KRONE BiG X TT 2014 Advanced Forage Harvester Service Training Manual

Forage Harvester BiG X

Training

Season 2014

Name: ________________________________ Company:

No. 150 331 449 05 EN BiG X TT 2014 Advanced

________________________________

Training date: __.__. 20__ to __.__. 20__ BiG X Service Training 2014 Advanced

Update level: January 2014

© KRONE Training Team, Spelle

2014 BiG X Electrical System

2

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

Contents

1.

2.

3.

4.

5.

3

Terminal Operation (4-13) System Technology – Sensors (14-35) System Technology – Calibrations (36-69) Electrical System / Electronics (70-109) Software (110-120)

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: Basic Screen Blow-off valve

intake

Variable measuring units

Colored display of the speed under load

ISOBUS steering system Change of the load display

Driving strategy / Traction Control mode

4

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: Machine Settings Pick-up EasyFlow:

When using EasyFlow, select “lifting unit ground pressure control” (Р) in the “General Machine Settings” menu.

Value (А) for working with EasyFlow should be within the range 20-30 % based on conditions.

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

Recommendation: 400 - 420 rpm as basic speed.

P

X-Disc direct cutting system:

When using X-Disc, select the ground pressure control (Р) in the “General Machine Settings” menu. In exceptional cases (stony conditions) the machine can be driven in lifting gear position mode (α).

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

U А 5

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: Machine Settings Maize header EasyCollect:

When using Easy Collect without sensing skids, select lifting gear position control (α) in the “General Machine Settings” menu.

α

When using EasyCollect with sensing skids, lifting unit distance control (d) should be selected in the "General Machine Settings" menu.

d

6

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

Recommendation: 380 - 420 rpm as basic speed.

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

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

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

If this is the case, the “Joystick Memory Buttons” setting mask can be selected at menu item 1-10 or by pressing button D from the basic screen. The following functions can be assigned to the joystick memory buttons:

M1

M2

- Raise / lower plant divider (only in the corn) / holdingdown device (only in the grass)

- Increase / reduce working width

±

- Retrieve saved cutting lengths (of the small cross switch lever) 1 or 2

1/2

- Increase / reduce header speed

±

- Rotate pendulum frame left / right If buttons M1/M2 have been assigned functions, the illustrated setting mask screen appears when the machine is started.

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

7

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: AutoScan Settings

(as standard)

2

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

3 10

7

8

9

6

1 4 5

“AutoScan Setting” menu within the machine settings range 1-2 1.

Setting min./max. chop length

2.

Graphic representation of the settings

3.

Setting for degree of maturity sensor available / not available

4.

AutoScan status automatic adjustment of chop length active

6.

Currently determined degree of maturity If the display stays at 50%, the sensor will not detect a valid maturity.

7.

Current chop length

8.

Current position on the characteristic curve within the working range

9.

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

10.

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

manual adjustment of chop length active 5.

8

Activation of the automatic cutting length adjustment via button "D"

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: PowerSplit (optional) BiG X 700/850/1100 Eco-Power – X-Power

Eco-Power is used when maximum machine performance is not required. If you require more power, switch to X-Power on the BiG X 700, 850 and 1100 by pressing button (1). As an option, this power change can be carried out automatically depending on the engine capacity. This mechanism gives you flexibility and reduces diesel consumption. The use of large, powerful forage harvesters is therefore more economical even in weak or highly changeable mowing conditions.

1

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

BiG X 700 TRi-Power

On the BiG X 700, you can also switch to TRi-Power by pressing key (1).

(Standard on machines from YOM 2014).

In older machines, this option can only be released by KRONE customer service.

BiG X 600

The BiG X 600 is only equipped with X-Power mode

9

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: PowerSplit (optional) BiG X 700/850/1100 1. Diesel engine speed

when machine automatically changes from ECO-Power to X-Power (i.e: 1600)

2.

Setting the mode (X-Power or ECO-Power) when the machine is in X-Disc or corn mode after restarting the machine.

3.

Setting the mode (X-Power or ECO-Power) when the machine is in grass mode after restarting the machine.

4.

Setting the mode (X-Power or ECO-Power) that has to be active in road operation after the machine has been restarted.

5.

Current performance mode

6.

Setting the automatic switchover between activating/deactivating ECO-Power and X-Power and switchover course.

Characteristic

: Abrupt change when speed is reached

Characteristic

: Change is gradual and starts approx. 100 rpm before speed is reached : PowerSplit deactivated

10

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: Settings ContantPower ConstantPower – Load limit control The ConstantPower load limit control varies the forward driving speed based on the engine load. The result is constant load on the engine.

This keeps the machine in its optimal performance range and lowers fuel consumption.

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

4

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

1

2

5 6

3

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

1.

Setting speed reduction depending on speed (key „1“) z.B.: 10%  2000 rpm – 10% = 1800 rpm

2.

Adjustment speed reduction depending on engine duty (key „2“) z.B.: 80% 

3.

Adjustment of min. / max. speed.

ConstantPower varies forward speed only in that range.

4.

Current engine speed

5.

Current engine load

6.

Nominal diesel engine speed The BiG X 1100 can only be set dependent on speed (key 1).

11

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. Terminal: Settings RockProtect RockProtect - Rock detection (optional) Sensitivity can be adjusted by the driver from 0-100%. Due to varying conditions (swath shape and size), it may be necessary to adjust the sensitivity several times a day. To ensure that the system works properly, the sensitivity must be adjusted to the given conditions. To do this, adjust the sensitivity with parameter 27500 (see the graphic below).

Sensitivity 0%

12

BiG X Service Training 2014 Advanced

100 %

© KRONE Training Team, Spelle

1. Terminal: Submenu Structure (Software 200830521) 1. Settings 2. Counters

3. Calibrations

4. Diagnostics 5. Closing Submenu

1-1-22

1-1-25

1-1-26

4-4-4

4-4-5

13

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Namur Sensor Namur sensors The NAMUR proximity switches are two-wire sensors which record metallic materials without contact.

The sensors are supplied with a constant voltage of 8.2 V. They emit two different signals. These sensors detect if the sensor is alive with metal or not. The sensors are connected to an analog input of the corresponding voltage. Not only the sensor can be evaluated but also the wiring can be diagnosed. The following four states are possible:

14

Condition

Voltage

Current

Cable break

approx. 8.6 V

0 mA

Sensor alive

approx. 7.3…8.3 V

20% of the maximum value

Sensor is not alive

approx. 2.4…5.2 V

60% of the maximum value

Short circuit

approx. 0.0 V

Maximum current

+ 8.2 V

Diagnostic s

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Namur Sensors Namur sensor M12x1 302 409 1 (Switching distance 2 mm) B25 – Header right B28 – Spout position middle B29 – Spout position bottom B36 – Grinding stone position left B37 – Grinding stone position right B55 – Header left B59 – Maintenance flap grinding device closed B92 – Cylinder tension roller main belt Namur sensor M18x1 302 312 1 (Switching distance = 4 mm) B58 – Cutting drum speed Namur sensor M12x1 302 448 0 (Switching distance 2 mm) B30 – Spout rotation pulses (cannot be set)

X

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

1

Setting dimension X= 2 mm (M12 and M18)

2

15

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Brake Namur Sensor NPN - normally closed contact When actuated, a NPN transistor switches the output to minus.

NPN - normally open contact When actuated, a NPN transistor disconnects the output from minus.

1

3

2 NPN - normally open contact

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

– 12V – 0V

NPN sensor 00 302 897 0 Opener, switching distance 4 mm B40 – service brake switch

X

When metal is detected, the signal line is disconnected from minus.

Nominal power supply 12 V DC Setting dimension X= 1.5 mm Tightening torque: max. 10 Nm.

16

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

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

B52 – Transverse inclination pendulum frame

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

3

2

1

IV 250°

0°

1V

2

1

I

III 5V→1V

1V→5V

V

3 180°

5V

II 17

70°

During installation, the flattened side of the sensor shaft must always point in the direction of the plug.

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

1. System Technology - Sensors: Bosch Angle Sensors Hall angle sensor The sensor works with a power supply of 8 to 10 volts. 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=10V 0°

2.5V→7.5V

Sensor

Function

Angle

B47

Header contour left

B48

Header contour right

B50

Lifting unit position

B61

Row registration right

B65

Row registration left

B64

Steering axle (Autopilot)

82°

B 107

Steering axle (Bosch traction drive)

110°

Ub+

U signal

Part No.

10 V

2.5 V – 7.5 V

8.5 V

2.1 V – 6.4 V

72°

10 V

2.5 V – 7.5 V

303 164 0 (Bosch R 917 005 166)

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

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

3 2 1

72° (82°)

During installation, the notch (K) on the sensor shaft must always point towards the plug (see figure).

18

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Steering Angle Sensor Angle sensor steering axle The sensor to record the steering angle is on the rear axle on the left-hand side on the steering knuckle. This sensor is merely used for the traction drive in order to be able to implement the traction control function.

After replacing the sensor or working on the steering, re-adjust the steering angle sensor. To do this, the wheels must be moved to straight-ahead driving and the sensor must be set to 5.0 +/- 0.1 volts.

