100 (Bosch traction drive)

A14

A16

A17

A5

A22 A3

A2

A2 A3

A6

A7

A1

A19

For part designations, see circuit diagram!

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8. Electrics/Electronics Realy circuit board console The relay circuit board (A22) includes fuses for work functions (supply voltages of job computers).

The GAL logic module (G) integrated on the circuit board controls the activation of the individual supply voltages (see circuit diagram)

A22

A4

G

A22

Cabin circuit board Relay circuit board

174

Relais circuit board cabin The cabin circuit board (A4) protects among other things the “vehicle” electronics (light, wiper, brake light ...)

The fuses for ignition stage 1 and ignition stage 2 are also located on the cabin circuit board.

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

8. Electrics/Electronics Potential distributor circuit board Tasks: Grouping of power supplies and ground cables from sensors and valves in the machine, as well as grouping of the ground cables for the supply voltages of the job computers.

A17

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8. Electrics/Electronics CANBUS – Diagnostics on the terminal Controller Area Network

CAN bus overview

CAN bus systems The different CAN bus systems are shown with colour-coded connection lines.

CAN1: blue CAN2: green CAN3: violet Error display The diagnostics functions allow you to see which controller is active at the CANBUS and which is not connected to the terminal. Controllers that are not connected to the terminal are shown with a red background and an exclamation mark (see manual operation).

Counter In addition, complete software versions 200814617 and higher include a counter that can be used to determine sporadic brief connection interruptions.

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8. Electrics/Electronics CAN 1 BUS – Design and diagnostics CAN 1

120Ω

120Ω

A2 KMC 2

1

A1

SD/DRC A6

2

120Ω

DIOM

A5

R AP

CAN high

Diagnostics

120Ω

CAN low

Resistance measurement between CAN high and CAN low.

A15 KMC 3

CUC A14

A16

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 both CANBUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor at their ends. This prevents the transmitted data from being reflected as an “echo”. The terminating resistors for the CAN 1 are located as external resistors in the console (next to the CUC (1) and in the front part of the console (2)).

STLP_CAN 1_MAN_DE

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120 Ω ║120 Ω  60 Ω total resistance © KRONE Training Team, Spelle

8. Electrics/Electronics CAN 3 BUS – Design and Diagnostics CAN 3 120Ω LUC

120Ω

2

A9

1

ECU

120Ω ECU

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 both CANBUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor at their ends. 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 LUC (2)).

STLP_CAN 3_MAN_DE

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120 Ω ║120 Ω  60 Ω total resistance © KRONE Training Team, Spelle

8. Electrics/Electronics CAN 2 BUS – Design

A2

CAN 2

120Ω

KMC 2

120Ω

AutoScan

A35

A55

RockProtect (option)

CropControl (option)

120Ω

A40

Option

~150Ω

120Ω

KMC 4

CAN high NIR moisture sensor (option)

CAN low

A11

A10 Resistor connected in KMC 2 ~150Ω

Terminating resistors The both CAN bus lines (CAN high / CAN low) are terminated with a 120 - 150 Ω resistor on their ends. This prevents the transmitted data from being reflected as an “echo”. The terminating resistors of the CAN 2 are integrated into the job computer KMC 2 and in the metal detection, or in the AutoScan sensor and the metal detection, depending on whether AutoScan is installed or not.

179

BiG X 600_1100 TT Basic 2017

Without AutoScan: Resistor connected in the KMC 2 With AutoScan: Resistor disconnected in the KMC 2 120 Ω ║~150 Ω  ~ 66 Ω total resistance

© KRONE Training Team, Spelle

8. Electrics/Electronics B25 B26 B27 B28 B29 B30 B55 B58 B60 M12 M12 A10 B91

Header right Intake rotational speed

Ground 12V supply

Supply voltages 12V V1_KMC2 V2_KMC2 V3_KMC2 Supply 12V V4_KMC2

Intake backward Header forward

Header rotational speed Header backward Spout position centre Rotate spout to the left

A2

Spout position bottom

KMC 2 Turn spout right

Spout angular momenta Raise spout flap

120Ω *

Header left

120Ω switched!

Lower spout flap

Rotational speed chopping drum Raise spout Silage additives filling level

Supply Sensors

Lower spout

CAN 1

Central lubrication status

CAN 2

Central lubrication Malfunction KMC 2 (KRONE Machine Controller 2, 16bit job computer) Stop signal metal

Tasks Control of working hydraulics such as intake, header and spout * Terminating resistor is located on the BiG X 500/650 in the computer,

BiG X 600_1100 TT Basic 2017

Y5 Y6 Y7 Y8

Y20 Y21 Y22 Y23 Y24 Y25

Accumulator switch grass/maize

Y53 Fold spout 1

Fold spout 2 (not used!)

Pressure leakage oil filter On the BiG X 600/700/770/850/1100, the resistor is externally in the cable harness adjacent to the computer!

180

Intake forward

Horn follow-up alarm © KRONE Training Team, Spelle

Y76 Y77 K10

8. Electrics/Electronics B20 B36

B37 B42

B43 B44

B46 B52 B59 B70 B77 B87 B88 B85 B92

B112 181

Return suction filter Position grinding stone left Ground 12V supply

Supply voltages 12V V1_KMC3 V2_KMC3 V3_KMC3 Supply 12V V4_KMC3

Position grinding stone right

Main coupling

Y12

Header small/holding-down clamp

Y26

Header small/holding-down clamp

Y27

Position corn conditioner rollers

Plant divider/support wheels

Hydraulic oil filling level

Plant divider/support wheels

Y28

Filling level fuel

Y29

KMC 3

A3

Grinding stone right

Air filter contamination

Grinding stone left

120Ω *

Transverse inclination position

120Ω *

Pendulum frame 1 free

Maintenance flap Oil pressure main gearbox

Supply Sensors

CAN 1

CAN 3

Silage additives flow

* On the BiG X 500/650 the terminating resistor is located in the

Pendulum frame left top

computer.

On BiG X 600/700/770/850/1100, the resistor is located externally in the cable harness next to the computer!

Pendulum frame right top Hydraulic oil temperature Main belt tensioning arm Brake pad wear

KMC 3 (KRONE Machine Controller 3, 16bit job computer) Tasks Control computer for the complete system. It also controls the display, the counterblade, the grinding process, silage additives and the SmartDrive monitoring (toggle signal/life signal/safety output)

BiG X 600_1100 TT Basic 2017

Pendulum frame 2 free Counterblade left Counterblade right Conditioner distance Silage additives pump SmartDrive release © KRONE Training Team, Spelle

Y30 Y31 Y54 Y55 M9 M10 M11 M16 GAL

8. Electrics/Electronics Y51 Y52 Y56

Y61 Y62 Y65 Y66 Y67 Y73 Y75 Y82

Auxiliary hydraulics 1 up Ground 12V supply

Supply 12V

Auxiliary hydraulics 1 down Terminating resistor CAN2-KMC2

Diesel engine coupling

K15 Auxiliary hydraulics 2 up Auxiliary hydraulics 2 down

Signal horn metal

A6 DIOM

Battery switchover 12V/24V

Grinding flap closed Steering lock left

Intake/header release Steering lock right Compressed air cleaning Pressure relief Header connections

CAN 1

Valve block hydraulic fan control

Tasks Coupling diesel engines, auxiliary hydraulics (optional), 12/24 V changeover relay, grinding flap, compressed air cleaning, lock steering, silage additives pump, valve hydraulic fan drive (only for BiG X 600 / 700 / 770 / 850 / 1100) 182

Molasses output

BiG X 600_1100 TT Basic 2017

A6 © KRONE Training Team, Spelle

K18 K28 K39 K41

GAL

8. Electrics/Electronics Task The CUC receives the input signals from the panel switches and buttons. The panel switches are are plugged directly into the CUC. The “commands” are transmitted via CAN bus.

S1 S2

S3 S4 S5 S6 S7 S9

S68 S69 S90 S91 183

Road/field release switch

Ground 12V supply

Supply 12V

Autopilot release switch Traction drive release switch

A16 CUC

Intake/header release switch Maintenance release switch

Buzzer

Four-wheel release switch

(Starter sequencing relay)

Axle separation release switch

U3 25K2

Activation moisture measurement Parking brake Door switch

Supply Switch

CAN 1

Seat switch Quick-stop console Quick stop manual operation

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

8. Electrics/Electronics Proximity switch + 8.2 V

Proximity switches are two-wire sensors which detect metallic materials without contacting them.

The sensors are supplied with a constant voltage of 8.2 V, and emit two different signals which detect whether the sensor is attenuated or not. The sensors are connected to an analogue input of the corresponding voltage. At this input the wiring can also be diagnosed in addition to evaluating the sensor. This results in four states:

Condition

Voltage

Current

Cable break

approx. 8.6 V

0 mA

Sensor attenuated

approx. 7.3…8.3 V

20 % of maximum value

Sensor not attenuated

approx. 2.4…5.2 V

60 % of maximum value

Short circuit

approx. 0.0 V

Maximum current

184

Diagnostics

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

8. Electrics/Electronics Proximity switch M12x1 (Switching distance 2 mm) B25 – Header right B28 – Spout centre position B29 – Spout bottom position B36 – Grinding stone position left B37 – Grinding stone position right B55 – Header left B59 – Maintenance flap grinding device closed B92 – Cylinder tension roll main belt Proximity switch M18x1 (Switching distance = 4 mm) B58 – Chopping drum speed Proximity switch M12x1 (Switching distance 2 mm) B30 – Spout rotation pulses (cannot be set)

X

185

Rated supply voltage 8.2 V DC Internal resistance 1 kΩ Temperature range min./max. –25 °C / +70 °C

From the 2016 year of manufacture, the proximity switch (1) for the rotational speed of the chopping drum (B58) is on the right as seen in the direction of travel, in the bearing block and no longer on the left as seen in the direction of travel on the pulley.