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

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

Uvers=10 V

Pin 1:

0 V (earth)

Pin 2:

2,5 V…7,5 V (steering angle)

Pin 3:

+10 V

3 2 1

0°

2.5V→7.5V

72° (82°)

19

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology – Sensors: Pivoting Angle Sensor Pivoting angle potentiometer traction drive pumps (Poclain) The pivoting angle potentiometer is recorded and evaluated by the SmartDrive traction drive control. The SmartDrive power supply voltage is 5 volts.

The value range of the potentiometer is 0…5 volts. When the pump is in the centre position (machine at standstill), the potentiometer must be set to 2.5 +/- 0.02 volts.

When installed, the value range of 1,.8…4.3 volts is set.

Forward travel:

Value range 2.5…4.3 volts

Reverse travel:

Value range 2.5…0.7 volts (partially limited!!!)

B 38 / B 39 axle

270016270 Pivoting angle potentiometer front axle / rear

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

20

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Pivoting Angle Sensor Pivoting angle sensor traction drive pump (Bosch) The pivoting angle sensor records the position of the captive washer on the drive pump. It also monitors whether the control signal transmitted from the control to the pump has been correctly implemented, i.e. whether the pump swivels out to the extent specified by the control.

When the pump is in the central position, the potentiometer must be set to 2.5 +/- 0.02 volts.

Forward travel:

Value range approx. 2.5…4.0 volts

Reverse travel:

Value range approx. 2.5…1.0 volts

Pin A:

0 V (earth)

Pin B:

12 V (power supply voltage)

Pin C:

approx. 1…4 V

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

4. Finally, the sensor must be calibrated with BODAS.

21

BiG X Service Training 2014 Advanced

C

© KRONE Training Team, Spelle

A

2. System Technology - Sensors: Brake Pedal Sensor Angle sensor brake pedal (Bosch traction drive) On BiG 700-I, 850-I und 1100-I, an angle sensor is mounted on the brake valve to record the position of the brake pedal. A current is generated depending on the position of the brake pedal.

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

B109 – angle-position encoder 20 081 500 0

22

Measuring range:

120°

Power supply voltage:

12 V

Signal:

4…20 mA

BiG X Service Training 2014 Advanced

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

GND 12 V 4…20 mA free free free

© KRONE Training Team, Spelle

2. System Technology - Sensors: Brake Pressure Sensor Pressure sensor The sensor works with a 12V power supply. The signal voltage changes from 1V to 5V if the sensor is charged with the pressure (P) from 0 to 130 bar.

The pressure in the service brake pressure line is determined by the pressure sensor B16. The data is transmitted to the computer A1 SmartDrive and there it is evaluated together with the B40 service brake switch signal.

P

B16 – Pressure sensor 00 302 029 2

1

2

P 1

2

3

23

U 3

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

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Lifting Gear Pressure Sensor Pressure sensor The sensor works with a power supply from 8V to 10V. The signal voltage range depends on the power supply.

Signal voltagemin 0.25 x Uvers Signal voltagemax 0.75 x Uvers The signal voltage changes if the sensor is charged with pressure (P) from 0 to 200 bar.

1

3

P

B49 – Pressure sensor 00 302 530 0

3 2

U

1

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

U (V) 8.0 250 digits = 7.5 7.0 6.0 5.0 4.0 3.0 0 digits = 2.5 2.0 1.0

P (bar)

0 20 24

40

60

80 100 120 140 160 180 200

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

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

B63 – pressure sensor 302 647 0 Measuring range:

0…250 bar

Power supply voltage:

12 V

Signal voltage:

1…5 volts

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

25

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: High Pressure Sensor Pressure sensor Hydac 500 bar – High pressure sensor (Poclain traction drive) On the BiG X with Poclain traction drive, a Hydac high pressure sensor is installed.

This sensor records the pressure in the "forwards" high-pressure line of the front axle traction drive pump.

B13 – pressure sensor 302 473 2 Measuring range:

0…500 bar

Power supply voltage:

12 V

Signal voltage:

1…5 volts

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

26

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: High Pressure Sensor Pressure sensor Bosch bar – High pressure sensor (Bosch traction drive) On the BiG X with Bosch traction drive, two high pressure sensors are installed. They record the pressure in both high-pressure lines of the traction drive. They are installed in the drive pump, directly next to the SAE flanges.

B101 / B 102 – pressure sensor 27 007 711 0

27

Measuring range:

0…600 bar

Supply voltage:

10 volts

Signal voltage:

0.5…4.5 V

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

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

B91 – pressure sensor 27 005 687 0 Measurement range:

0…4 bar

Power supply voltage:

12 V

Signal voltage:

1…5 volts

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

Pin 4: not assigned

28

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Poclain Wheel Motor Speed Sensor Speed sensor wheel motor Poclain This speed sensor is used on BiG X 700 / 850 / 1100 in the rear wheel motor on the right hand side. The SmartDrive uses this signal to calculate the driving speed. This information is required for the indicated travelling speed, the acreage counter as well as for the travel path. Prior to this, these values have been determined from the signals of the both captive washer potentiometers of the variable displacement pump (feedback sensors).

1

3

B90 – speed sensor 27 007 142

4

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

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

The sensor is activated and deactivated via parameter 22049. If the value of the parameter is O, no signal is interrogated here.

29

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Bosch Wheel Motor Speed Sensor Speed sensor (Bosch traction drive) On BiG X 600-I, 700-I, 850-I und 1100-I, a speed sensor is installed on each adjusting motor for each wheel drive.

This speed sensor is used for recording the travelling speed as well as for the traction control system.

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

10 volts Pin 1:

+10 volts

Pin 2:

GND

Pin 3:

Frequency signal

Pin 4:

Direction of rotation

sensor

2

1 On machines from YOM 2014, new speed sensors (1) have been installed. These speed sensors cannot be replaced by the shown ones (2).

30

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Intake / Header Speed Sensor Sauer

Linde

Krone no. 919 938 0

Krone no. 270 016 900

Speed measurement intake / header A speed sensor is installed on the hydraulic motors for the header and intake drive.

The sensor (Hall Effect Sensor) detects a magnetic ring. This ring is attached around the cylinder of the unit.

If the speed sensor is now supplied with voltage, it emits a digital frequency signal based on the magnetic ring speed.

Parameter designation

Make of the engine

Absorption volume engine

Parameter 25491

Type engine feed drive

Sauer

75 cm³

0

Linde

75 cm³

1

Type engine header

Sauer

55 cm³

0

Linde

55 cm³

1

Linde

75 cm³

2

From complete software version 200814618 on, the speed is controlled by the speed of the intake sensor. This speed control controls the speed depending on the set cutting length and the current engine speed.

31

Parameter 25492

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Hydraulic Oil Temperature Sensor Temperature sensor The semi-conductor temperature sensor can be used to measure temperatures from 0°C to 120°C. Due to the pressure resistance up to 600 bar, this sensor is ideal for hydraulic applications for the use in the industrial and mobile area.

The BiG X 700/850/1100 uses this sensor to measure the temperature of the hydraulic oil returning to tank. The determined value is used to control the hydraulic fan drive.

Connection diagram

B85 – Temperature sensor 20081040.0

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

Tightening torque: 20Nm

32

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Seat Switch Seat switch for self-propelled machine – S 69 (up to YOM 2010) New seat switches have been installed in the new cabs since YOM 2011 to improve protection against failure and manipulation.

Manipulation is impeded due to integrated resistors and the safety for the user is thus increased.

The new seat switch can be identified by the plug connection facing the driver’s seat:

Observe parameter!

Digital seat switch: Parameter 33659 = 0

Single switch (digital): 2-pole plug connection rear right on the driver’s seat

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

33

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

2. System Technology - Sensors: Poclain Seat Switch Seat switch for self-propelled machine – S 69 (Poclain traction drive) BiG X 500 / 650 / 700 / 850 / 1100

Observe parameter!

Diagnostics-capable switch: 16-pole plug connection rear left in the driver`s seat (removed here)

Diagnostic s symbol

34

Analog seat switch 5 volts: Parameter 33659 = 1

Meaning

Diagnostics value

Voltage

Seat switch open (no driver)

333…452

3.00…3.82 volts

Seat switch closed (driver on seat)

142…261

1.40…2.12 volts

Cable break

0…142

0…1.40 volts

Short circuit

>452

> 3.82 volts

BiG X Service Training 2014 Advanced

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

© KRONE Training Team, Spelle

2. System Technology - Sensors: Bosch Seat Switch Seat switch for a self-propelled machine - S 69 (Bosch traction drive) BiG X 500 / 650 / 700 / 850 / 1100

Observe parameter!

Diagnostics-capable switch: 16-pole plug connection rear left in the driver`s seat (removed here)

Diagnostic s symbol

35

Analog seat switch 10 volts: Parameter 33659 = 2

Meaning

Diagnostics value

Voltage

Seat switch open (no driver)

714…900

6.00…7.64 volts

Seat switch closed (driver on seat)

333…500

2.80…4.24 volts

Cable break

0…333

0…2.80 volts

Short circuit

> 900

> 7.64 volts

BiG X Service Training 2014 Advanced

Manipulations may result in serious or even fatal injuries! Any modification is forbidden!