BiG X 600_1100 TT Basic 2017

1

2

1

© KRONE Training Team, Spelle

8. Electrics/Electronics Hall angle sensor The sensor works with a power supply of 8 to 10 V. The signal voltage range depends on the power supply.

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

Uvers=10 V

Sensor

Function

Angle

B47

Ground contour left

B48

Ground contour right

B50

Position lifting unit

B61

Row registration right

B65

Row registration left

B64

Steering axle (autopilot)

82 °

B 107

Steering axle (Bosch traction drive)

110 °

Ub+

10 V

U signal

Spare parts no.

2.5 V – 7.5 V 303 164 0 (Bosch R 917 005 166)

72 °

8.5 V

2.1 V – 6.4 V

0°

2.5 V→7.5 V

10 V

2.5 V – 7.5 V

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

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

3 2 1

72 ° (82 °)

On installation, the notch (K) on the sensor shaft must always point toward the plug (see picture).

186

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Component overview Poclain tarction drive Pos.

4

Benennung

1

Axial piston variable displacement pump front axle

2

Axial piston variable displacement pump rear axle

3

Charge pump

4

Wheel motors with drum brake

5

Wheel motors

6

Combination valve block (valves for 4-WD and axle seperation; flush valves)

5

1

7 2

3

5 187

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Transmission Poclain – Charge pressure circuit

5 4

6

7

2

8

3

Designation

1

Charge pump

2

Valve main clutch and displacement shift rear axle

3

Combination valve (4-wheel drive and axle seperation)

4

Tensioning cylinder main belt

5

Valve sharpening flap

6

Cylinder sharpening flap

7

Tensioning cylinder cornconditioner belt

8

Charge pressure supply lifting gear

9

Valve displacement shift front axle

10

Drive cooler sieve (not in drawing)

9

1

188

Item

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Linde pumps Poclain traction drive

11

11

4

3 8

1 9

3

2

10

8

9

1

2

10

5

(1)

Receiving disc for swivel angle potentiometer

(2)

Swivel angle potentiometer

(3)

High-pressure limiting valves

(4)

Charge pressure limiting valves

(5)

Cold start valves

(6)

Charge pressure gearwheel pumps

(7)

Feed pump end cover

(8)

Adjustment unit

(9)

Solenoid switches safety valves Y69 or Y70

7

(10) Proportional solenoids pump control Y1 to Y4

6

(11) Gasket sets adjustment unit and pump flange

6 3

4

3 When unscrewing the high-pressure limiting valves, the charge pressure limiting valves as well as the cold start valves, the O-ring seals may be destroyed!

189

Nominal size of the pump

Tightening torque highpressure PLV

Tightening torque charge pressure PLV

55 cm³

140 Nm

30 +5 Nm

75 cm³

140 Nm

30 +5 Nm

105 cm³

140 Nm

30 +5 Nm

135 cm³

250 Nm

40 +5 Nm

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Wheel motors Poclain traction drive The machine is driven by four radial-piston wheel motors. The displacement of the wheel motors is varied depending on the speed, as shown in the table.

1C = full displacement -> high torque, low speed 3C = smallest displacement -> low torque, high speed

Front axle

BiG X 700 3-stage wheel motors optional

Rear axle

4250 cm³ (1C)

2099 cm³ (1C)

1500 cm³ (2C)

1049 cm³ (2C)

4333 cm³ (1C)

2099 cm³ (1C)

2833 cm³ (2C)

1049 cm³ (2C)

1500 cm³ (3C) BiG X 850 BiG X 1100

5133 cm³ (1C)

2808 cm³ (1C)

3300 cm³ (2C)

1404 cm³ (2C)

1833 cm³ (3C) 190

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Poclain 2-stage wheel motor (BiG X 700)

Minimess 7

Y11 The valves Y14 and Y11 re open when not energised. Charge pressure is applied to the control lines, the wheel motor is in low displacement

Y14

If Y14 or Y11 is energised, the valve closes. The control lines are depressurised and the wheel motor is in the large displacement.

Diagnostics: On Minimess 6 or Minimess 7 the switching function and the pressure in the low-pressure circuit can be checked

Observe the switching logic!

191

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Overview high-pressure circuit Poclain

5

System control and monitoring by SmartDrive:

Inputs (1) (2) (3) (4) (5) 192

Axial piston variable displacement pumps traction drive (Tandem unit: 105/75 ccm (BiG X 700) or 135/75 ccm (BiG X 850 / 1100) Wheel motor front (with integrated drum brake) 2-stage (BiG X 700), or 3-stage (BiG X 700 (opt.) 850 / 1100) Rear wheel motor 2-stage (BiG X 700 / 850 / 1100) Combination valve (valves four-wheel and axle separation) incl. flush valve High-pressure sensor (on front axle pump, sometimes connected to short hose)

BiG X 600_1100 TT Basic 2017

Outputs © KRONE Training Team, Spelle

9. System Technology Poclain traction drive Flush valves (1), hydraulically actuated  Oil is conveyed out of the return line to the cooling system. > 400 bar

1

M Changeover

System control and monitoring by SmartDrive:

Inputs: B13, B14, B38/B39, …(see circuit diagram)

Outputs: Y1/Y2, Y3/Y4, Y69/Y70, …(see circuit diagram) 193

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Poclain traction drive “Front axle” and “rear axle” circuit are connected to axle separation valve (1) as long as axle separation is not activated.

M When connecting the four-wheel drive, both drive pumps operate in parallel on four wheel motors.  large circuit, still connection between “front axle” circuit and “rear axle” circuit -> four-wheel valve (2)

Wheel motors front axle

1

2

Axle separation: Two circuits separated from each other  “Front axle” pump and “rear axle” pump operate on two wheel motors only.

A speed difference between two wheel motors of an axle can still be compensated  Cornering with activated axle separation is possible!

194

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Poclain diagnostics M1 : p = 30 – 435 bar

M2 : p = 30 – 435 bar

(Supply line in case of forward travel)

(Supply line in case of forward travel)

M3 : p = 30 – 435 bar

M4 : p = 30 – 435 bar

(Return line in case of forward travel)

(Return line in case of forward travel)

The high-pressure circuits of the traction drive can be checked on the measurement connections M1 to M4.

Before measuring the high pressure, activate four-wheel drive and axle separation to obtain two circuits separated from each other. Otherwise detailed diagnostics are not possible!

Removal of the valve plugs from the switching valves Y14/Y68 and Y11 facilitates reaching the maximum pressure.  The wheel motors operate in the small displacement and therefore reach a correspondingly lower torque.

195

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Leakage oil and cooling circuits – BIG X 700 / 850 / 1100 (Poclain traction drive)

2

3

3

Pos.

Designation

1

Tank

2

Return suction filter

3

Tank return filter

4

Cooler

2 1

4

• The leakage oil of the wheel motors is routed to a separate return filter.

• No collector is needed for the leakage oil.

• The flush oil from the traction drive and from intake and header drive runs via the cooler. A bypass runs parallel to the cooler to protect the cooler.

196

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Leakage oil and cooling circuits – Hydac pressure sensor 4 bar: Pressure sensor leakage oil filter (Poclain) The sensor operates with a 12 V power supply. The signal voltage changes from 1 V to 5 V when the sensor is charged with pressure (P) from 0 to 4 bar.

The sensor measures the pressure at the leakage oil return filter on the BiG X with Poclain traction drive. If the pressure upstream of the filter here reaches a certain value, relevant error messages are outputted.

B91 – pressure sensor

Measuring range:

0…4 bar

Supply voltage:

12 V

Signal voltage:

1…5 V

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

197

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Pressure switch return suction filter When the permitted contamination is reached, the return line pressure upstream of the filter increases to over 2 bar. In this case the pressure switch transmits an electrical signal to the job computer and a warning icon appears on the terminal.

Pressure sensor tank return air filter wheel motors (only for Poclain traction drive) When the filter is contaminated, the pressure on the sensor increases.  - If the pressure exceeds 1.5 bar for longer than 6 seconds, error message “Leakage oil filter contaminated” appears  If the pressure is over 2 bar for longer than 5 seconds, the error message “Check wheel motors” appears

Level switch If the oil level in the oil tank is too low, a warning icon is output via the level switch on the hydraulic oil tank.

198

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Poclain brake Work hydraulics pump (1) High-pressure filter (2)

3 Accumulator charging valve < 70 bar

The accumulator charging valve (priority valve) initially supplies both brake circuits (parking brake and service brake) with oil.  Brake system has priority over working hydraulics.

The hydraulic accumulators (3) serve as a pressure accumulator. A pressure balance is actuated via control lines. This ensures that both brake circuits are filled evenly.

4 When the switching pressure of p = 150 bar is reached, the PLV (4) opens. As a result, the pressure balance (5), actuated via control lines, releases the oil flow to working hydraulics (EF connection). At the same time, a non-return valve closes the brake circuits.

If the pressure in the brake circuits drops below 120 bar, the pressure balance (5) ensures refilling.

5

1

199

Power take-off gear

2

The pressure switch B 18 (opener) monitors the pressure in both brake circuits. If the pressure drops below 70 bar, SmartDrive signals an alarm.

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Poclain brake To release the parking brake, the parking brake valve Y18 is energised. The single-acting parking brake cylinders are opened against the spring force.

The hand pump (1) is used as an emergency release device. The stop cock (2) must be closed in order to release the brake manually.

Pedal switch B40

The brake valve opens when actuating the foot brake pedal. The pressure in the brake line is dependent on the pedal travel. When the valve is fully open, a maximum pressure of p ≈ 120 bar is reached. This can be checked at measurement connection 8.

2

Plausibility check

1

200

From a specific pedal travel, the brake pedal switch B40 detects that the brake has been applied. The pressure sensor B16 must measure a brake pressure of p = 70 - 90 bar at this changeover point. Otherwise a hydraulic full braking will be triggered. The switching point can be adjusted by moving the switch in the oblong hole B40.