© KRONE Training Team, Spelle

3. System Technology - Calibration: Pendulum Frame Sensor Calibrating pendulum frame sensor The calibration of the pendulum frame sensor (1) must be carried out every time repair or maintenance work is done on the pendulum frame.

Even if the sensor or the job computer KMC3 is replaced or removed.

General information to calibrate the pendulum frame The following conditions must be met to calibrate the pendulum frame: - Road / field release switch (2) in field mode - Traction drive release switch (3) off.

It is best done with the header (EC, EF, X-Disc) on the machine so that an exact level is achieved.

1 The header can be aligned horizontally with the keys (4) if the hydraulic cylinder (maize) is installed on the pendulum frame.

2 On

4 3 Off 36

1 Calibration is only necessary for BiG X 500, 650-I, 800 und 1000.

Parameter 33634 = 0 (angle sensor Elobau)

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Pendulum Frame Sensor

V 1

2

3 D

Calibrating the pendulum frame sensor Open “Maintenance/Calibration/Pendulum Frame” menu 3-3 in the terminal.

If the pendulum frame is in horizontal position, the value (1) of sensor B52 must be between 350 - 450. Align the sensor in the oblong holes again, if necessary.

When installing the sensor, ensure that the flattened side of the sensor shaft (W) faces the plug (S).

Press the button (D) to save the current, displayed value as a horizontal position.

1. Actual value sensor (V) 2. Saved value sensor (V) in horizontal position 3. Permitted deviation from the saved value (2)

37

BiG X Service Training 2014 Advanced

W

S

© KRONE Training Team, Spelle

3. System Technology - Calibration: Pendulum Frame Sensor Intake BiG X 700, 700-I, 850, 850-I, 1100, 1100-I B87 Pendulum frame position left top, B88 pendulum frame position right top (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 alive by a movement of the pendulum frame, this means: B87 alive = pendulum frame + front attachment higher on left B88 alive = pendulum frame + front attachment higher on right As the sensors are in a fixed position in the feed drive housing, calibration is no longer required.

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

B 88

B 87

Parameter 33634 = 1 (Namur sensors)

38

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Lifting Unit P

Lifting unit sensors The adjustment of the lifting unit must be performed once before starting the respective header or after replacing a sensor relevant for control, the EMR or the KMC 3, or in general after making mechanical, electronic or hydraulic changes to components relevant for function.

Installing the angle sensors (V) The angle sensor (V) should be installed so that the notch (K) points to the plug (S). The pin (P) in the axle must face the other side.

K

2

1

α P

1

α

3 d

d

1.

2.

3.

Pressure sensor (Р) Position sensor (α) Spacer sensors (d) left right

В49 В50 В47 В48

S

2 3

39

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

V

3. System Technology - Calibration: Lifting Gear 2

1

α P

1.

2.

3.

α

3 d

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

Default setting of the lifting gear sensors Open “Service/Diagnostics/Lifting Unit” menu 4-1-5.

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

When the lifting gear 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 or to d adjust sensor B50 to its minimum position, mind that the minimum position cannot be reached if a header is installed on the machine. In this position, the value of the 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. Readjust the sensors in the oblong holes.

W

V 40

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

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

- Pick-up, maize header or X-Disc must be mounted. In the “General Machine Settings“ menu of the terminal, an appropriate header must be set because a lifting unit calibration must be performed for each mode (Easy Collect, Pick up, X-Disc) consider different header weights.

- The machine on level ground and the header unfolded - Align the header horizontally.

1

41

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Lifting Unit Adjusting procedure 3 The maximum position of the lifting unit is adjusted (B50 – 100%) and, if fitted, the maximum height of the header contour lifting gear control type (B47 and B48 - 100%).

Simultaneously hold down button (2) and button (N) on the joystick for approx.

7 s. Lifting unit moves to the upper stop. Hold down button combination until the message "EMR Adjustment 3 OK" appears in the terminal.

1

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 lifting unit into working position by pressing button (1) on the joystick. Caution: Approach position from above, do not raise lifting unit again!

Stop just before contact with ground (glide skids of the header contour must be on the ground).

Hold down button (N) on the joystick for approx. 7 s until the message "EMR adjustment 2 OK" appears in the terminal.

N

В50

В48

В49 α P

42

В47

α d

d

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

Set the lifting unit completely down on the ground using key (1) on the joystick. Hold down key (1) and key (N) simultaneously for approx. 7s until the message “EMR adjustment 1 OK” appears in the terminal.

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Lifting Unit Checking the calibration of the lifting unit The diagnostics and the corresponding values of the sensors can be checked in the diagnostics menu. On the one hand, the actual values (I) are displayed here. On the other hand the saved values for the corresponding positions (II) are shown.

On the sensor B49, the value is saved in the centre position (adjusting procedure 2) during calibration. 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 assignment of the values to the appropriate position can be taken from the respective adjacent symbol.

I II

Menu 4-1-5

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

43

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Lifting Unit Calibrating 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 to perform the cutting height calibration: - Road/field release switch (1) in field mode - Traction drive release switch (2) OFF -Front attachment is attached and it is horizontal. The corresponding operating mode in the terminal has been set.

Open menu “Maintenance/Calibration/Pendulum Frame” 3-3 in the terminal.

Calibrating 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 - In case of maize header or direct cutting system, measure the distance between ground and cutter blade Select the field (4) “Height of the lifting unit at 80%“ with the rotary potentiometer and enter the determined dimension.

Calibrating lower lifting unit height Lower lifting unit until the current lifting height (3) value is 20%.

- Determine values as above Select the field (5) “Height of the lifting unit at 20%“ with the rotary potiometer and enter the determined dimension.

44

BiG X Service Training 2014 Advanced

1 On

2 Off

4

3

5

The cutting height is only calibrated for the display of the cutting height in the terminal. The function of the lifting unit control is not influenced.

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibrating the autopilot sensors Starting with the complete software version 200814616, two different autopilots are available if the machine is equipped accordingly. On the one hand an autopilot exists. This autopilot functions by means of the mechanical row tracers. On the other hand it is possible to use a GPS based system. This system works via a standardized 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 can be made in “Machine Settings” menu.

The autopilot via row tracer is only available in maize operation. Working with the GPS based system is possible in every mode.

For the autopilot via the mechanical row sensors, the sensors on the row tracers, of the steering angle sensors and the currents on the steering valve must be calibrated.

A calibration of steering angle sensor and steering valve is necessary for GPS based systems. The turning circle of the machine must also be saved here.

On GPS based systems, an additional start-up of the additionally installed system is also required. To do this, observe the notes of the respective manufacturer.

45

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibrating the autopilot sensors To ensure a proper function of the autopilot, carry out 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).

P K

S

1 On

3

2 On

On General information on the calibration of the 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 sits on the driver's seat and the cab door is closed - The EasyCollect is attached and folded out - The machine is on a level surface

4

5

Installing the autopilot sensors When installing the angle sensors (4) В65 and В61 for the row tracers, ensure that the notch (K) points towards the plug (S).

The pin (P) in the axle must point to the opposite side.

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

46

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot L 1

R

2

R

L

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

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

The actual value (1) of the sensor (L) В65 must be within the range 265 ± 50; if required re-adjust sensor mechanically in the oblong holes. Activate the row tracer to limit obstruction. When the row tracer is pushed to the end of its stroke there must be a difference of 300 – 320 in the value. (important is that the value increases).

Select the "Row tracer on 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 sensor (R) В61 must be in the range 590 ± 50, re-adjust the sensor mechanically in the oblong holes, if necessary. Activate the sensor to the limit obstruction. When the row tracer is pushed to the end of its stroke there must be a difference of 300 – 320 in the value. (important is that the value decreases).

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

47

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibrating the flexible row tracers For the flexible row tracers, the idle state must be calibrated. To do this, drive onto a plane surface and make sure that the row tracers can swing freely.

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

The calibration must be performed again if the sensor has been used approx. 100ha.

In the used condition, the following values can be determined: B66 (row registration left) = 50-120 B66 (row registration right)= 50-120 If one of the sensor values is greater than 120 or smaller than 40 in zero position, the plastic paddle may be defective and it must be replaced, if necessary.

For control: The following values can be determined if the sensor is completely activated: B66 (row registration left) = 450 +/-10 B66 (row registration right) = 450 +/-10 For this system, the following software versions must be loaded: KMC2: 150200102-27 KMC3: 150200103-27 Terminal: 150200104-28 Autopilot: 150200029-17 Or higher.

The parameter 26025 (1-1-14) must also be set to the value 1.

48

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibrating the steering angle sensor (B64)

1 3

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 the field (1) and should now be 400 ± 10; if required re-adjust 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 wheel all the way to the left. The actual value (1) must not be smaller than 220, set the sensor or the coupling rod and start the calibration process again.