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Compressed air brake – Trailer valve

Compressed air supply from reservoir

Parking brake valve signal

Actuating cylinder parking brake

To the trailer connection coupling (reserve line)

3/2 directional valve Service brake valve signal

(Trailer brake valve)

To the trailer connection coupling (brake line)

201

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Position of components in the machine (Bosch)

14 4

10 6

9

8

11

7 3b 5

2 13

6

16

14

3a 12

6

Parts

1a

Drive motor front left

1b

Drive motor front right

2

Planetary gearbox at front

3a

Drive motor rear left

3b

Drive motor rear right

4

Planetary gearbox at rear

5

Variable displacement pump

6

Speed sensor

7

High-pressure sensor B101

8

High-pressure sensor B102

9

“Forward” valve

10

“Backward” valve

11

Swivel angle sensor

12

Feed valves

13

Drive motor valve at front

14

Drive motor valve at rear

15

Accumulator for feed

4 1b 15

12 13 15

1a

2

6

202

Pos.

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Overview charge pressure circuit (Bosch)

8

4 3

1 2

7

(1) Feed pump integrated in traction drive pump (2) Main coupling valve (3) Clamping cylinder main belt (4) Clamping cylinder main belt valve (reversing function). Optionally also for Poclain traction drive (5) Grinding flap valve (6) Corn conditioner belt clamping cylinder (7) Auxiliary function lifting unit (8) Rotating screen drive 203

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Function description Bosch traction drive 1.

Acceleration forwards 0 - Vmax in road mode As soon as the driver has given the drive command via the control lever, the drive pump starts to swivel out. If the driver accelerates continuously, the drive pump then swivels continuously up to the maximum displacement. Shortly before the pump has reached the maximum displacement (approx. 8-9 km/h), the wheel motors start to reduce the displacement. This results in a continuous, smooth acceleration from standstill up to the maximum speed of 40 km/h. The maximum speed backwards is limited to approx. 14 km/h.

2.

Acceleration forward 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 is limited to 25 km/h. The maximum speed backwards here is also approx. 14 km/h (electronically limited).

204

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Function sequences Bosch traction control system 3.

Traction control system function (TC) The traction control system prevents individual wheels from rotating uncontrollably if the traction forces on one wheel can no longer be transmitted due to the ground. This enables all wheels to spin equally. A theoretical speed is calculated for each wheel depending on the speed of the other wheels and the steering angle. If the speed of a wheel is higher, the displacement of the hydraulic motor is reduced on the corresponding wheel. This happens until the torque on the wheel is so low due to the displacement that it is no longer adequate to turn the wheel.

At the same time the swivel angle of the pump is reduced to adjust the volumetric flow required for the current speed.

205

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Hydraulic motors and Bosch wheel motor Combination hydraulic motors + wheel hub gearbox The BiG X forage harvester is driven via 4 axial piston motors with an adjustable displacement, in connection with a wheel hub gearbox.

The wheel hub gearbox (1) on the front axle also contains a brake plate package (2) which is used as a service brake and as a parking brake.

On all wheel hub gearboxes, the hydraulic motors (4) are inserted and flangemounted in the fixed part of the wheel hub gearbox in position (3). The wheel hub gearboxes have separate oil lubrication.

2 3

3

1 4 Hydraulic motors BiG X 600, 700, 770, 850, 1100 with Bosch traction drive

206

Front axle (Axial piston adjusting motor)

Rear axle (Diagonal axis adjusting motor)

V max = 115 cm³

V max = 62 cm³

BiG X 600_1100 TT Basic 2017

Gearbox

Front axle

Rear axle

GFT 0040

GFT 0013

i = 35.9

i = 37.6

© KRONE Training Team, Spelle

9. System Technology Traction drive – Planetary gearbox GFT 40 Bosch

3

2

1

4

10

6

207

Pos.

Parts

6

Planetary stage 1

1

Main frame machine

7

Planetary stage 2

2

Support axle

8

Brake plates

3

Rim

9

Slide ring seal

4

Wheel bearing

10

Brake piston

5

Hollow wheel/output

BiG X 600_1100 TT Basic 2017

7

8

5

9

© KRONE Training Team, Spelle

9. System Technology Traction drive – Parts Bosch drive pump

10

9

8 Parts

12

11

7

13 1 14 3

2

208

6 4

1

Drive shaft

2

Housing cover

3

Leakage oil connection

4

Charge pressure limiting valve

5

High-pressure limiting valve

6

Suction connection

7

High-pressure limiting valve

8

Valves for pump adjustment

9

Measurement connection set pressure X2

10

Measurement connection set pressure X1

11

Mech. zero position centring

12

Swivel angle sensor

13

Valve for pressure cut-off

14

Charge pressure connection

5

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Bosch drive pump parts

5

4

3

2

6 1

Parts 1

Swivel angle sensor

2

Measurement connection set pressure X2

3

Measurement connection set pressure X1

4

“Forwards” proportional solenoid

5

Setting valve block

6

“Backwards” proportional solenoid

7

Working connection B

8

Working connection A

9

High-pressure sensor MA

10

High-pressure sensor MB

7

10

8

209

9

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive – Terminal diagnostics Bosch

Pos.

Designation

1

Drive pump forward valve Y101

2

Drive pump reverse valve Y102

3

Swivel angle sensor B108

4

Steering angle sensor B107

5

High-pressure sensor forward B101

2

6

High-pressure sensor reverse B102

3

7

Parking brake pressure switch B110

8

Parking brake valve Y18

9

Brake pedal angle sensor B109

10

Service brake pressure sensor B16

11

Wheel motor valve currents Y103-Y106

12

Wheel motor speed sensors B103-B106

210

1

11 12

4

5

7

6

BiG X 600_1100 TT Basic 2017

8

9 10

© KRONE Training Team, Spelle

9. System Technology Traction drive - Hydraulic motor design A6VE Bosch Axial piston motors with steplessly adjustable displacement are used as wheel motors. These motors are bent axis motors which specify the intake volume via the position of the swivel axle with respect to the rotation axle of the motor.

2

1

Parts

5

6

1

Power unit

2

Speed sensor

3

Proportional valve

4

Non-return valve

5

Flush valve

6

Set piston

Technical data: Displacement Front axle 115 cm³ Rear axle 62 cm³

4 3

4

Vg,min Vg,max

approx. 400 mA approx. 1200 mA

Flush rate:

approx. 10 l/min

Flush valve:

3

Resistance coil

2 211

Currents =

BiG X 600_1100 TT Basic 2017

approx. 5.5 Ohm © KRONE Training Team, Spelle

9. System Technology Traction drive – Calibration of the Bosch traction drive Installation and production tolerances as well as component fluctuations ensure that the values of sensors differ slightly in defined positions and that actuators (valves) have a slightly different behavior. It is therefore necessary to save these component-specific properties once in the control unit and after each relevant change in the system. Therefore the following components are calibrated in case of Bosch traction drive:   

 

Angle sensor brake pedal B109 (1) - Signal current with brake pedal not depressed (0 bar) - Signal current with brake pedal fully depressed (100 bar) Steering angle sensor B107 (2) - Setting the sensor for straight-ahead driving (5.0 +/-0.1 V) Swivel angle sensor B108 (3) - Setting the sensor with pump in centre position (2.50 +/-0.02 V) - Saving the difference from the setpoint value (offset) - Maximum values of the sensor at full displacement Proportional valves pump Y101 + Y102 (4) + (5) - Minimum current (response threshold) - Maximum current (end of the control range) Proportional valves drive motors Y103, Y104, Y105, Y106 (e.g. (6)) - Maximum current (response threshold) - Minimum current (end of the control range)

1

2

3 4

5 All calibrations of Bosch traction drive are carried out by means of “KRONE Diagnostics”.

6 212

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive - Overview brake system Bosch traction drive

6

3 4

5

1 2 213

Pos.

Parts

1

Work hydraulics gearwheel pump

2

Work hydraulics high-pressure filter

3

Accumulator charging valve

4

Service brake pressure accumulator

5

Parking brake pressure accumulator

6

Service brake valve

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

9. System Technology Traction drive - Bosch traction drive brake system concept (service brake) The deceleration of the machine functions differently, depending what means the driver has used to issue the deceleration command to the machine: 1. Deceleration of the machine via control lever - Displacement on drive motors is increased - Pump is supported on the diesel engine (support moment of the diesel engine is used)

2.

-

Decelerating the machine using brake pedal Displacement on drive motors is increased Pump is supported on the diesel engine (support moment of the diesel engine is used) High-pressure limiting valves are used (hydraulic energy is converted into heat) From a specific braking requirement by the driver a multi-disc brake will also be activated (dynamic brake)

Brake system concept (parking brake) The parking brake is applied by the same plates as the dynamic brake.

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9. System Technology Traction drive – Function brake system Bosch traction drive Parking brake released, service brake not actuated If connection S (static brake) is charged with pressure, the piston (1) moves against spring force (2) to the left. As a result, the plunger (3) is released and thus no force acts on the blade package (4).

S

2 1

Parking brake released, service brake actuated The parking brake is released via connection S as described above. If connection D (dynamic brake) is charged with pressure, the plunger (3) presses against the blade package (4). Pressure-dependent braking results.

3

4

3

4

D

2 1

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9. System Technology Traction drive – Measurement connections brake system Bosch traction drive

Measurement connection D: D = dynamic brake (service brake) Pressure: approx. 0…100 bar (depending on position of brake pedal)

D

Measurement connection S: S = static brake (parking brake)

Pressure:

0 bar (parking brake applied) 30 bar (parking brake released)

S The respective brake can also be vented by way of the relevant measurement port here!

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9. System Technology Axle suspension rear axle The rear axle suspension is provided by a hydraulic cylinder (1) in connection with a hydraulic accumulator (2). The pressure in this closed system can be read on the pressure gauge (3). The system is charged via a Minimess connection (4). The hand pump is used to adjust the running gear to the dimension a of 30 - 40 mm between the frame (5) and the axle (6).

Always carry out the adjustment with the header and the rear weights (where appropriate) mounted.

Pressure gauge

Hydraulic cylinder Damping element

3 2

Hydraulic accumulator 1.4 l / 60 bar

1

5

4

a

Minimess line to connect to the hand pump

6

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9. System Technology Additional axle – Component overview

Pos.

Designation

1

Accumulator charging valve additional axle

2

Valve block additional axle

3

Pressure limiting valve additional axle

4

Axle with lifting cylinders

3 2 1

4

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9. System Technology Steering/autopilot – Steering hydraulics components (1)

Steering hydraulics pump

(2)

High-pressure filter

(3)

Steering unit

(4)

Steering cylinder

(5)

Autopilot valve

(6)

2/2 directional seat valves autopilot

(7)

Measurement connection

(8)

Steering pressure sensor

3

8

1 5 2

7

6

4

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9. System Technology Steering/autopilot – Calibration of autopilot sensors Starting with the complete software version 200814616, two different autopilots are available if the machine is equipped accordingly. On the one hand, there is the autopilot, which operates using the mechanical row tracer. On the other hand, there is the option of using a GPS-based system that operates using a standardised ISOBUS interface. However, this is only possible if an appropriate system (Trimble, Reichhardt, Topcon or Autofarm) is installed on the machine.

The selection between the two systems is made on the “Machine Settings” menu.

The autopilot using the row tracer is only available in maize mode, while a GPS-based system can be used in all operating modes.

For the autopilot using the mechanical row tracer, it is necessary to calibrate the sensors on the row tracers, the steering angle sensor and the flows at the steering valve Calibration of steering angle sensor and steering valve is necessary for GPS based systems. In addition, the turning circle of the machine must be stored here.

For the GPS-based systems, the additional system installed must also be started up. For information, refer to the instructions from the corresponding manufacturer.

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9. System Technology Steering/autopilot – Calibration of autopilot sensors To ensure that the autopilot functions perfectly, run a calibration process before using the autopilot for the first time or whenever making changes (of a mechanical, hydraulic or electronic type) to system-relevant components (e.g. replacement of a valve, a sensor or autopilot job computer).

1

On 3 2

P

On General information on the calibration of autopilot sensors The following conditions must be met: - Engine running - Road/field release switch (1) in field mode - Traction drive release switch (2) switched on.

- Autopilot release switch (3) switched on.

- The driver is on the driver's seat and the cabin door is closed - The EasyCollect maize header is mounted and folded out - The machine is on level surface

K

On 4

5 S Installing the autopilot sensors When installing the angle sensors (4) В65 and В61 for the row tracers, make sure that the notch (K) points towards the plug (S). The pin (P) in the axle must face the other side.

When installing the angle sensor (5) В64 to determine the steering angle, make sure that the notch (K) faces the plug (S). The pin (P) in the axle must also face the plug.

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9. System Technology Steering/autopilot - Calibration of autopilot sensors

L 1

R

2

R

L

Calibration of autopilot sensors Open “Maintenance/Calibration/Autopilot” menu 3-4 in the terminal.

Calibration of row tracer left (L) B65 and right (R) B61: Both row tracers (on left and right) are calibrated once in their basic position without being activated.

The actual value (1) of the sensor (L) В65 must be in the range 265 ± 50 in order to readjust the sensor mechanically in the oblong holes as necessary. Actuate the row tracer as far as the end stop. The current sensor value must show a difference with respect to the zero position of 300 – 320 (Important: When activated, the value must be larger!).

Select “row tracer left” field (1) and save the current sensor value as zero position by pressing the rotary potentiometer twice (activate + save).

The actual value (2) of the sensor (R) В61 must be in the range 590 ± 50. Readjust the sensor mechanically in the oblong holes. Actuate the sensor as far as the end stop. The current sensor value must show a difference with respect to the zero position of 300 – 320 (Important: When actuated, the value must be lower!).

Select the “row tracer on right” field (2) and save the current sensor value as zero position by pressing the rotary potentiometer twice (activate + save).

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9. System Technology Steering/autopilot – Calibration of flexible row tracers The rest position must be calibrated for the flexible row tracers. To do this, drive onto a plane surface and make sure that the row tracers can swing freely.

In calibration screen 3-4, both sensors B66 must show a value of 50 +/- 10 in case of zero position. As for the mechanical row tracers, this value must then be saved.

If one of the sensor values exceeds 120 or is less than 40 in zero position, the plastic paddle may be defective and must be replaced.

To check: If the sensor is fully actuated, the following values result: B66 (row registration left) = 450 +/-10 B66 (row registration right) = 450 +/-10

1

For this system, the following software versions must be installed: KMC2: 150200102-27 KMC3: 150200103-27 Terminal: 150200104-28 Autopilot: 150200029-17 or higher.

Likewise, the parameter 26025 (1-1-14) must be set to the value 1.

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9. System Technology Steering/autopilot – Calibration of steering angle sensor (B64)

1 3

   

224

2

4

Move steering axle exactly to straight-ahead driving.

The actual value of the steering angle sensor can be read on the display in field (1) and should now be 400 ± 10; if required adjust the sensor mechanically in the oblong holes.  Select the “steering angle sensor middle” field (2) and save the current sensor value as straight-ahead driving by pressing the rotary potentiometer twice (select + save).

Turn the steering all the way to the left. The actual value (1) must not be less than 220, set the sensor or the coupling rod and restart the calibration process from the beginning as necessary.

Select “steering angle sensor left” (3) field and save the current sensor value as the maximum steering angle left by pressing the rotary potentiometer twice (select + save).

Turn the steering all the way to the right. The actual value (1) must not exceed 630. If necessary, set sensor or coupling rod and restart the calibration process from the beginning as necessary.

Select the “steering angle sensor right” (4) field and save the current sensor value as a maximum steering angle right by pressing the rotary potentiometer twice (select+ save).

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9. System Technology Steering/autopilot – Calibration of minimum currents of steering valves Y39 and Y40

Move steering axle to straight-ahead driving. Park the machine on a level, asphalted surface. The calibration specifies the minimum and maximum power consumption on the solenoid valves Y39 and Y40.

From software version 150 200 104 – 08 onwards, an automatic calibration of the minimum valve currents left/right is possible. To ensure that automatic calibration can be started, the steering angle sensor В64 must be correctly calibrated first.

The automatic calibration process is started by pressing key (A). A new window (F) is shown. Then the valves are automatically actuated. The steering axle moves automatically to the left and right limit end stop.

A

1 2

F 4

3

1.

2.

3.

4.

Current PWM pulse duty. Current as % at which the particular coil is actuated.

Current flowing at present through the corresponding coil Current value of steering angle sensor В64 Status of calibration:

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9. System Technology Steering/autopilot – Calibration of turning circle For the GPS-based ISOBUS autopilot systems, the average turning circle when steering to the left and right must be calibrated.

To do this, drive a circle on a fixed area at slow speed. The steering must be turned in completely. Then the incircle diameter of the turning circle must be measured. Then add the width of the machine to this value. The result is the centre turning circle diameter. Now the determined turning circle diameter must be entered into the according field (A).

This process must be performed separately for each side.

A

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9. System Technology Lifting unit

(1)

Maize / maintenanceGrass

LUC valve Y 32 - Lifting valve

4

Y 33 - Lowering valve (2) Accumulator switching block

3

(3)

Three-way valve grass/maize

(4)

Safety shut-off valve

(5)

Pressure sensor

4

1 5 2

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9. System Technology Lifting unit – Lifting unit sensors

P

The lifting unit must be adjusted once before start-up for the respective header or after replacement of a sensor relevant for control, the LUC or the KMC 3, or in general after making mechanical, electronic or hydraulic changes to components relevant for function.

Assembly of angle sensors (V) When mounting the angle sensors (V), make sure that the notch (K) points towards the plug (S). The pin (P) in the axle must face the other side.

K

2

1

3 α P

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

1.

2.

3.

α d

S

d

1

2 3

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V

9. System Technology Lifting unit – Basic setting of lifting unit sensors

2 1 3 α

α

P

d

d 1.

2.

3.

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

In the terminal open the "Service/Diagnostics/Lifting Unit" 4-1-5 menu.

The values (W) of sensor В47/В48/В50 are displayed.

When the lifting unit is completely down (header is situated completely on level ground), the values of the sensors B47/B48 must not be less than 20. If required, re-adjust sensors in the oblong holes. To test sensor B50 concerning its minimum position or to set it, make sure that no header is mounted on the machine so that the minimum position can be reached. In this position, the value of sensor B50 must not be less than 20.

When the lifting unit is completely up, the values of the sensors B47/B48/B50 must not be greater than 235. If required, re-adjust sensors in the oblong holes.

W

V

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9. System Technology Lifting unit – General information for calibration of the lifting unit sensors The following conditions must be met for calibration of the lifting unit sensors: - Engine running - All release switches on the console (1) are switched off.

- The header must be mounted. On the terminal's “General Machine Settings” menu an appropriate header must be set, as the lifting unit must be calibrated for each operating mode (EasyCollect, pick-up, XDisc) to allow for the different header weights.

- The machine is on a level surface and the header has been folded out.

- Align header horizontally.

1

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9. System Technology Lifting unit - Calibration of lifting unit sensors From the latest complete software version 200851632, it is possible to perform the calibration process very simplified for all lifting unit sensors.  Open menu 3-12 first. (If menu 3-12 is not available, the machine is not fitted with the latest software level).

 Now the message “Perform calibration on a level surface” appears.

Use the key (D) on the terminal to start the calibration process.

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9. System Technology Lifting unit - Calibration of lifting unit sensors

 Now the message “Press the “Lower lifting unit automatically” key (1) and hold it down in order to calibrate the upper end position” appears.

During the entire calibration process, keep the “Lower lifting unit automatically” (1) key pressed. If the key is not held down during the process, the system cancels the calibration process (2).

1

2  When the key (1) has been kept pressed down, only the upper end position (3) is approached automatically and all important sensor values are saved.