- 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 be greater than 630. If necessary, set sensor or coupling rod and start calibration process again.

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

49

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibrating the minimum currents of steering valves Y39 and Y40 Move steering axle to straight-ahead driving. Bring the machine to a level and asphalted surface. The minimum and maximum power consumption on the solenoid valves Y39 an Y40 is determined with this calibration.

From software version 150 200 104 – 08 on, 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 button (A). A new window (F) is shown. Then the valves are automatically actuated.

The steering axle moves automatically to the left and right limit obstruction.

А 1

2

4 3

F

1.

2.

3.

4.

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

Current currently flowing through the corresponding coil Current value of steering angle sensor В64 Status of the calibration: Calibration of valves Y39 and Y40 Calibration run successfully and values are saved Stop calibration

50

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Autopilot Calibration of the turning circle For the GPS based ISOBUS steering systems, a calibration of the middle turning circle for left turn and for right turn is necessary.

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

This process must be carried out separately for each side.

А

51

BiG X Service Training 2014 Advanced

А

© KRONE Training Team, Spelle

3. System Technology - Calibration: Spout Spout sensors The calibration of the spout has to be carried out each time the end position is not reached or if for example modifications (electronic, mechanical, hydraulic changes) have been made on the system.

Default setting of spout sensors The sensor В30 (1) counts pulses in the gearbox of the spout while it turns.

The sensor (1) is screwed to the stop with the copper ring into the gearbox housing with 10 Nm torque.

Sensor В29 (2) monitors the spout position bottom/top. When the spout is raised, 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 has been passed over. This point is used as a starting point for counting pulses to the right and left.

N

M

M

1

2

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

- Tighten hexagonal nuts (M) with 10 Nm torque.

3

X 52

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Spout E

1

M On

2 Off

Calibrating the electronic limit obstructions of the spout Calibration of the spout specifies the “electronic” limit obstructions (E) for the machine to prevent the spout from becoming unbraked via the joystick until the mechanical stops (M) can be approached. In the long run ,this would lead to a damage of components in the rotating drive. The calibration specifies the maximum distance the spout can be turned to the right or left side using the joystick. As the relevant parts are not symmetrical, the “electronic” end positions right and left may deviate from each other. It is therefore necessary to calibrate both sides separately. The determined values may not be alike! Parameter settings specify from which distance (e.g. to the calibrated end position or to the centre position) the spout reduces its rotation speed (see section Parameters).

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

53

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Spout 1 2 3 5

4 6

1.

2.

3.

4.

5.

6.

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

Current spout position up/down Current spout position middle/right/left The current number of pulses of the gearbox sensor for the present side The current power of the respective valve for turning spout (on 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)

Key (А) and (С): Saving the currently counted pulses as an electronic maximum left and right Key (В) and (D): Manual control of the spout to the left and right

Calibration of the electronic stops of the spout Use the joystick key (L) to move the spout to the far left. The spout stops if the maximum number of pulses for this side has been reached.

By pressing key (B), the spout can continue turning at minimum current. Hold down key until the spout is just in front of the mechanical limit obstruction (ensure that the obstruction is still not touched!). Save this position by pressing key (A). The new electronic maximum to the left is therefore set.

Use the joystick key (R) to move the spout to the far right. Spout stops if the maximum number of pulses for this side has been reached. By pressing key (D), the spout can continue turning at minimum current. Hold down key until the spout is just in front of the mechanical limit obstruction (ensure that the obstruction is still not touched!).

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

54

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Spout Calibration of valve currents for spout rotation The calibration of the currents for the valves (Y20 and Y21) for turning the spout is made automatically. The currents are calibrated once after every restart of the machine. This calibration is carried out automatically when the spout is mirrored the first time in the according direction.

The minimum currents determined during calibration can indeed be set as parameters and they are active then, but they are transcribed by new determined values after the next restart.

From complete software version 20 081 461 7 on, the parameters “Turn spout factor Imin left“ (25228) and “Turn spout factor Imin right” (25229). If necessary, the control of the spout can be reinforced or reduced via these parameters. This means that the speed for turning can be set for the respective direction.

Diagnostics current turn spout valves For diagnostics as well as for a more detailed functional test, the actual current on the valves Y20 or Y21 can be checked in the menu for the the calibration of the spout (3-5).

55

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Corn Conditioner 1

Calibrating the corn conditioner Calibration is necessary when re-installing the corn conditioner or when the actual value of the roller distance deviates significantly from the setpoint value.

I. e.: The measured roller distance does not match the roller distance indicated in the terminal.

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

It is recommended to carry out the calibration process at least once a year at the start of the season.

On

General information on calibrating the corn conditioner To perform the calibration, the following conditions must be met: - Road/field release switch (1) in field mode - Corn conditioner installed.

56

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Corn Conditioner 1 S

3

4 F

2

Calibration of the corn conditioner (roller conditioner) Before starting the calibration, the appropriate type for the adjustment of the corn conditioner must be set via parameters (refer to description design corn conditioner adjustment).

Open “Maintenance/Calibration Corn Conditioner” menu 3-6.

For an exact calibration, it is necessary to measure the distance between rollers (1) and (2) exactly using a feeler gauge (F).

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

Select the field (S) with 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. Press the rotary potentiometer to save the value and leave the input field.

57

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Spout 3

1

4 X

S

2

Calibrating the corn conditioner (disc conditioner) Setting the corn conditioner type used (roller or disc conditioner) by means of parameters.

Open “Maintenance/Calibration Corn Conditioner” menu 3-6.

To ensure a precise calibration, it is necessary to determine the exact distance (X) between the discs (1) and (2) directly on the tip using a suitable measuring tool.

The distance can be reduced or increased by pressing the key (3) or (4) in order to facilitate the determination of the gap dimension.

Select the field (S) with 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. Press the rotary potentiometer to save the value and leave the input field.

58

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Header Drive Calibrating the header The header should only be calibrated if the actual speed deviates significantly from the setpoint speed or after replacement of the KMC2 job computer. The calibration must also be carried out after working on components of the header drive (pump or hydromotor).

A new calibration is also required if an overspeed (n > 750 rpm) has been detected.

1 On

2 On

4

3 Off

General information on calibrating the header The following conditions must be met to calibrate the intake / header: - Road/field release switch (1) in field mode - Intake / header release switch (2) ON - Diesel engine speed: 2000 rpm (BiG X 500, 650), 1900 rpm (BiG X 700/800/850/1000/1100) - Maintenance release switch (3) OFF - Traction drive switch (4) OFF - Intake is not turning - Header is not turning - The driver must be on the driver’s seat - In case of BiG X 700/850/1100, the main clutch must be switched on!

Calibrate intake / header only when the oil is warm!

59

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Header Drive Calibrating the intake The header should be calibrated any time the actual cutting length is different from the displayed cutting length. Calibration is also necessary if the KMC2 job computer has been replaced or after working on components of the intake drive (pump or hydraulic motor).

1 On

2 On

4

3 Off

Mode of operation intake control From the complete software version 20 081 461 6 on, the intake speed is controlled actively during operation. This means that the cutting length is always held on the value set by the driver - regardless of the pressure or other feeding issues. In this process, the speed reduction of the diesel engine is also considered. If the speed sensor for the intake does not work, the system works like a control.

The active control can be activated with the parameter 25507.

General information on calibrating the intake The following conditions must be met to calibrate the intake / header: - Road/field release switch (1) in field mode - Intake / header release switch (2) ON - Diesel engine speed: 2000 rpm (BiG X 500, 650), 1900 rpm (BiG X 600/700/850/1100) - Maintenance release switch (3) OFF - Traction drive switch (4) OFF Calibrate intake / header only when the oil - Intake is not turning is warm!

- Header is not turning - The driver must be on the driver’s seat - In case of BiG X 700/850/1100, the main clutch must be switched on!

60

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Intake / Header 6 2

1

3

4 5

61

A

B

C

D

Е The currents to be determined: The following 3 currents are determined: „I0“ - is the current at which the unit starts to rotate. „Imin“ - is the current at which the unit reaches the minimum speed to be set. „Imax“ - is the current at which the unit reaches the maximum speed to be set.

Open menu “Maintenance/Calibration Intake and Header” 3-7 in the terminal.

Progress screen of intake or header calibration: 1. Progress screen of intake calibration (support value 1 and support value 2) 2. Progress screen of header calibration (support value 1 and support value 2) 3. Actual value of current on the valve of the intake or header pump 4. Actual value of speed of the 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 Softkey button (A) and (C): Start the intake or header calibration Softkey button (B) and (D) Intake or header calibration is stopped Softkey button (E): Automatic engine speed setting, 2000 rpm (BiG X 500/650), 1900 rpm (BiG X 700/850/1100) BiG X Service Training 2014 Advanced © KRONE Training Team, Spelle

3. System Technology - Calibration: Header Drive Е 2

1

3

4 5 A

B

C

D

Button (E) can be used to raise engine speed to the required speed.

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

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

62

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: RockProtect Calibration RockProtect The signal voltage value of acceleration sensor В76 is determined in idle state with the calibration of RockProtect.