3

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9. System Technology Lifting unit - Calibration of lifting unit sensors

During the entire calibration process, keep the “Lower lifting unit automatically” (1) key pressed.

The header is now lowered completely until it rests on the ground (2) with its entire weight.

The “lower end position” is approached. Then all important sensor values are automatically saved.

1

2

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9. System Technology Lifting unit - Calibration of lifting unit sensors

During the entire calibration process, keep the “Lower lifting unit automatically” (1) key pressed.

 Now the header weight is calibrated. The header raises somewhat from the lower end position and evens out at an optimum working height (2). After a few seconds, the message “Calibration successfully completed (3)” should appear. Therefore calibration is complete and you can go back to the main menu (4) to perform further work.

1

2

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9. System Technology Lifting unit - Calibration of lifting unit sensors On machines with an older machine software, the lifting unit must be calibrated as described below. This also works on machines with the latest software levels.

1

Adjusting procedure 3 The maximum position of the lifting unit is adjusted (B50 – 100%) and, if fitted, the maximum height of the ground contour lifting unit control type (B47 and B48 - 100%).

Keep the key (2) and the key (N) pressed on the joystick for approx. 7 seconds. Lifting unit moves to the upper stop. Hold down the key combination until the message “LUC adjustment 3 OK” appears on the terminal.

2

Adjusting procedure 2 The weight of the header is adjusted, i.e. the hydraulic pressure in the lift line with free floating header (B49 - 0%).

Slowly lower the lifting unit via the key (1) on the joystick. Caution: Approach position from above, do not raise lifting unit again! Stop shortly before contact with ground (the sliding skids of ground contour must rest on the ground).

Hold down the key (N) on the joystick for approx. 7 seconds until message “LUC adjustment 2 OK” appears on the terminal.

N

В50

Adjusting procedure 1 The minimum position of the lifting unit is adjusted (B50 – 0%) and, if available, the minimum height of the ground contour lifting unit control type (B47 and B48 - 0%).

Lower the lifting unit all the way onto the ground by pressing the key (1) on the joystick.

Simultaneously hold down the key (1) and the key (N) for approx. 7s until the message “LUC adjustment 1 OK” appears on the terminal.

В48

В49 α P

В47

α d

d 235

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9. System Technology Lifting unit – Checking the lifting unit calibration The diagnostics and the associated values from the sensors can be checked in the diagnostics menu. On the one hand, the current values (I) are displayed here. On the other hand the saved values for the corresponding positions (II) are shown.

The value when calibrating in the centre position (adjusting procedure 2) is saved for sensor B49. The values of sensors B 47, B 48 and B 50 are saved during calibration in the top position and in the lowest position (adjusting procedure 1 and 3). The corresponding adjacent icon indicates how the values are assigned to the relevant position.

I II

Menu 4-1-5

Checking pressure sensor calibration After successful calibration, the relative values (blue values) are calculated from the absolute sensor values (black values). The relative value of the pressure sensor (B 49) must be in the negative range with lifted header (-> no ground pressure).

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9. System Technology Lifting unit – Calibration absolute lifting unit height (cutting height calibration) When the lifting unit sensors have been calibrated, the absolute lifting unit height should be calibrated. The following conditions must be met in order to calibrate cutting height:  - Road/field release switch (1) in field mode  Traction drive release switch (2) OFF  Header is mounted and is horizontal. The corresponding operating mode in the terminal is set.

On the terminal open the “Maintenance/Calibration/Pendulum Frame” menu 3-3.

1 On 2 Off

Calibration of upper lifting unit height Raise lifting unit until the current lifting height (3) value is 80%.  In case of pickup, measure the distance between the ground and the lowest point of a spring tine.  For a maize header or direct cut header, measure the distance between the ground and the cutter blade.

Using the rotary potentiometer, select the “height of lifting unit at 80 %” field (4) and enter the determined dimension.

3

4

5

Calibration of lower lifting unit height Lower the lifting unit until the current lifting height (3) is 20%.  Determine the values as above Using the rotary potentiometer, select the “Height of lifting unit at 20 %” field (5) and enter the determined dimension.

The calibration of cutting height is only used to display the cutting height on the terminal, and has no effect on the lifting unit control.

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9. System Technology Intake/header – Intake on BiG X with MAN engine technology B87 Pendulum frame position at top left, B88 Pendulum frame position at top right (on left/right always in direction of travel) If both sensors are not alive, the pendulum frame is in the horizontal position.

If a sensor is attenuated by moving the pendulum frame, this means: B87 attenuated = pendulum frame + header higher on left B88 attenuated = pendulum frame + header higher on right As the sensors are firmly positioned in the intake housing, calibration is no longer necessary.

The installation distance must be set to 1.5 – 2.0 mm.

B 88

B 87

Parameter 33634 = 1 (proximity switch)

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9. System Technology Spout – Moisture sensors The spout must be calibrated if the end position is not reached, for example, or if changes (electronic, mechanical, hydraulic) have been made to the system.

Basic setting of moisture sensors The sensor В30 (1) counts pulses in the gearbox of the spout while it turns. The sensor (1) is screwed with the copper ring all the way into the gearbox housing with a torque of 10 Nm. Sensor В29 (2) monitors the spout position top/bottom. With raised spout, sensor B29 detects metal and the spout is shown as raised in the calibration screen.

Sensor В28 (3) monitors the centre position of the spout. If the spout is turned, metal is detected by sensor B28 when the centre position is overrun. This point is used as a starting point to count pulses to the right and left.

1

2

N

M

M

Assembly sensors В28/В29  

- Set the sensor (N) so that the distance is (X) 2 - 4 mm.

Tighten the hexagon nuts (M) with a torque of 10 Nm.

3

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9. System Technology Spout – Calibration

E

1 On

M

2

Off

Calibration of electronic limit stops of spout Calibration of the spout presets the “electronic” end stops (E) for the machine to prevent the spout from being moved unbraked as far as the mechanical stops (M) using the joystick. This would eventually damage the components in the rotating drive. The calibration thus specifies the maximum distance the spout can be turned to the right or left side via joystick. Due to a non-symmetrical arrangement of the relevant components, the “electronic” end positions on the right and left may deviate from each other. It is therefore necessary to calibrate both sides separately. The values obtained must not be identical! Parameter settings specify from which distance, e.g. to the calibrated end position or to the central position, the spout reduces its rotating speed (see section Parameters).

General information on the calibration of the spout The following conditions must be met to perform spout calibration:  Engine running  Road/field release switch (1) in field mode  Maintenance release switch (2) off  - The driver is sitting on the driver's seat and the spout must be raised

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9. System Technology Spout – Calibration 1.

2.

3.

1 2 3 5

4.

5.

4 6

6.

Open “Maintenance/Calibration Spout” menu 3-5 on the terminal.

Current spout position top/bottom Current spout position middle/right/left The current number of pulses of the gearbox sensor for the present side The present current of the respective valve for turning the spout (to the left or right) The saved number of maximum pulses for left (electronic maximum left) The saved number of the maximum pulses for right (electronic maximum right)

Keys (A) and (C): Saving the currently counted pulses as an electronic maximum on left and right Key (В) and (D): Manual control of the spout to the left and right

Calibration of electronic stops on the spout Move the spout all the way to the left by pressing the key (L) on the joystick. The spout stops when the max. number of pulses for this side has been reached.

The spout can be further rotated with minimum current by pressing key (B). Hold down the key until the spout is just in front of the mechanical end stop (making sure it is not yet touching the stop!). Save this position by pressing the key (A). The new electronic maximum to the left is therefore set.

Move the spout all the way to the right by pressing the key (R) on the joystick. The spout stops when the max. number of pulses for this side has been reached. By pressing key (D), the spout can continue turning at minimum current. Hold down the key until the spout is just in front of the mechanical end stop (making sure it is not yet touching the stop!).

Save this position by pressing the key (C). The new electronic maximum to the right is therefore set.

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9. System Technology Spout – Calibrating the flows from the valve for turning the spout The flows for the valves that rotate (Y20 and Y21) the spout are automatically calibrated. Every time the machine is restarted, the flows are calibrated once. This takes place automatically the first time the spout is reversed in the corresponding direction.

The minimum flows determined during calibration can also be adjusted as parameters and are then active. However, they are overwritten by newly determined values after the next re-start.

However, complete software versions 20 081 461 7 and higher provide the parameters “Rotate spout left factor Imin” (25228) and “Rotate spout right factor Imin” (25229). With these two parameters, you can increase or reduce activation of the spout if necessary.

This means that you can adjust the speed of rotation for the respective direction.

Diagnostics flows turn spout valves For diagnostics purposes and for more precise function testing, you can check the current flow at valves Y20 or Y21 in the menu for calibrating the spout (3-5).

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9. System Technology Spout – Extension The folding of the extension is implemented by the “Raise spout” (Y24) and “Lower spout” (Y25) valves.

Y76

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

1

0.075 l 45 bar Y24

Y25

1

The lowering brake valve ensures even folding.

With effect from the 2013 year of manufacture, all machines with the Bosch traction drive are fitted with an additional hydraulic accumulator which cushions vibration on the spout.

This accumulator is also available as a repair kit (150 381 654).

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The two throttle check valves (1) are integrated into the connections on the hydraulic cylinder only from the 2014 year of manufacture. Up to the 2013 year of manufacture they are fitted externally in the line (on the spout slewing ring)

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9. System Technology Corn conditioner calibration

1

The calibration should be run when re-installing the corn conditioner, or if the actual value of the roller distance deviates markedly from the setpoint value.

I. e.: The measured roller distance does not match the roller distance displayed on the terminal.

Furthermore, recalibration is required as soon as the minimum distance of the rollers has been changed mechanically.

It is recommended to carry out the calibration at least once a year at the beginning of the season.