RockProtect should only be calibrated before the machine is used for the first time or after relevant parts for the system have been replaced.

Open menu “Maintenance/Calibration/RockProtect” 3-9 in the terminal.

Before starting the calibration, make certain that the header is in the harvest position. Furthermore, the intake must be kept free of crop and the pre-compression rollers must rest on the lower stop. The intake must not be turned off. The calibration is started by pressing the key (A) under the softkey. The calibration is fully automatic.

1 2

A 1. Current value of the signal voltage of sensor В76 2. Saved value of the signal voltage of sensor В76 А - Start calibration RockProtect

The sensitivity of the system can be set in the “Settings/Parameter/RockProtect” menu 1-1-21. The value is set to 50 in the factory. Higher value increases sensitivity reacting to smaller stones.

63

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Main Clutch Calibrating the main clutch From terminal software version 150 200 104-08, a calibration of the valve current is possible for the main clutch. As a result, the switching behaviour is influenced.

The calibration should be made when switching on the main drive is hard, or if you repair or change system components or if you replace the job computer KMC 3.

1 On

2

3 Off

Off

General information on the calibration of the main clutch To carry out the calibration of the main clutch, the following conditions must be met: - Engine running - Road/field release switch (1) in field mode - Traction drive release switch (2) OFF - Maintenance release switch (3) OFF - The driver must be on the driver’s seat and the door must be closed - The intake must be installed in front of the forage harvester

64

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Main Clutch 3

1.

1

2.

3.

2

5

6

5.

6.

The current power consumption value of valve Y12 The current value of the blade drum speed The current value of the engine speed Start the calibration of the main clutch Stop the calibration of the main clutch

Calibrating the main clutch Open “Maintenance/Calibration Main Clutch” menu 3-10 in the terminal.

Press key (5) to start calibration. It runs automatically. If there is no speed detected on the cutting drum, the automatic calibration is interrupted at 1400 mA. When the calibration is successfully completed, a green check mark appears.

65

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: Bosch Ground Drive Calibrating the Bosch traction drive Installation and production tolerances as well as component fluctuations cause the values of sensors to differ slightly in specific positions. Valves will often have a slightly different behaviour. Due to this, it is necessary to save these componentspecific properties in the control unit and after each relevant change in the system.

The following components are therefore calibrated for the Bosch traction drive:

1

• Brake pedal angle sensor 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) - Pivoting angle sensor B108 (3) - Setting the sensor when pump is in centre position (2.50 +/-0.02 V) - Saving the difference from the setpoint value (offset) - Maximum values of the sensor in case of full absorption volume - 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)

2

3

4

5

6 66

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: CropControl 1

2

4

3 9

5

8

6

1 2, 3, 4 5 6 7 8 9

Display Buttons for softkeys „+“ key „Esc“ key „OK“ key „-“ key Menu key

7

Control unit CropControl 67

Inductive displacement transducer on intake

BiG X Service Training 2014 Advanced

B73

B72

Pressure sensor in intake drive © KRONE Training Team, Spelle

3. System Technology - Calibration: CropControl Calibration path recorder B 72: Before placing the machine in service the first time and after any assembly work on the path recorder, it must be calibrated. Ensure there is no crop in the intake and that the precompression rollers are in the lower limit stop.

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

1

2

3

Menu level 1 - 1 Calibrating the path recorder

Setting the minimum excursion: Use the minimum excursion to set from what excursion of the pre-compression rollers the measurement is started. The higher the minimum excursion is set, the more crop must flow through the rollers to activate the yield counter.

Guide value for minimum excursion: 5mm, to be set via button (1), "DEF" softkey.

The minimum excursion can be changed by pressing the "+" and "-" buttons. Then confirm the new value by pressing the "OK" button.

1

2

3

Menu level 1-3 Setting minimum excursion

68

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

3. System Technology - Calibration: CropControl 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 pre-compression rollers are in the lower limit stop.

Calibration pressure sensor B 73:

The following conditions must be met for calibration: • Cutting drum turned on • Intake turned on • Engine at working speed (~2000 rpm) • Intake must be in the working position (-> not too high)

1

2

3

U Menu level 1 - 2 Calibration pressure sensor

• Cutting length is set to the minimum possible value (depending on the number of blades)

A

O

(U) Drive pressure lower intake speed (A) Current drive pressure

(O) Drive pressure upper intake speed 1. Calibrating the drive pressure for the lower intake speed: Press button (2), the “Calibration” symbol is displayed inversely. An arrow appears underneath the shaded area on the left. The cutting length must now be increased until the black bar is within the shaded area. After a short time the value (~40-70bar) will be written in the memory and the arrow will appear underneath the shaded area on the right.

2. Calibrating the drive pressure for the upper intake speed: After the arrow symbol can be detected under the right hatched area, the chop length must be further increased until the black bar is in the right hatched area. After a short time this value is also placed in the temporary storage (~65-95 bar) and the “Calibration" symbol is no longer displayed inversely.

3. Saving the calibrated values: Press the "OK" button to save the calibration permanently.

69

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

BiG X 500 / 650 / 800 / 1000, from YOM 2006 BiG X 600 / 700 / 850 / 1100 Table of contents - circuit diagram

Contents The table of contents shows which function is on the diagram and where it can be found. At the top is a list of the machines.

Labels of some parts can be found in the appendix. This labels should help to recover parts quicker and easier.

70

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

Circuit diagram design The circuit diagram is displayed on several pages. Each page is named and numbered according to its function.

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

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

71

D6

D7

D8

E6

E7

E8

F6

F7

F8

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

1 Colored field For a better understanding of the circuit diagram, the electronic components are marked with colored fields.

3

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

2

1

4 72

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

Change The areas marked with a letter indicate that something there has been changed. Changes with the same letters were plotted at the same time.

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

73

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Continuation arrow (1) This arrow indicates that the electric potential continues on to another page.

The number placed adjacent to the tip of the arrow identifies the page number (before the dot) and the circuit path (behind the dot) where the circuit continues to. Example: Page 109, circuit path 1 Potential designation (name) (2) This provides the continuation arrow with a “name” that can also be found on the referenced page. In some cases there are also standardised short designations which are also used here as follows: 15. Ignition stage 2 (+12V (switched) 30: Permanent positive (+12V) 31: Ground 49: Input flash encoder 49a: Output flash encoder 50: Starting 54: Brake light 56a: Full beam, full beam control 56b: Dipped beam 58: Backlight 58R: Clearance lamp right 58L: Clearance lamp left 61: Charge indicator C2: Flash encoder 2. Indicator lamp R: Flashing lamp right L: Flashing lamp left 75: Ignition stage 1 (+12V switched, turned off during starting) Additional KRONE designations: E: Electronics L: Power Wire designation and wire color (3) Each wire is labelled with its designation. The designation (3) can also be found on the circuit diagram. Example: Yellow lead with black label PLD1 15

Circuit Diagram Layout

1

2

3

Wire colors BX 500 / 650 / 800 / 1000:

Wire designation BX 700 / 850 / 1100: Power supply Signal line / switch circuit Earth (white) 74

CAN high CAN low

RT = red  Power supply BL = blue  CAN high GE = yellow  Signal line / switch circuitGN = green  CAN low WS = white  earth

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

11. Plug number

X...

Contact number

Plug

1X... Smart Drive (A 1)

Plug

2X... KMC 2 (A 2) 3X... KMC 3 (A 3) 4X... Cab circuit board (A4) 5X... Autopilot (A 5) a – Pin contact b - Socket contact

6X... DIOM (A 6) 9X... EMR (A 9) 11X... Manual operation (A 11) 14X... Terminal (A14) 15X... Joystick (A 15) 16X... CUC (A 16) 17X... Potential distributor circuit board (A 17) 19X... EasyControl (A 19)

B49 - Part

One plug is designated with X. The number before the x describes the affiliation with the module, the number after – the affiliation with a component or the number of the plug. The small letter "a" indicates male contacts and "b" indicates female contacts. The number by itself is the contact number. A letter may also stand for certain plugs. In addition to the actual plug designation, there may be another designation in brackets. This is the plug designation for components which could be transferred from the "old" generation of machines, as they are identical in design but are labelled according to the "old" system.

20X... Console (A 20) 22X... Console relay circuit board (A 22) 75

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: 1

Input - output job computer

Engine corn conditioner rollers Voltage V2 / LD 12

2 3 4 5

5 4

2

76

1. Function of input or output.

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

3

1

Circuit Diagram Layout

- CAN High - CAN Low

4. Connector contact (e. g. plug X3 Pin 12) 5. Module designation

Position corn conditioner rollers

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics:

Circuit Diagram Layout

Job computer - complete overview The complete overview describes all inputs and outputs according to function. The representation (X1) and (X2) indicates the pin assignment of the plugs on the job computer.

2

1 X2

Supply voltages, Power supply of electronics: The marked area (1) indicates the 4 supply voltages for the computer or the power supply for the electronics. It shows which supply voltage is used for which outputs of the computer (e.g.: Supply PWM_LA 5-8 = load outputs 5-8). For diagnostic purposes the respective LED is also noted which identifies whether the respective supply voltage is applied to the computer (LD 37, 39, 40, 41).