On

General information on corn conditioner calibration To perform calibration, the following conditions must be met:  Road/field release switch (1) in field mode  Corn conditioner installed

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9. System Technology Calibration of corn conditioner (roller conditioner)

1 S

2 3

4

F

Before starting the calibration, set the relevant type for adjustment of the corn conditioner by means of parameters (see description of corn conditioner adjustment design) Open the “Maintenance/Calibration Corn Conditioner” menu (3-6) on the terminal.

To ensure precise calibration, measure the exact distance between the rollers (1) and (2) using a feeler gauge (F).

Press the key (3) or (4) to reduce or increase the roller distance to make it easier to determine the gap dimension.

Select the field (S) using the rotary potentiometer. The input field is highlighted in colour. Press the rotary potentiometer to jump to the input field. Enter the measured actual value using the rotary potentiometer. Save the value by pressing the rotary potentiometer and leave the input field.

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9. System Technology Calibration of corn conditioner (disc conditioner)

S

3

4

X

1

2 Setting the corn conditioner type used (corn conditioner with rollers or with discs) by means of parameters.

Open menu 3-6 “Maintenance/Calibration Corn Conditioner” on the terminal.

To ensure precise calibration, it is necessary to determine the distance (X) between the discs (1) and (2) directly on the tip using a suitable measuring tool.

Press the key (3) or (4) to reduce or increase the distance to make it easier to determine the gap dimension.

Select the field (S) using the rotary potentiometer. The input field is highlighted in colour. Press the rotary potentiometer to jump to the input field. Enter the measured actual value using the rotary potentiometer. Save the value by pressing the rotary potentiometer and leave the input field.

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9. System Technology Intake/header - Overview (1) (2)

(3) (4) (5)

(6)

Axial piston variable displacement pump intake 105 ccm (BiG X 600 / 700 / 770 / 850 / 1100), Axial piston variable displacement pump header 55 ccm BIG X 700 / 850 / 1100 to YOM 2010) 75 ccm ( BIG X 600 / 700 / 770 / 850 / 1100 from YOM 2011) Gearwheel pump charge pressure Fixed displacement motor intake 75 ccm (all BiG X) Fixed displacement motor header 55 ccm (BiG X 700 / 850 / 1100 up to YOM 2010) 75 ccm (BIG X 600 / 700 / 770 / 850 /1100 from YOM 2011) Quick-stop valve

4 6 5

1

Aufbau Hydraulikkreis

247

2 3

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9. System Technology Intake/header – Intake calibration

1

The intake should always be calibrated if the actual chop length differs from the displayed length. Calibration is also necessary if the KMC2 job computer has been replaced or after work on components of the intake drive (pump or hydraulic motor).

On

2 On 3

4

Off

Mode of operation intake control From complete software version 200814616, the rotational speed of the intake is controlled actively in operation. This means that the cutting length is always maintained at the value set by the driver irrespective of the pressure and other outside interferences. In this case, diesel engine load is taken into account. If the speed sensor for the intake does not work, the system acts as a controller.

The active control can be activated with parameter 25507.

General information on intake calibration To calibrate intake/header, the following conditions must be met: - Road/field release switch (1) in field mode - Intake/header release switch (2) ON - Diesel engine speed: 1,900 rpm (BiG X 600/700/770/850/1100) - Maintenance release switch (3) OFF - Traction drive switch (4) OFF - Intake does not rotate - Header does not rotate - The driver must be sitting on the driver's seat - On the BiG X 600/700/770/850/1100 the main coupling must be switched on!

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Calibrate intake/header only when oil is warm!

© KRONE Training Team, Spelle

9. System Technology Intake/header – Menu display intake/header calibration

6 2

1

3

4

5 A

B

C

Е The currents to be determined: The following three currents are determined: „I0“ - is the current at which the unit starts to rotate. „Imin“ - is the current at which the unit reaches the rotational speed which can be set at minimum. „Imax“ - is the current at which the unit reaches the speed which can be set at maximum.

D

In the terminal, open the "Maintenance/Intake and Header Calibration" 3-7 menu.

Progress screen of intake or header calibration: 1. Progress screen of intake calibration (support value 1 and support value 2) 2. Progress bar of the header calibration (support value 1 and support value 2) 3. Actual value on the valve of the intake pump or header 4. Actual value of rotational speed of intake or header motor 5. Display of the saved currents

I0 – Start-up current; Imin – Current at minimum speed; Imax – Current at maximum speed 6.

Diesel engine speed Softkeys (A) and (C): Start intake or header calibration Softkeys (B) and (D) intake or header calibration is stopped Softkey (E): Automatic engine speed setting, 1,950 rpm (BiG X 600/700/770/850/1100) 249

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9. System Technology Intake/header – Header calibration

1

The header should only be calibrated if the actual speed deviates markedly from the setpoint speed or after replacement of the KMC2 job computer. The calibration must also be run after working on parts of the header drive (pump or hydraulic motor).

Even if overspeeding (n > 750 rpm) has been detected, recalibration is required.

On

2 On 4

3

Off General information on header calibration To calibrate intake/header, the following conditions must be met: - Road/field release switch (1) in field mode - Intake/header release switch (2) ON - Rotational speed of diesel engine: 1,900 rpm (BiG X 600/700/770/1100) - Maintenance release switch (3) OFF - Traction drive switch (4) OFF - Intake does not rotate - Header does not rotate - The driver must be sitting on the driver's seat - On the BiG X 600/700/770/850/1100 the main coupling must be switched on!

Calibrate intake/header only when oil is warm!

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9. System Technology Intake/header – Calibration of header/intake

E 2

1

3 4

5 A

B

C

D

By pressing the key (E), the engine speed can be raised to the required speed.

Calibration of header Actuate the key (C) to start the calibration process. Valve Y7 “Header forward” is controlled. The header should start turning after a short time.

The calibration takes up to 120 seconds. If the necessary data cannot be acquired during this time, the calibration is interrupted. Press the key (D) to cancel the calibration process. The progress bars can be used to track the current state of programming.

Calibration of intake Start calibration process by actuating the key (A). Valve Y5 “Intake forward” is controlled. The header should start turning after a short time.

The calibration takes up to 120 seconds. If the necessary data cannot be acquired during this time, the calibration is interrupted. Press the key (B) to cancel the calibration process. The progress bars can be used to track the current state of programming.

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9. System Technology RockProtect calibration The RockProtect calibration determines the value of the signal voltage of the acceleration sensor В76 at rest.

The RockProtect should be calibrated before it is used for the first time or after replacement of components relevant for the system.

On the terminal open the “Maintenance/Calibration/Rock Protect” menu 39.

Before starting the calibration, make sure that the header is in the harvest position. In addition, the intake must be free from crops and the precompression rollers must rest against the bottom limit stop. The intake must not be switched on. The calibration is started by pressing the key (A) under the softkey. The calibration is fully automatic.

1

2

A

B76

252

1. Current value of the signal voltage of sensor В76 2. Saved value of the signal voltage of sensor В76 А - Start calibration of Rock Protect

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9. System Technology CropControl operation unit

2

4

1 5

3

1. Error message present 2. Currently active cultivated area 3. Currently active counterweighing for the displayed cultivated area 4. CropControl counts yield. The following conditions must be met to enable CropControl to count yield:  Intake rotating  Header in working position  Machine moves forward  Excursion of pre-compression rollers more than set minimum excursion 5. The cultivated area is active, but CropControl is not counting yield.

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Pressure sensor in intake drive © KRONE Training Team, Spelle

9. System Technology Operation unit CropControl 1.

2.

3.

4.

5.

6.

One cultivated area forward or backward.

Start or stop the yield counter of the active cultivated area.

Open the CropControl menu level.

Start/reset load counter.

Start or stop counterweighing.

Open “Yield Counter” menu.

1 2

5

3 6

7.

8.

9.

10.

11.

12.

13.

14.

Excursion of pre-compression rollers.

Excursion of pre-compression rollers as numerical value.

Harvested yield of selected cultivated area.

Average yield per area unit.

Current yield per area unit.

Average yield per time unit.

Current yield per time unit.

Load counter

4

9 10

11

7 8

12

13 14

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9. System Technology Setting the minimum excursion In menu 1-1 “Minimum Excursion”, you can set from which excursion of the pre-compression rollers the measurement is started. The higher the minimum excursion setting, the more crops must flow through the rollers to activate the yield counter.

Guide value for minimum excursion: 5mm, to be set by pressing the key (1), “DEF”.

The minimum excursion can be changed by using the “+” (2) and “-” (3) keys. Then confirm the new value by pressing the “OK” key.

2 3

1

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9. System Technology Calibration path sensor B 72 Before placing the machine in service the first time and after any assembly work on the path sensor (1), it must be calibrated. Ensure that no crops are in the intake and that the upper pre-compression rollers are at the lower limit stop.  Open main menu 2 “Calibration”.  Open menu 2-1 “Calibration Path Sensor”.  The left bargraph (2) and the value below show the calibrated voltage value for the path sensor (1). The right bargraph (3) shows the current voltage value of the path sensor. When the right bar (3) is within the red bordered area (4), the path sensor can be calibrated using the “OK” key (5).

2

3

5

1

4

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9. System Technology Calibration pressure sensor B 73: The pressure sensor must be calibrated before starting up the machine for the first time, after any assembly work, and weekly during operation. Ensure that no crops are in the intake and that the upper pre-compression rollers are at the lower limit stop.  Open main menu 2 “Calibration”.  Open menu 2-2 “Calibration Pressure Sensor”.

To perform calibration, proceed according to the following steps:  Move the lifting unit into working position (not lifted).  Switch on chopping drum.  Switching on intake  Move the diesel engine to max. rotational speed (1,950 rpm).

 Set the chop length in the machine terminal to the smallest possible value.

B73

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9. System Technology Calibration pressure sensor B 73:

 Slowly increase the chop length in the machine terminal until the black bar is within the lower green area (1).

2

 Press the function key (2), the calibration is now started and an arrow (3) appears briefly next to the green area.

 The arrow next to the bottom green area disappears and an arrow appears next to the upper green area (3).  The flashing icon (4) now indicates that the chop length must be further increased until the black bar reaches the upper green area (5).

1

6

3 4

5 7

 The flashing icon (4) disappears and you can use the “OK” key (6) now to save the calibrated value.  Press the “ESC” key (7) to leave the “Calibration Pressure Sensor” menu

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9. System Technology Main coupling calibration From terminal software version 150 200 104-08 the valve current can be calibrated for the main coupling (1). The switching behavior is affected in this way.

The calibration should be run for hard switching of the main drive, after repairs or replacement of system components or after replacement of the KMC 3 job computer.

1

General information on calibrating the main coupling To carry out the calibration of the main coupling, the following conditions must be met: - Engine running - Road/field release switch (2) in field mode - Traction drive release switch (3) off - Maintenance release switch (4) off - The driver must be sitting on the driver's seat and the door must be closed - The intake must be mounted in front of the forage harvester

2

On 3

4 Off

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Off © KRONE Training Team, Spelle

9. System Technology Main coupling calibration

3

1.

1

2

2.

3.

5.

6.

5

The current power consumption value of valve Y12 The current value of blade drum speed The current value of engine speed Start calibration of main coupling Stop calibration of main coupling

6

On the terminal open the “Maintenance/Main Coupling Calibration” menu 3-10.

Press the key (5) to start calibration. It runs fully automatically. If no speed is detected on the chopping drum, the automatic calibration is interrupted at 1400 mA. If the calibration process is successful, a green tick appears.

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9. System Technology Main drive brake Functional sequence: The inertia of the diesel engine and the braking power of the brake saddle are used for braking.

Example: The forage harvester is in chopping mode, running at about 1,950 rpm, and the chopping drum on the headland is switched off.

1. The diesel engine reduces its rational speed to idling speed (1,100 rpm), so utilising the supporting torque of the diesel engine.

2. Hydraulic coupling (1) is disconnected.

3. Tensioning force on clamping cylinder (2) for main belt is increased.  In chopping mode, a charge pressure of 30 bar is applied to the piston ground and piston ring side. During braking, the piston ring side is switched to the tank.

4. Pressure is applied to the brake (3).

5. All rotating components for crop flow reduce their rotational speed to 0 rpm.

1

2

3

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9. System Technology Working hydraulics – Hydraulic connection for molasses pump

1

3

2 4 - Additional gearwheel pump (1) on main gearbox - High-pressure filter (2) in the supply - Valve block (3) for single-acting function in the rear of the machine - Couplings (4) for pressure line and depressurised return

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9. System Technology Working hydraulics – Double-acting control unit

1

3

2 - Additional gearwheel pump (1) on main gearbox - High-pressure filter (2) in the supply - Valve plate Bosch 5/3 directional valve SB 12 (3)

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9. System Technology Working hydraulics – Two double-acting control units

1

2

3 - Additional gearwheel pump (1) on main gearbox - High-pressure filter (2) - Valve block (3) from Hydac with two 4/3 directional valves

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9. System Technology Engine overview The BiG X machines are fitted with the following MAN engines:

D 2868 LE 121

BiG X 600 BiG X 700 BiG X 770

D 2862 LE 121

BiG X 850 BiG X 1100

D

28

6

8

L

E

1

2

3

4

5

6

Pos.

265

Designation

1

D - Diesel engine

2

28 - Cylinder diameter 128 mm

3

6 - Cylinder stroke 160 mm

4

8 - Number of cylinders

5

L - Charging with charge cooling

6

E - Built-in engine

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9. System Technology MAN engine electronics ECU (Engine Control Unit) Forms the interface between KRONE bus system and MAN bus system.

EDC (Electronic Diesel Control) The main function of the EDC control unit is to control correct fuel injection, adapted to the different operating conditions, and so control the engine performance and emissions. The control unit (software/hardware) can be used for a maximum of six cylinders.

Therefore a second control unit is required to operate an engine which has more than six cylinders. The both control units communicate via CAN and operate in the so-called Master / Slave mode.

Up to YOM 2011:

CAN MAN

A7

ECU

Power supply 12 V

CAN 3

2

From YOM 2012:

For welding on the machine disconnect both batteries and interconnect the positive and ground wires.

1 EDC (Master / Slave)

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9. System Technology The BiG X machines are fitted with the following Liebherr engines:

D 9508 A7 00

Pos.

267

BiG X 700-3 BiG X 770-3

D

95

08

A7

00

1

2

3

4

5

Designation

1

D - Diesel engine

2

95 - Cylinder diameter cylinder stroke 157 mm

3

08 - Number of cylinders 8 cylinders

4

A7- Common Rail fuel system

5

00 - Emissions Level

128 mm /

BiG X 600_1100 TT Basic 2017

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9. System Technology Liebherr engine electronics

CAN 3

BiGX 700-3, 770-3 On the BiGX 700-3 and 770-3, there is no control unit which is installed in the console and responsible for the engine. The Liebherr control unit (Engine Control Unit 2) which is installed on the engine is directly connected to the KRONE CAN3 bus. Furthermore the Liebherr control unit is continuously supplied with a voltage of 24 V.

1

Continuous power supply 24 V

(1) Motor control module cooled by fuel from Liebherr (Engine Control Unit 2) Fuses The 4 adjacent fuses (2) in the battery compartment exclusively serve to protect the motor control module (1).

The fuse (3) is present on the BiG X with MAN engine as well as on the BiG X with Liebherr engine. This fuse protects the both electronic fuel pumps (4).

3

2

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4

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9. System Technology Fan drive – Mode of operation High pressure measurement connections

 Drive runs in the closed system

6

 Pump in actuated in one direction only -> fan has only one direction of rotation  When the plug is removed, the pump swivels all the way out -> maximum fan speed (fail-safe function)  Fan speed is controlled depending on the temperature of charge air, coolant and oil

7 5 1 3 2 4 (1)

Fixed displacement motor with flush valve

(2)

High-pressure limiting valve/feed valve

(5)

Charge pressure limiting valve (25 bar)

(3)

Pressure cut-off

(6)

Measurement connections high pressure

(4)

Feed pump (integrated)

(7)

Setting valve Y 82

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10. KRONE Diagnostics

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11. Maintenance Maintenance and care are the key factors that guarantee trouble-free operation of the machine.

On the following pages (Chapter 14), you can find some information on this topic.

The operating instructions is a decisive document for maintenance.

There are operating instructions for the basic machine as well as for the various headers.

The appropriate operating instructions can be identified by matching the imprinted machine number.

The document number is used for repeat orders. All operating instructions can also be downloaded from KRONE Media Center (www.krone.de).

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11. Maintenance Periodical maintenance Periodic maintenance refers to the maintenance procedures which are to be carried out after a certain number of operating hours. . This page details the procedures to be carried out after 10 operating hours, i.e. daily.

Check:

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•

Coolant

•

Hydraulic oil

•

Engine oil

•

Water separator

•

Air filter cartridges

•

Tyre pressures

•

Light functions

•

Warning lights

© KRONE Training Team, Spelle

11. Maintenance Central lubrication – General information

2

Central lubrication system The BiG X forage harvester is equipped as standard with a central lubrication system. The system is manufactured by BEKA-MAX. The system consists of a pump (1) with integrated PLV (2) 300 ± 20 bar, main distributor (3) with a switch for central lubrication cycle (4) and the distributors for intake, chopper unit, spout, rear axle and corn conditioner.

1

4 Error detection

3

273

The functionality of the system is signalled by the flashing of the LED in the central lubrication cycle switch. If the piston in the distributor plate moves, the LED flashes. If the LED is not flashing, there may be a blockage in the hose or tanks may be empty. If this is the case, the filling as well as the hoses to the subdistributors must be checked for hardness. Manual lubrication is possible except for the distributor of intake and chopping drum (hard hose is an indicator for blockage).

In the event of a blockage, the system attempts to run 3 more cycles (lubricate/pause) before the error is indicated on the display.

BiG X 600_1100 TT Basic 2017

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11. Maintenance Central lubrication BEKA-MAX – Lubricant fill The lubricant is filled via the conical grease nipple (1) DIN 71412-AM10x1 by means of customary grease gun.

A hydraulic breakaway coupling is fitted ex works to provide quicker filling. The mating part of the coupling is included in the accessories kit of the machine.

- Mount the coupling sleeve 27 001 595 0 (5) on the filling pump (4).

Filling cylinder 940 393 0 (6): - Remove locking screw M20x1.5 (7) and replace it by filling connection 940 392 0 (8).

Filling through the cover is not permitted, as this may allow dirt and air bubbles to enter the reservoir and cause disturbances.

1 7 5 8

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11. Maintenance Central lubrication BEKA-MAX – Programming The central lubrication system can be “activated” manually as required by opening menu 3-7, “Maintenance/Calibration – Intake and Header” and turning on the “Road/Field” and “Header” switches. Troubleshooting can then be carried out on the system, or intermediate lubrication can be activated, by pressing the key (A) directly on the central lubrication system. The cycle time or the number of cycles can be set using the grid switches (Z) and (T) in the controller view window.

A

KRONE factory setting: BiG X 600/700/770/850/1100: Cycle time: Lubrication duration:

8min 34 cycles

Number of cycles

lubrication duration

cycle time

T

Z

Grid switch (Z) : Setting of cycle time in min Grid switch (T) : Set lubrication duration in cycles

- One cycle more or less corresponds to 0.5% lubricant - Two minutes of cycle time more corresponds to 20 % less silage additives - Two minutes of cycle time less corresponds to 20 % more silage additives

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11. Maintenance Central lubrication BEKA-MAX – Diagnostics/intermediate lubrication The central lubrication system can be "activated" manually as required by opening menu 3-1, "Maintenance" and turning on the "Road/Field" and "Header" switches.

When you press key 5 the system starts an intermediate lubrication routine and at the same time a troubleshooting sequence is initiated.

Operation unit (F)

LED (G) : green

5

F

G

R

LED (R) : red

After an error in the central lubrication, the system troubleshooting procedure must be run as described above in order to resume normal operation!