3

Inputs:

X1

This area (2) shows all inputs of the computer in the overview. Inputs are usually sensors.

Outputs:

The area (3) shows all outputs of the computer in the overview.

Outputs are actuators, e.g. solenoid valves or electric motors.

77

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System / Electronics: CAN Bus BiG X Sensors

KMC 4

Actuators

A35

A40

Option

A1

Sensors Actuators

~150Ω

Keys LED

120Ω

120Ω

120Ω

CAN 2 A2

A6

Actuators

A10

A11

Smart Drive / DRC

A37

Sensors

KMC 2

Actuators

120Ω

Sensors

switched!

KMC 3

Actuators

DIOM

A5

Sensors Actuators

EMR

A3 Autopilot

120Ω

CAN 1

CAN 3

A9

Joystick

120Ω

A15 Switch Actuators 78

CAN MB,

CUC

A16

MFR (MAN), ADM 2 (MB)

A14

BiG X Service Training 2014 Advanced

A7

CAN MAN

A8 © KRONE Training Team, Spelle

Sensors Actuators EDC (MAN), PLD (MB)

4. Electrical System/Electronics: Console Component Overview Console BIG X 500 / 650 / 800 / 1000

Console BiG X 700 / 850 / 1100

A16 A14

A16

A14 A33 A31

A22

A22

A6

A8

A3

A1 A3 A2

A5 A12 A7

Part designations see circuit diagram!

79

BiG X Service Training 2014 Advanced

A7

A2

A17

A6

A5

A1 © KRONE Training Team, Spelle

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

A16

A17

A5

A22 A3

A2

A2 A3

A6

A7

A1

A19

Part designations see circuit diagram!

80

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN-Bus Basic Information 12 V GND

S1

S2

S3

S4 CAN high

R1

R2

CAN low CAN bus network permits different controls (here: S1-S4) to exchange data.

For this, all controls are connected with two lines. Data is sent in digital form via these lines.

A mutual voltage signal containing the data is sent on both lines.

To prevent the messages from being “reflected” on the ends of the bus lines, two terminating resistors are used in each CAN bus system.

Each control can only be an active participant on the CAN bus when the power supply is in good order.

81

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN BUS CAN BUS – Distributor Circuit Board

CAN 3 (A 33)

(only for BiG X 500 / 650 / 800 / 1000) Controller Area Network

Tasks: Grouping of all CAN bus lines (CAN 1 and CAN 3) of the individual computers in the machine / console.

CAN 2 is guided directly from the KMC 2 to the console rear panel!

The models with a new console (BiG X 700/850/1100) do not have a CAN BUS distributor circuit board. The wiring is correspondingly the same. However, the lead connections are located in the cable harness.

The terminating resistors are designed as external resistors and they are located in the cable harness in the console.

A33

A31

CAN 1 (A 31)

A31 A33

82

BiG X Service Training 2014 Advanced

Blue lead: CAN HIGH Green lead: CAN LOW

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN BUS CAN BUS – Diagnostics in the terminal Controller Area Network

CAN BUS overview

CAN BUS systems The different CAN Bus systems are displayed by connecting pipes marked with different colours.

CAN1: blue CAN2: green CAN3: violet Display of errors The diagnostics can be used to display which control is active on the CAN bus and which control is not connected with the terminal. Controls with no connection to the terminal are shown with a red background and an exclamation point (refer to manual operation).

Counters In addition, a counter is available from complete software version 200814617 on. Brief and sporadic connection problems can be determined by means of this counter.

83

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN 1 BUS (BX 500/650/800/1000) CAN 1 BUS – Design and Diagnostics CAN 1 120Ω

120Ω

A2 KMC 2 A1 SD

A31

A6

120Ω

DIOM

A5 AP

A15

R CAN high CAN low KMC 3

CUC

A14

A16

A3

120Ω

Resistance measurement between CAN high and CAN low. Measurement points on A 31 freely selectable.

Diagnostics The total resistance in CAN 1 can be measured on the CAN BUS distributor circuit board.

Always measure without voltage!

Terminating resistors

The both CAN BUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor on their ends. This prevents the transmitted data from being reflected as an “echo”. The terminating resistors for the CAN 1 are integrated in the job computers KMC 2 and KMC 3.

120 Ω ║120 Ω  60 Ω total resistance STLP_CAN 1_DE

84

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN 3 BUS (BX 500/650/800/1000) CAN 3 BUS – Design and Diagnostics CAN 3 120Ω EMR

A33

120Ω

R

A9 ADM 2

A8

120Ω ADM 1

A7

CAN high CAN low KMC 3

A14

A3

120Ω

Resistance measurement between CAN high and CAN low. Measurement points on A 33 freely selectable.

Diagnostics The total resistance in the CAN 3 can be measured on the CANBUS distributor circuit board.

Always measure without voltage!

Terminating resistors

The both CAN BUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor on their ends. This prevents the transmitted data from being reflected as an “echo”. The terminating resistors of the CAN 3 can be found in the job computer KMC 3 and in the cable harness next to the EMR.

120 Ω ║120 Ω  60 Ω total resistance STLP_CAN 3_DE

85

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN 1 BUS (BX 700/850/1100) CAN 1 BUS – Design and Diagnostics CAN 1

120Ω

120Ω

A2 KMC 2 A1

1

SD/DRC

2

A6

120Ω

DIOM

A5 AP

R CAN high CAN low

A15

A16

Resistance measurement between CAN high and CAN low.

KMC 3

CUC

A14

Diagnostics

120Ω

The individual terminating resistors or the cable connections can be checked by removing a resistor and a subsequent resistance measurement in the open plug connection.

Always measure without voltage!

A3

Terminating resistors

The both CAN BUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor on 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 control unit console (1) and in the front part of the console (2)).

STLP_CAN 1_MAN_DE

86

BiG X Service Training 2014 Advanced

 120 Ω terminating resistor

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

4. Electrical System/Electronics: CAN 3 BUS (BX 700/850/1100) CAN 3 BUS – Design and Diagnostics CAN 3 120Ω EMR

A9

1

Engine control computer (MFR)

A7

Engi ne contr ol com puter (MFR )

R

CAN high

Resistance measurement between CAN high and CAN low.

KMC 3

The individual terminating resistors or the cable connections can be checked by removing a resistor and a subsequent resistance measurement in the open plug connection.

Always measure without voltage!

A3

Terminating resistors

The both CAN BUS lines (CAN high / CAN low) are terminated with a 120 Ω resistor on 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 EMR (2)).

STLP_CAN 3_MAN_DE

87

120Ω

Diagnostics

120Ω

CAN low

A14

120Ω

2

BiG X Service Training 2014 Advanced

 120 Ω terminating resistor

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

4. Electrical System/Electronics: CAN BUS CAN 2 BUS – Design

AutoScan

120Ω

A40

A55

A35

RockProtect (option) CropControl (option)

Option

~150Ω

120Ω

KMC 4

CAN high

NIR moisture sensor (option)

CAN low

A11

A10 ~150Ω

Resistor connected in the KMC 2 Without AutoScan Resistor connected in the KMC 2

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 in the job computer KMC 2 and in the metal detection or in the AutoScan sensor and in the metal detection, depending on whether AutoScan is attached or not.

88

CAN 2

120Ω

A2 KMC 2 120Ω

BiG X Service Training 2014 Advanced

With AutoScan: Resistor disconnected in the KMC 2

120 Ω ║~150 Ω

 ~ 66 Ω total resistance © KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN BUS CAN 2 BUS – Diagnostics A2 KMC 2 120Ω

A55

AutoScan

Resistance measurement in CAN 2 As the CAN 2 is guided directly from the KMC 2 to the rear wall of the cab, diagnostics can be run only with difficulty in the closed circuit. It is therefore recommended to disconnect the CAN 2on an easily accessible point and to measure the terminating resistors individually. e.g. on intake plug 25X12.

Resistor connected in the KMC 2 STLP_KMC 2_DE

120Ω

A40

RockProtect (option) CropControl (option)

Option

A35

AutoScan attached: Terminating resistor of 120 Ω in the AutoScan sensor can be measured on the 25X12 plug.

AutoScan is not attached: Terminating resistor of 120 Ω in the KMC 2 cannot be measured on the 25X12 plug as the resistor is only connected when it is powered. It is therefore necessary to set a bridge in order to “simulate” the connection (cf. circuit diagram).

A11

KMC 4

A10

NIR moisture sensor (option)

25X12

~150Ω

R

R

~ 150 Ω 25X12 pin A + B 89

BiG X Service Training 2014 Advanced

Bridge in: 22X5b PIN 10 + 13 © KRONE Training Team, Spelle

4. Electrical System/Electronics: CAN BUS CAN 2 BUS – Wiring KMC 2

A2

120Ω

A40

CAN2 in

Sensor

Reserve

Voltage

CAN2 out

25X9

120Ω AutoScan (option)

Option

A55

25X12

A10 ~150Ω

RockProtect (option)

A11

CropControl (option)

A35

KMC 4

A37 NIR moisture sensor (option)

90

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: ISOBUS ISOBUS – Design and diagnostics ISOBUS-Incab Socket 30X6

120Ω

ISOBUS

120Ω

A2 KMC 2 A1 SD/DRC

A6 DIOM

A5

ISOBUS diagnostics socket

AP

30X9

CAN ISO

CAN 1

CAN high

120Ω

CAN low

A15

KMC 3

CUC

120Ω A14

A16

A3

ISOBUS system design The preliminary setup for ISOBUS is available from YOM 2013 on. It can be refitted with a colour terminal for all the BiG X. The preliminary setup for ISOBUS merely contains another autopilot computer as well as the corresponding wiring with the both sockets for the diagnostics and for the connection of additional ISOBUS devices (for example KRONE CCI 200 terminal, ISOBUS steering systems, etc.)

The auopilot computer forms the interface between CAN1-Bus and ISOBUS. 91

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: KMC 2 B25 B26 B27 B28 B29 B30 B55 B58 B60 M12 M12 A10 B91

Supply voltages 12V V1_KMC2 V2_KMC2 V3_KMC2 Supply 12V V4_KMC2

Header right Intake speed

Earth 12V supply

Intake forward Intake backward

Header forward

Header speed

Header backward

Spout position centre

Spout rotat. left

A2

Spout position bottom

KMC 2 Spout rotat. right

Spout rotation pulses Header left

120Ω *

Raise spout flap

120Ω

switched!

Lower spout flap

Cutting drum speed Level of silage agent

Raise spout Supply Sensors

Lower spout

CAN 1

State of central lubrication

CAN 2

Storage switch grass/maize

Malfunction central lubricationKMC 2 (KRONE machine controller 2, 16-bit job computer) Stop signal metal Pressure leakage oil filter

Fold DC 1

Tasks Control of work hydraulics such as intake, header and spout

Fold DC 2 (not used!)

* Terminating resistor is located on the BiG X 500/650 in the computer,

Horn coastdown alarm

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

92

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

Y5 Y6 Y7 Y8 Y20 Y21 Y22 Y23 Y24 Y25 Y53 Y76 Y77 K10

4. Electrical System/Electronics: KMC 3 B20 B36 B37 B42 B43 B44 B46 B52 B59 B70 B77 B87 B88 B85 B92 93

Supply voltages 12V V1_KMC3 V2_KMC3 V3_KMC3 Supply 12V V4_KMC3

Suction return air filter

Position grinding stone left

Earth 12V supply

Position grinding stone right

Main coupling

Y12

Header small/holding-down device

Y26

Header small/holding-down device

Y27

Position corn conditioner rollers

Plant divider/support wheels

Hydraulic oil filling level

Plant divider/support wheels

A3

Fuel level

KMC 3 Grinding stone right

Air filter contamination

Grinding stone left

120Ω *

Transverse inclination position

120Ω *

Pendulum frame 1 free

Maintenance flap Oil pressure main gearbox Silage agent flow Pendulum frame left top Pendulum frame right top Temperature hydraulic oil Tensioning arm belt drive

Supply Sensors

CAN 1

Pendulum frame 2 free

CAN 3

Counterblade left

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

computer.

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

Counterblade right

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

BiG X Service Training 2014 Advanced

Corn conditioner distance Silage additive pump Smart Drive release

© KRONE Training Team, Spelle

Y28 Y29 Y30 Y31 Y54 Y55 M9

M10 M11 M16 GAL

4. Electrical System/Electronics: DIOM Y51 Y52 Y56 Y61 Y62 Y65 Y66 Y67 Y73 Y75 Y82

Auxiliary hydraulics 1 up

Earth 12V supply

Supply 12V

Auxiliary hydraulics 1 down Terminating resistor CAN2-KMC2

Diesel engine coupling Auxiliary hydraulics 2 up Auxiliary hydraulics 2 down

Signal horn metal

A6

Molasses output

DIOM

Battery changeover 12V/24V

Grinding flap closed Locking steering on left

Intake / header release

Locking steering on right Clean compressed air Pressure relief Header connections

CAN 1

Valve hydraulic fan control

Tasks Coupling diesel engines, additional hydraulics (optional), 12/24 V changeover relay, grinding flap, compressed-air cleaning, lock steering, silage additive pump, valve hydr. fan drive (only for BiG X 700 / 850 / 1100), hydraulic fan drive valve (only for BiG X 700 / 850 / 1100) 94

BiG X Service Training 2014 Advanced

A6

© KRONE Training Team, Spelle

K15 K18

K28 K39 K41 GAL

4. Electrical System/Electronics: Smart Drive B13 B14 B16 B18

B38 B39 B40

High pressure

Flush valve temperature

Earth 12V supply

Supply 12V

Service brake pressure

Drive pump rear axle forward

Brake tank pressure

Pivoting angle Pump rear axle Brake pedal switch

K43.1

Axle separation

A1

Pivoting angle Pump front axle

Parking brake pressure K20.1

B90

Poclain traction drive

Drive pump front axle backward Y1 Drive pump front axle forward Y2 Drive pump rear axle backward Y3

Supply Sensors

1/2 absorption volume front axle Y14 1/3 absorption volume front axle Y68 Stop valve pump front axle

Stop valve pump rear axle

Traction drive release

Intermediate lubrication

CAN 1 A1

Reversing light / horn Brake light Life signal (toggle)

Tasks Smart Drive controls and monitors driving hydraulics

95

Y10

1/2 absorption volume rear axle Y11 All-wheel Y13 Smart Drive

Wheel speed

Y4

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

Y69 Y70 M12 K29 K30 KMC3

4. Electrical System / Electronics: S3 S 69

B101 B102 B18 B110

B16 B109 B108 B107 B103 B104

B105 B106 96

BODAS Control Unit DRC

Bosch traction drive

Traction drive release

Supply Earth

Seat switch

Supply 12V

High pressure MA High pressure MB

Reversing signal

A1

Brake tank pressure

Brake signal

Parking brake pressure

Pump forward

Service brake pressure

Pump backward

Brake pedal angle

Hydraulic motor front left

Pivoting angle

Supply sensors

Hydraulic motor front right

Steering angle

Hydraulic motor rear left

Speed front left Speed front right Speed rear left Speed rear right

CAN 1

CAN 3

Hydraulic motor rear right

Control unit Bosch RC28 -14/30 Tasks BODAS control unit controls and monitors the driving hydraulics

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

K29 K30

Y101 Y102 Y103 Y104 Y105 Y106

4. Electrical System/Electronics: Autopilot Earth 12V supply

B61 B63

A5

Row registration right Autopilot

Steering wheel pressure

Steering to the left

Angle sensor B64 Steering axle

B65

Supply 12V

Supply Sensors

Steering to the right

Row registration left

Y39 Y40

CAN 1

A5

Tasks After the autopilot has been activated, the computer takes over evaluation of all sensors installed in the autopilot system and controls the machine. The autopilot parameters are also stored in the computer.

97

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Autopilot Earth 12V supply

B61 B63

A5

Row registration right

Autopilot ISOBUS

Steering wheel pressure

Steering to the left

Angle sensor B64 Steering axle

B65

Supply 12V

Supply Sensors

Steering to the right

Row registration left

A5

Y39 Y40

CAN 1 Tasks

CAN-ISOBUS

The ISOBUS autopilot computer takes over all functions the autopilot computer executes. This means that driving over row sensors can still be done with the autopilot.

Furthermore the ISOBUS autopilot computer offers an additional interface. Additional devices can be connected via the standardised ISOBUS protocol (e. g. GPS controlled autopilots, KRONE-CCI 100, etc.)

98

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: EMR EHR / EMR (electronic lifting gear control or electronic mowing unit control) Tasks The EHR / EMR evaluates the information of all sensors relevant to the lifting unit (pressure sensor, header contour, position sensor) and controls accordingly the height of the attached header or the position of the pendulum frame.

CAN 3

B47 B48

B49 B50

Height sensor left

A9

Height sensor right Lifting gear pressure

Supply Sensors

Y33

Raising lifting unit Lowering lifting unit

Lifting unit accumulator

Y34

Rotating pendulum frame left

Y37

Lifting unit position

Rotating pendulum frame right

Y38

Earth 12V supply 99

EMR

Y32

Supply 12V

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: CUC Task The CUC receives the input signals from the panel switches and buttons. The panel switches are directly plugged into the CUC. The "commands" are transmitted via the CAN BUS.

S1 S2 S3 S4

S5 S6 S7 S9 S68 S69 S90 S91 100

Parking brake road / field

Earth 12V supply

Supply 12V

Parking brake autopilot Parking brake traction drive Parking brake intake / header

A16

CUC

Parking brake maintenance

Buzzer

Parking brake all-wheel

(Starter sequencing relay)

Parking brake axle separation Parking brake Door switch

Supply Switch

U3 25K2

Activation moisture measurement

CAN 1

Seat switch Quick stop console Quick stop manual operation

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: EasyTouch and Joystick A14

Power supply

“Easy Touch” Info Center Machine setting and monitoring or diagnostics of the machine.