The red LED (R) always indicates a fault The flash code indicates the type of disturbance:

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11. Maintenance Central lubrication BEKA-MAX – Lubrication chart

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11. Maintenance Manual lubrication points

Although the central lubrication system supplies almost all lubrication points, there are a few points which must be supplied with grease manually.

250 h

250 h

250 h

100 h

250 h

250 h

250 h 50 h

250 h

250 h

100 h

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11. Maintenance Fuel filter overview MAN engines Pos.

4

Designation

1

Prefilter of hand pump

2

Prefilter with water separator

3

Prefilter of hand pump (vents the system)

4

Main fuel filter (only for V12 engines)

5

Fuel main filter

6

Electric fuel pumps

5

2

3

4 5 Caution

2

Ensure extreme cleanliness when removing filters.

3

6 1

1

6

Even the tiniest particles (0.02 mm) may cause the Common Rail system to fail.

Fuel schematic - BiG X with MAN V12 engine. V8 engines have one high-pressure pump and one main filter fewer.

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11. Maintenance Engine oil – maintenance MAN engines Each BiG X includes operating instructions and a maintenance booklet from the respective engine manufacturer. These documents are fundamental for the maintenance of diesel engines. Additional useful information, e.g. lists of consumables, can be found on the Internet.

These lists provide information on which types of oil have been released by which manufacturer for the particular engines. This list is always up-to-date! You are therefore recommended to use the link below.

https://mmrepro.mn.man.de/bstwebapp/BSTServlet

Specification M3277 High-performance diesel engine oil Oil change intervals: • D 2868 LE 121 • D 2862 LE 121

Every 500 operating hours

(engine oil according to specification M3277) Checking the valve play.

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Every 500 operating hours

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11. Maintenance Fuel filter overview Liebherr engines Pos.

Designation

1

Prefilter of hand pump

2

Water separator with filter (monitored by sensor)

3

Hand pump (vents the system)

4

Fuel main filter

5

Electric fuel pumps

3 2

4

Caution Ensure extreme cleanliness when removing filters.

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Even the tiniest particles (0.02 mm) may cause the Common Rail system to fail. © KRONE Training Team, Spelle

11. Maintenance Engine oil – Liebherr engines Each BiG X includes operating instructions and a maintenance booklet from the respective engine manufacturer. These documents are fundamental for the maintenance of diesel engines. Additional useful information, e.g. lists of consumables, can be found on the Internet.

These lists provide information on which types of oil have been released by which manufacturer for the particular engines. This list is always up-to-date! You are therefore recommended to use the link below.

Engine oils according to specification: ACEA: E4-99, E6, E7 API: CF-4, CG-4, CH-4, CI-4 Also permitted: Engine oils according to MAN specification M 3477 Oil change intervals: • D 9508 A7 00

Every 1,000 operating hours

Checking the valve clearance.

282

Every 1000 operating hours (YOM 2016 all 500 hours!)

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11. Maintenance Gearbox oils Oil change intervals and oil types Power take-off gear and transfer gearbox are filled with PAO gearbox oil (PAO Mobil SHC 630) or (PAO Renolin Unisyn CLP 220). The two oils can be mixed.

Older BiG X machines have PGLP DIN 51502 on these gearboxes/viscosity 220  This oil cannot be mixed with a PAO oil.

WARNING

Power take-off gear: First oil change interval: 50 h Then every 1,000 hours or at least once a year.

PAO Mobil SHC 630 or PAO Renolin Unisyn CLP 220

Never mix PGLP and PAO oils.

Intake gear: • Top roller drive • Transfer gearbox (GL 5 SAE 85W90)  lower roller drive partly PAO Renolin Unisyn CLP 220 Oil change every 1,000 hours, or at least once a year

Spout tower gearbox: Oil change: every 1,000 hours or at least once a year Mobil Glygoyle gearbox oil 460

Planetary gearbox Bosch: First oil change interval: 50 hours 2. Oil change once after 500 hours Oil change every 1,000 hours but at least once a year SHELL SPIRAX S4 CX 50

283

VariLOC gearbox First oil change interval: 50 hours Then every 700 drum hours or at least once a year.

PAO-Renolin Unisyn CLP 220

PAO-Renolin

Transfer gearbox: Oil change every 1,000 h, or at least once a year PAO Mobil SHC 630 or PAO Renolin Unisyn CLP 220

BiG X 600_1100 TT Basic 2017

PAO-Mobil

© KRONE Training Team, Spelle

11. Maintenance Gearbox oil cooling

4

1 6

(1)

Gearwheel pump

(2)

Integrated pressure limiting valve

(3)

Pressure switch

(4)

Nozzle

(5)

Filter

(6)

Non-return valve

(7)

Measurement connection

6a

3

2 from the cooler

7

3a

to the cooler

5 Depending on the year of manufacture, the non-return valve (6) at position (6a) is mounted above the power take-off gear or, as shown, in the hydraulic lines. Mounted facing the cooler (6). Measurements taken at measurement connection (7) should always be below 30 bar. At operating temperature, the pressure there should be approx. 1-3 bar.

A pressure switch (3) additionally monitors the cooling system. With effect from the 2015 year of manufacture, the pressure switch (3) is no longer fitted directly on the gearwheel pump (1), but further towards the cooler (3a).

284

1

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

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11. Maintenance Hydraulic oil change interval: 500h

3

Tank capacities: BiG X 600 / 700 / 770 / 850 / 1100

approx. 150l

1

For approved hydraulic oils and specifications refer to the operating instructions. Hydraulic oil according to specification HLP VG 46 or HEPG VG 46 When changing the oil, always replace the hydraulic oil filter inserts, as well.

Hydraulic oil change: At the 500 h hydraulic oil service the hydraulic oil should be drained out of the tank (1) into a suitable container with a hose (supplied) via the quick coupler (2). Furthermore the hydraulic oil filters (3) must be replaced.

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2

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11. Maintenance High-pressure fine filter for working hydraulics and steering hydraulic pump   

286

With contamination indicator Replacement of the filters as required or when hydraulic oil changed Bypass function in case of contaminated filter

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11. Maintenance Venting the wheel motors (Poclain traction drive)

BiG X 700/850/1100 Front wheel motors, hexagon sockethead screw inside

Rear wheel motors, hexagon socket-head screw top

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

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11. Maintenance Venting the fan drive components Variable displacement pump fan drive The leakage oil pipes must be connected and the pump housing must then be vented via the upper filler plug (X).

X

Fixed displacement engine fan drive The engine must be filled as far as possible via the leakage oil connection (T). Further venting is then not required.

T

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

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11. Maintenance Venting the components of Bosch traction drive Variable displacement pump traction drive To vent the pumps, detach the hydraulic hoses on the top of the pumps (> leakage oil lines connection X) until the air has escaped and the hydraulic oil flows out without bubbles.

X

Traction drive adjusting motor The engine must be filled as far as possible via the leakage oil connection (T). There is then no further need for venting.

T

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

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11. Maintenance Bleeding the pumps To vent the pumps, detach the hydraulic hoses on the top of the pumps (leakage oil lines) until the air has escaped and the hydraulic oil flows out without bubbles.

BiG X 600, 700, 770, 850, 1100

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

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BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

11. Maintenance Main drive brake Wear monitor: When the brake pads (1) have reached their wear limit, a notification is displayed on the terminal: Message 5013 “Check main drive brake pad wear”

1

291

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

11. Maintenance Checkpoints Intake

Corn conditioner/ grass channel

•

Bars on the two intake rollers • Inner wear plates left/right • Scraper • Flat roller (pay attention to gap)

Chopping drum • • • •

292

Counterblade Blade Drum base Grinding stone

BiG X 600_1100 TT Basic 2017

• •

Rollers Wear plates

Discharge accelerator/StreamControl • • • •

Discharge scoop Rear wall top, rear wall bottom Scraper Wear plates, left/ right side

© KRONE Training Team, Spelle

11. Maintenance Checkpoints Spout

Transfer shaft

•

Wear replaceable separately

• Wear plate back • Wear plates, left/ right side

plates

Main drive brake • Brake pads • Brake disc

293

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

11. Maintenance Conversion from grass to maize 1.

2.

3.

4.

5.

6.

7.

Rotate toothed bars on upper feed rollers Mount grain capture sheets (2 units) Replace tension spring by double-acting cylinder Replace counterblade and blades Conversion grass channel/corn conditioner Corn conditioner calibration Open the air inlet opening on the discharge accelerator 8. Assembly of spout extension 9. Assembly of rear weights 10. Switch over hand valve on lifting unit hydraulics 11. Adjust settings in the terminal 12. Calibration of lifting unit

1

2

3 4

294

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

11. Maintenance Conversion from grass to maize 1.

2.

3.

4.

5.

6.

7.

Rotate toothed bars on upper feed rollers Mount grain capture sheets (2 units) Replace tension spring by double-acting cylinder Replace counterblade and blades Conversion grass channel/corn conditioner Corn conditioner calibration Open the air inlet opening on the discharge accelerator 8. Assembly of spout extension 9. Assembly of rear weights 10. Switch over hand valve on lifting unit hydraulics 11. Adjust settings in the terminal 12. Calibration of lifting unit

6

5

7 8

295

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle

11. Maintenance Conversion from grass to maize 1.

2.

3.

4.

5.

6.

7.

Rotate toothed bars on upper feed rollers Mount grain capture sheets (2 units) Replace tension spring by double-acting cylinder Replace counterblade and blades Conversion grass channel/corn conditioner Corn conditioner calibration Open the air inlet opening on the discharge accelerator 8. Assembly of spout extension 9. Assembly of rear weights 10. Switch over hand valve on lifting unit hydraulics 11. Adjust settings in the terminal 12. Calibration of lifting unit

9

11

12

Grass

Maize/maintenance

10

296

BiG X 600_1100 TT Basic 2017

© KRONE Training Team, Spelle