A15

CAN 3

CAN 1 Joystick Specification of functions for traction drive and work hydraulics. Data transmission via CANBUS. Joystick with its own software!

101

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Engine Control MB ADM 2 (adaption module version 2) Tasks Forms the interface between KRONE bus system and Mercedes bus system.

A7

CAN MB

MR (engine control) Tasks Controls the engine (recording the motor parameters; connection of sensors and actuators)

ADM 2

Power supply

Star quad cable for data transmission between ADM 2 and MR via MERCEDES CAN BUS Diagnostics socket diesel engine 1 + 2

102

A8

CAN 3

MR Engine control

Before you perform welding work on the machine, remove both MR plugs and disconnect the main battery switch!

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System / Electronics: MFR/EDC MFR (engine control computer) Forms the interface between KRONE bus system and MAN bus system.

A7

The main task of the EDC control unit is to control the correct fuel injection and to adjust this control to the different operating conditions and therefore to control the engine output and the emissions of the engine. The control unit (software/hardware) can be used for a maximum of six cylinders. Thus a second control unit is required to operate an engine with more than six cylinders. The both control units communicate via CAN and operate in the socalled master / slave mode.

To YOM 2011:

CAN MAN

EDC (Electronic Diesel Control)

MFR

Power supply

CAN 3 2

From YOM 2012 on:

To carry out welding work on the machine, disconnect both batteries and connect the positive line and the earth line with each other.

1 EDC (Master / Slave)

103

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Potential Distributor Circuit Board A17

Potential distributor circuit board Tasks: Grouping of power supplies and earth cables from sensors and valves in the machine as well as grouping of the earth cables for the supply voltages of the job computers.

A17

Console BiG X 500 / 650 / 1100

A17

17X1

17X11

17X12 17X8

17X3

17X5

17X13

17X9

17X14 17X10

17X6

17X1 7

17X15 17X16

17X18

17X19

Console BiG X 700 / 850 / 1100 104

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

17X21

17X4

17X20

17X7 17X2

4. Electrical System/Electronics: Console and Cab Circuit Board Tasks Among other things, the console circuit board (A22) includes fuses for the work functions (supply voltages of the job computers).

The GAL logic module (G) integrated on the circuit board controls the connection of the individual supply voltages (comp. circuit diagram)

Installation position BX 500/650

Cab circuit board

A22

A4

G

Console circuit board

105

Installation position BX 700/850/1100

A22

Cab circuit board

Tasks The cab circuit board (A4) protects among other things the “vehicle" electronics (light, windscreen wiper, brake light ...)

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

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Logic Power Supply Voltages + 12 volts Release switch Road / field

22F78 Voltage V3 KMC3

Quick stop switch 22K32 Maintenance release switch

22LD32

IN9

IN7

IN13

GAL-Logik -IC1

-A22

OUT 6

F12 LD40

PWM_LA8

Relay circuit board Console

LD31

Grinding stone valve on left

0V

KMC 3

-A3

Y31

Both job computers (KMC2 + KMC3) have separate load and electronic power inputs. The load inputs supply power for the output circuit of the job computers. The load inputs come from the relay board and are switched there depending on the different inputs (release switch, etc.) from the GAL logic.

106

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Overview Job Computers

107

(1) ● LD 27 – LD 29

LEDs power supply voltages

(2) ● F2, F6, F12, F13

Internal fuses load voltages V1 – V4

(3) ● LD 37 – LD 41

LEDs load voltage V1 – V4

(4) ● LD 1 – LD 12 und LD 30 – LD 36

LEDs outputs

(5) ● LD 13 – LD 26

LEDs inputs

(6) ● LD 38

Life LED (status of the job computer)

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: GAL Inputs GAL logic module Tasks GAL logic module specifies which input conditions are required for the individual supply voltages (see circuit diagram) The inputs can be checked via light-emitting diodes (LD xxx).

Inputs

LD xxx

GAL

108

Relay circuit board console

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

4. Electrical System/Electronics: Safety Outputs KMC SmartDrive voltage release Module:

KMC 3

(Output LA_1)

Diagnostics LEDs:

22LD102

(console relay circuit board)

LD2

(KMC 3)

Switching conditions: When diesel engine is stopped:

KMC 3 active

When diesel engine is running:

KMC 3 active and toggle signal* from SmartDrive is received *Toggle signal: Life signal (frequency approx. 3 Hz) of the Smart Drive, check via 22LD116

Voltage release intake / header Module:

DIOM

(Output DIG_OUT_10)

Diagnostics LEDs:

22LD112

(relay circuit board console)

Switching conditions: -> Road / field release switch ON -> Intake / header release switch ON -> Maintenance release switch OFF

109

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: KRONE Download Center

2

3 A

1 4

5

Download Center The Download Center is necessary to perform a software update on different computers in KRONE machines. To do this, you need a laptop with USB port. The connection with the computer for software update is made via CAN diagnostics socket (A) in the console.

The complete package to download all KRONE machines (incl. installation cd, all required cable connections and the programmed PCAN dongle) can be ordered from the spare part storage under no. 27 006 523 0. When placing an order, please indicate the name as well as the date of birth of the person for whom the PCAN dongle is to be programmed.

1. CD with the “KRONE Download Center” software and “Phases” (Poclain) 2. PCAN-USB dongle 3. Data cable 4. Data cable extension with adapters 5. SmartDrive diagnostics cable (Y-piece) 110

BiG X Service Training 2014 Advanced

SI_150369998 Komponenten Softwareupdate_DE

WHB_7.10.1.KRONE Download Center_DE

© KRONE Training Team, Spelle

5. Software: Phases

WHB_7.10.2_ Phases_DE

1

3

2

SmartDrive – Software update and diagnostics To load the SmartDrive software onto the driving computer, the PHASES program from Poclain Hydraulics is required. The program is included in the KRONE Download Center CD (1) and can be installed from the CD. If the KRONE Download CD has already been installed completely, the individual installation is not required.

The connection to the computer for software update and diagnostics is made via SmartDrive diagnostics cable (2) which is directly connected to the SmartDrive. To do this, a serial interface is required on the laptop. If there is no serial interface, an adapter from the USB to the serial interface (3) must be used.

The SmartDrive diagnostics cable (Y-piece) and the USB serial adapter can be ordered separately from KRONE spare parts storage:

SmartDrive diagnostics cable (Y-piece): 27002462.0 USB - serial adapter: 27004132.0 111

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline 1. Download the latest machine software

www.krone.de/software

Installation starts automatically after downloading the machine software in the KRONE Download Centre

Machine software, Software information service technician,

Software information in detail (password required)

Smart Drive parameters (password required)

112

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline 2. Establish a connection

3. Download software

4. Compare software versions

Machine

Download Center

5. Follow instructions in the Download Center

113

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline 6. Determine, compare and update SmartDrive software version and parameter set

Software

Depending on the equipment of the machine, continue with step 7a or 7b!

7a = Machines with Poclain traction drive 7b = Machines with Bosch traction drive 7a. Connect SmartDrive connection USB adapter only if there is no serial interface!

Send program file

8a. Download software Making correct selection!!

114

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline Send parameter file

9a. Download parameter set

Make correct selection!!

10a. Determine tyre circumferences

11a. Enter tyre circumferences Parameters in “Service” level: 22001 and 22002

115

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline Machines with Bosch traction drive 7b. Establish a connection

8b. Determine, compare and update DRC (BODAS control unit) software version and parameter set

Software

BODAS parameter

9b. Save parameter of the DRC on PC

Parameter

Save files on the PC exactly according to the instructions! Data will be required again after the download!

116

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Software Update Guideline 10b. Download software (flash control unit)

11b. When the software has been downloaded successfully, the machinespecific parameters must be transmitted back into the DRC.

Software

Parameter

The handling of the Bosch BODAS software is described in a manual.

The sequence and the procedure for updating the software are described in detail in the manual.

117

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Replacing the Job Computer / Configuration Parameters and settings to be checked after replacing a job computer When specific job computers have been replaced, various settings or configurations are required depending on the job computer. In some cases there are parameter settings which require the input of release codes/passwords. Other cases require calibrations to be made. The attached list is an overview of those actions which are to be implemented depending on the individual controls (depending on the machine configuration).

Before replacing any job computer, find out about the actions involved and ensure that you can also implement these properly!

Caution: In some cases it is absolutely essential to telephone KRONE customer service!

Incorrect configurations may cause a machine breakdown or the loss of the operating licence!

The hardcopy list is in the appendix to the training document.

Parameter check Maschinenkonfiguration_DE

118

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Electronics Packages Checking optional electronic systems

Option is not released Option is released

Output of machine data for documentation

Interface for ISOBUS steering system Load limit control Autopilot via row sensor Electronic power adaption

Output of machine data for documentation

Fuel consumption measurement

119

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

5. Software: Parameter Settings Parameter_Service BiG X 700_1100_DE

Parameters must generally be set if: - A control is replaced (e.g. KMC) - Software update (as specified in customer service info) - Required changed regarding the setting 120

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle