Krone BiG X TT 2014 Advanced Forage Harvester Service Training Manual - PDF DOWNLOAD

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 Hydraulic System

2

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

Contents

1.

2.

3.

4.

5.

6.

3

Ground Drive Hydraulics (4-32) Intake / Header Hydraulics (33-38) Fan Drive Hydraulics (39-40) Open Circuit Hydraulics (41-78) Cooling and Leakage Hydraulics (79-82) Hydraulics Maintenance (83-92)

BiG X Service Training 2014 Advanced

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1. Ground Drive Hyraulics: Poclain Charge Pressure Circuit Charge pressure circuit overview

4 6

1

3

7 5

Changeover

2

8

WHB_5.1 Speisedruck_DE

WHB_5.1 Umschaltung_DE

(1) (2) (3) (4) (5) (6) (7) (8)

4

Feed pump with connection line to the pumps of the traction drive (Filling of the high-pressure circuit and pump adjustment) Valve main coupling and step switchover at rear Combination valve (all-wheel valve and axle separation) Clamping cylinder corn conditioner belt Valve stage switchover front Grinding flap valve Auxiliary function lifting unit (maintenance) Drive radiator rotary sieve (only BiG X 600/700/850/1100)

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1. Ground Drive Hydraulics: Poclain Charge Pressure Circuit Charge pressure circuit 500 - 700

High pressure circuit

4

High pressure circuit

2

Charge pressure circuit

1

3

5

(1)

Feed pump traction drive

(2)

High-pressure filter

(3)

Charge pressure limiting valves drive pumps (p = 30 bar)

(4)

High pressure sensor B13 (p = 0…500 bar)

BiG X Service Training 2014 Advanced

3

Measurement points WHB_5.1_Speisedruck_DE

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1. Ground Drive Hydraulics: Poclain Charge Pressure Circuit

4

Charge pressure circuit 850 - 1100 High pressure circuit

Charge pressure circuit

1 2

Measurement points

3 (1)

Supply pumps traction drive

(2)

Cold start valves (p = 30 bar)

(3)

Charge pressure limiting valves drive pumps (p = 30 bar)

(4)

High pressure sensor B13 (p = 0…500 bar)

3

WHB_5.1_Speisedruck_DE

6

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1. Ground Drive Hydraulics: Poclain Pump Adjustment Pump adjustment E2 Charge pressure is present at the high-pressure limiting valves / feed valves (1). If the pressure in the highpressure circuit (supply line or return line) drops below charge pressure, the valve opens and the high-pressure circuit is refilled.

2

The safety valve Y69 or Y70 (2) closes the depressurised tank return line of the charge pressure. Pressure builds up behind throttle D3. The pilot valve (3) switches to “unthrottled” and the pressure is present at the same time at the pump adjustment valves Y1 / Y2 or Y3 / Y4.

3

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

Safety function: If the safety valve Y69 / Y70 is de-energized, the pilot valve (3) is always in the "throttled" position. The pump swivels back in a controlled manner.

1 7

LINDE DBV_DE

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LINDE_Schaltplan E2_DE

LINDE Austausch DBV_DE

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1. Ground Drive Hydraulics: Overview Linde pumps Poclain traction drive 11

11

4

3

8

1

9

3

2 10

8

2 9

1 10

5 7

3

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

8

Holding washer for pivoting angle potentiometer

(2)

Pivoting angle potentiometer

(3)

High pressure limiting valves

(4)

Charge pressure limiting valve

(5)

Cold start valves

(6)

Charge pressure gear pumps

(7)

Feed pump end cover

(8)

Adjustment unit

(9)

Switching magnet safety valves Y69 or Y70

(11) Gasket kits adjustment unit and pump flange

6 4

(1)

(10) Proportional solenoids pump control Y1 to Y4

6

3

of Linde Pumps

Nominal size of the pump

Tightening torque high pressure PLV

Tightening torque charge pressure PLV

55 cm³

140 Nm

30 +5 Nm

75 cm³

140 Nm

30 +5 Nm

105 cm³

140 Nm

30 +5 Nm

135 cm³

250 Nm

40 +5 Nm

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1. Ground Drive Hydraulics: Poclain Stage Switchover 2 – stage wheel motor (BiG X 500* / 650 / 700)

Measurepoint minimess 7

* No switching of the rear wheel motors for BiG X 500!!

Y11 The valves Y14 and Y11 are opened in the de-energized state.  The control lines are pressurised with charge pressure, the wheel motor is in the small absorption volume

Y14

If Y14 or Y11 is powered, the valve closes. The control lines are depressurized and the wheel motor is in the large intake volume.

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

Observe switching logic!!

WHB_5.1 Umschaltung_DE

9

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Changeover

3-stage wheel motor (BiG X 650* / 700* / 850 / 1100) Front axle: MS 50 (1C/2C/3C); 5165 ccm / 3332 ccm / 1833 ccm

*Front axle: MS 50 (1C/2C/3C); 4333 ccm / 2833 ccm / 1500 ccm

Absorption volume 1C (largest torque)

Connection of the changeover on the wheel motor: Y1 (wheel motor) -> Y14 (switching valve on front axle)

Umschaltung_Radmotor

10

Y2 (wheel motor) -> Y68 (switching valve on front axle) BiG X Service Training 2014 Advanced

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3-stage wheel motor (BiG X 650* / 700* / 850 / 1100)

Measurepoint minimess 8

* optional for BiG X 650 / 700

HP circuit front axle

Y14

Y11

Valves Y68 and Y11 are open when they are not powered.

Valve Y14 is closed when it is not powered. If the control lines are depressurised, the wheel motors work with large absorption volume.

Y68

When the traction drive at at a standstill, valves Y68 and Y11 are powered. Y14 is not powered.

HP circuit front axle

Return filter wheel motors

Diagnostics: On minimess port 6, minimess port 7, or minimess port 8 the switching function and the pressure in the low-pressure circuit can be checked.

WHB_5.1 Observe switch logic!!

Umschaltung_DE

11

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Changeover

Circuit logic: stage switchover (Poclain wheel motors)

Two-stage traction drive

Speeds when accelerating

XY 14 (coil)

Y 14 (valve)

1. Level M = max

BIG X 500: approx. 0…13 km/h Big X 650, 700: approx. 0…11 km/h

12V

0 bar

BIG X 500: approx. 13…40 km/h Big X 650, 700: approx. 11…40 km/h

0V

30 bar

Speeds when accelerating

XY 14 (coil)

Y 14 (valve)

XY 68 (coil)

Y 68 (valve)

approx. 0…10 km/h

0V

0 bar

12V

0 bar

approx. 10…20 km/h

12V

30 bar

12V

0 bar

approx. 20…40 km/h

0V

0 bar

0V

30 bar

v = min

2. Level M = min v = max

Three-stage Traction Drive 1. Level M = max v = min

2. Level 3. Level M = min v = max

12

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1. Ground Drive Hydraulics: Poclain Combination Valve Rear axle variable displacement pump

Rear axle wheel motors

2.1

1.1

Front axle variable displacement pump / front axle wheel motor

3

2 1

Axle separation pilot valve (1), axle separation main valve (1.1) All-wheel pilot valve (2), all-wheel main valve (2.1), flush valves (3) When the diesel engine has been started, the charge pressure of p = 30 bar is on the Ps connection on the combination valve.

The appropriate pilot valve Y13 or Y10 is powered with 12 volts to switch on the respective “All-wheel” or “Axle separation” function. The control line is charged with charge pressure and it switches the hydraulically actuated main valve in the high pressure circuit.

Turning on all-wheel drive is only possible if the machine is at a standstill!

13

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1. Ground Drive Hydraulics: Poclain High Pressure Circuit Overview high pressure circuit Poclain

Changeover

WHB_5.1 Hochdruck Fahrantrieb_DE

5 System control and monitoring via SmartDrive:

Inputs (1) (2) (3) (4) (5) 14

Axial piston variable displacement pumps traction drive (Tandem unit: 105/75 ccm (BiG X 500 / 650 / 700) or 135/75 ccm (BiG X 850 / 1100) Wheel motor front (with integrated drum brake) 2-stage (BIG X 500 / 650 / 700) or 3-stage (BIG X 650 (opt.) 700 (opt.) 850 / 1100) Wheel motor at rear constant (BiG X 500) or 2-stage (BiG X 650 / 700 / 850 / 1100) Combination valve (flush valves) High-pressure sensor (on front axle pump, partially connected with short hose)

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Outputs © KRONE Training Team, Spelle

Flush valves (1), hydraulically actuated  Oil is conveyed out of the return to the cooling. > 400 bar

1 M

Changeover

System control and monitoring via SmartDrive: Inputs: B13, B14, B38/B39, …(see circuit diagram)

Outputs: Y1/Y2, Y3/Y4, Y69/Y70, …(see circuit diagram) 15

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M

"Front axle" and "rear axle" circuits are connected to axle separation valve (1) as long as the axle separation is not activated.

When connecting the all-wheel drive, both drive pumps operate in parallel on 4 wheel motors.  large circuit, still connection between “front axle” circuit and “rear axle” circuit. -> All-wheel valve (2)

Wheel motors front axle

1

2

Axle separation: Two circuits separated from each other

 “Front axle” pump and “rear axle” pump operate on two wheel motors only.

A speed difference between two wheel motors of an axle can furthermore be compensated  Driving around curves is only possible with activated axle separation!

16

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1. Ground Drive Hydraulics: Poclain Diagnostics M1 : p = 30 – 435 bar

M2 : p = 30 – 435 bar

(Supply line for forward travel)

(Supply line for forward travel) The high-pressure circuits of the traction drive can be checked on the measurement connections M1 to M4.

WHB_5.1 Hochdruck Fahrantrieb_DE

M3 : p = 30 – 435 bar

M4 : p = 30 – 435 bar

(Return line for forward travel)

(Return line for forward travel)

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

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

17

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1. Ground Drive Hydraulics: Bosch System: Charge Pressure Charge pressure circuit overview

1

(1) Charge pressure pump integrated in the traction drive pump (2) Main coupling valve (3) Clamping cylinder main belt (4) Valve clamping cylinder main belt (5) Grinding flap valve (6) Clamping cylinder belt corn conditioner (7) Auxiliary function lifting unit 18

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1. Ground Drive Hydraulics: Overview of Bosch System Position of the components in the machine

4

14

6

8

10

11

7 3b 5

2

6

13

14

3a 12 6

4 1b

15

12 13

1a

15 2

6

19

BiG X Service Training 2014 Advanced

Components

9

1a

Drive motor front left

1b

Drive motor front right

2

Planetary gearbox front

3a

Drive motor rear left

3b

Drive motor rear right

4

Planetary gearbox rear

5

Variable displacement pump

6

Speed sensor

7

High-pressure sensor B101

8

High-pressure sensor B102

9

“Forward” valve

10

"Backward" valve

11

Pivoting angle sensor

12

Feed valves

13

Drive motor valve at front

14

Drive motor valve at rear

15

Accumulator for feed

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1. Ground Drive Hydraulics: Functions of Bosch System Function description of Bosch traction drive 1.

Acceleration forward 0 - Vmax in road mode As soon as the driver has given the drive command with the joystick, the drive pump starts to swivel out. If the driver accelerates continuously, the drive pump swivels continuously until the maximum absorption volume is reached. Shortly before the pump reaches maximum absorption volume (approx. 8-9 km/h), the wheel motors start to reduce their absorption volume.This gives a continuous, smooth acceleration from standstill up to the maximum speed of 40 km/h. Reverse is limited to a maximum speed of approx. 14 km/h.

2.

Acceleration forward 0 – Vmax in field mode The sequence for the acceleration process is the same as for road mode. The only difference is that the maximum speed here is limited to 25 km/h. The maximum reverse speed is approx. 14 km/h (electronically limited).

20

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1. Ground Drive Hydraulics: Functions of Bosch System Function sequences of Traction Control 3.

Function of Traction Control (TC) Traction control prevents individual wheels from rotating uncontrollably if the tractive forces on one wheel can no longer be transferred to the ground. This enables all wheels to spin equally. Depending on the speed of the other wheels and the steering angle, a theoretical speed is calculated for each wheel. If the speed of a wheel is higher, the absorption volume of the hydraulic motor is reduced on that corresponding wheel. This happens until the torque on the wheel is so low due to the absorption volume which becomes smaller that it is no longer adequate to allow the wheel to spin. At the same time the pivoting angle of the pump is reduced to adjust the volume rate required for the current speed.

Animation TC

21

TC for use in practice

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1. Ground Drive Hydraulics: Bosch Drive Pump Components of the drive pump in the hydraulic circuit diagram 5 10 4

3a

6

7 9

8

3b

1

2

11 Components

22

1

Feed pump

5

Actuator valve

9

Angle sensor

2

Charge pressure limiting valve

6

Set piston

10

High pressure sensor

3

Combination valve

7

High pressure pump

11

High pressure sensor

4

Orifice

8

Pressure cut-off

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1. Ground Drive Hydraulics: Bosch Drive Pump Hydraulic pump function A4VG

5 Animation A4VG

4 6

7

3a 8

3b

1

2

When the diesel engine starts, the charge pressure pump (1) also starts to convey oil into the low-pressure circuit. The charge pressure PLV (2) limits the pressure to approx. 28 bar. This constant 28 bar is applied to the combination valves (3) as well as the orifice (4) on the actuator valve (5).

The high-pressure circuits are filled via the combination valves (3). In neutral position of the pump, there is a pressure of approx. 5 bar on the set piston (6) on both sides.

As soon as the actuator valve (5) for forwards is energised on the pump, a set pressure builds up on the set piston (6) and the piston swivels the pump (7) out.

This causes the pump (7) to convey oil and on the corresponding high-pressure side pressure builds up depending on the load. The combination valve on the current high-pressure side (3a) is sealed against the low-pressure circuit. The combination valve on the current return side continues feeding charge pressure.

23

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1. Ground Drive Hydrauilcs: Bosch Drive Pump Hydraulic pump function A4VG

5 Animation A4VG

4 6

7

3a 8

3b

1

2

If the load on the traction drive is greater, the pressure on the high-pressure side continues to rise. When a pressure of approx. 490 bar is reached, the pressure cut-off (8) responds.

This causes the pressure in front of the throttle (4) to drop reducing pressure at the control valve (5); the pump destrokes until the high pressure drops.

The PLV (3a) responds only to pressure peaks above 510 bar. No pressure cut-off has been integrated for reverse; the pressure limiting valve set to 470 bar protects against high-pressure.

24

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1. Ground Drive Hydraulics: Bosch Terminal Diagnostics Bosch terminal diagnostics

1. Forward drive pump valve Y101 2. Reverse drive pump valve Y102 3. Pivoting angle sensor B108 4. Steering angle sensor B107 5. High-pressure sensor forward B101 6. High-pressure sensor reverse B102 7. Manometric parking brake switch B110 8. Parking brake valve Y18 9. Brake pedal angle sensor B109 10. Service brake pressure sensor B16 11. Wheel motor valve currents Y103-Y106 12. Wheel motor speed sensors B103-B106

25

1 2 3

11 12

4 5

7

6

8

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9 10

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1. Ground Drive Hydraulics: Bosch Pump Control Circuit Pump adjustment monitoring Feedback position of pump

B108

Input IN_37

Drive control

DRC Output Y102

a

U

Drive pump

Output Y101

Y101

Y102

Setting signal pump forward As soon as the driver gives the drive command with the joystick, the DRC (BODAS control unit) transmits a setting signal to the corresponding solenoid valve of the drive pump (Y101/Y102). The pump swivels out depending on the height of the current. The pivoting angle of the pump is monitored by the pivoting angle sensor.

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

It is necessary to calibrate the pivoting angle sensor to ensure the monitoring of the pump position functions correctly!

26

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1. Ground Drive Hydraulics: Bosch Drive Pump Components of drive pump

12

10

9

Components

8

11

7

13 1 14 3

2

27

4

5

BiG X Service Training 2014 Advanced

6

1

Drive shaft

2

Housing cover

3

Leakage oil connection

4

Charge pressure limiting valve

5

High pressure limiting valve forward (510 bar)

6

Suction connection

7

High pressure limiting valve backward (470 bar)

8

Valve “backward” Y102

9

Measurement connection for set pressure X2

10

Measurement connection for set pressure X1

11

Mech. zero position centring

12

Pivoting angle sensor

13

Valve for pressure cut-off (490 bar)

14

Charge pressure connection

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1. Ground Drive Hydraulics: Bosch Drive Pump Components of drive pump 5

Components

4

3

6

2 1

7

10

8

28

1

Pivoting angle sensor B108

2

Measurement connection set pressure X2 (backward)

3

Measurement connection set pressure X1 (forward)

4

Valve “backward” Y102

5

Control valve block

6

“Forward” valve Y101

7

Working connection B

8

Working connection A

9

High-pressure sensor MA (B101) (forward)

10

High-pressure sensor MB (B102) (backward)

9

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1. Ground Drive Hydraulics: Bosch Wheel Motor Design hydraulic motor A6VE

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

2

1

Components

5

5

Partsunit Power 1. Power unit Speed sensorsensor 2. Speed 3. Proportional Proportional valve valve 4. Non-return valve Non-return 5. Flushvalve valve 6. Set piston Flush valve

6

Set piston

1 2

6

3 4

Technical data: Absorption volume Front axle 115 cm³ Rear axle 62 cm³

4 3

4 3

Flush valve:

Vg,min Vg,max

approx. 400 mA approx. 1200 mA

Flush rate:

approx. 10 l/min

Resistance coil

2 29

Currents =

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approx. 5.5 ohm

1. Ground Drive Hydraulics: M1

Hydraulic motor A6VE

Mode of operation:

3

Pump

2 Pump

G

Bosch Wheel Motor

As soon as the diesel engine is started, the drive pump also starts to rotate. After a short time, the charge pressure of approx. 30 bar also builds up in both high-pressure lines (A + B) on the engine.

The valve for adjusting the wheel motor (1) is powered at maximum level directly after the diesel engine has been started. This causes the same pressure to build up on the plunger ground side of the setting device (2) and on the plunger ring side.

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

As soon as the pump conveys oil to the motor, pressure builds up in a high-pressure line and the motor starts to rotate. At the same time the flush valve (3) is actuated via the differential pressure in the high-pressure lines. 10 l/min are flushed out of the low-pressure side to cool the system.

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

The result is a motor speed that depends on the current as well as on the pump volume rate.

1

Animation A6VE

30

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1. Ground Drive Hydraulics: Bosch Wheel Motor Hydraulic motor diagnostics A6VE Connection G Shuttle valves

Connection M1

On the connection G, always the respective higher pressure of the high pressure lines is over both shuttle valves. Thus it is possible to measure the actual high pressure here.

Target value forward: 30…490 bar Target value reverse: 30…470 bar (when driving) 30…490 bar (in case of high-performance braking) The set pressure of the motor must be measured on the connection M1. This set pressure should always be at the 0.4 ...

0.5-fold pressure on the connection G. 31

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1. Ground Drive Hydraulics: Bosch Wheel Gearbox Planetary gearbox GFT 40

3

2

1

4

10

6

7

8

5

9

Components

32

1

Main frame machine

6

Planetary stage 1

2

Supporting axle

7

Planetary stage 2

3

Rim

8

Brake plates

4

Wheel bearing

9

Sliding ring seal

5

Hollow wheel/output

10

Brake piston

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2. Intake / Header Hydraulics: Overview (1)

Axial piston variable displacement pump intake 105 ccm (BiG X 500 / 650 / 600 / 700 / 800 / 850 / 1100), 135 ccm (BiG X 1000)

(2)

Overview

Axial piston variable displacement pump header 55 ccm (all BiG X 500 / 650 / 800 / 1000 BIG X 700 / 850 / 1100 until YOM 2010) 75 ccm ( BIG X 600 / 700 / 850 / 1100 from YOM 2011)

(3) (4)

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

(5)

Fixed displacement motor header 55 ccm (BiG X 500 / 650 / 800 / 1000) BiG X 700 / 850 / 1100 to YOM 2010) 75 ccm (BIG X 600 / 700 / 850 /1100 from YOM 2011)

(6)

Quick-stop valve

Design

WHB_4.1 Hochdruck Einzug_DE

Hydraulic circuit

33

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2. Intake / Header Hydraulics: Quick Stop Valve Quick-stop function in the feed drive When metal is detected, an electrical signal is transmitted from the control to a 3/2-way pilot valve. The pilot valve hydraulically actuates the main slide of the quick-stop valve. The stop valve switches the oil flow to circulation and stops or decelerates the motor against a pressure limiting valve to a standstill.

The pressure limiting valve is set to p = 350 bar.

The stop time of the drive is less than 60ms.

Parallel to the quick-stop valve the pump is swivelled back to the neutral position.

34

Stop valve

Pilot valve

(Main valve)

(Y 35, conducts to earth)

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2. Intake / Header Hydraulics: Pump Adjustment Feed pump (1) When the diesel engine has been started, the charge pressure of p = 24± 3 bar is on the pump adjustment and on the feed valves. The charge pressure limiting valve (2) conveys the surplus oil back to the tank.

M

One charge pressure PLV for one pump!  Parallel switching of both valves in one circuit.

LINDE_Austausch DBV_DE

Diagnostics: For diagnostics, the intake / header charge pressure p = 24±3 bar on the measurement connection 13 can be checked.

LINDE_Schaltplan E1_DE

For adjustment of the E1 the control pressure is directly on the pump adjustment valves. A safety valve is not required here.

The current strength on the valves Y5/Y6 or Y7/Y8 specifies to what extent the pumps swivel out.  larger current means higher speed of the intake or the header.

A calibration specifies which current is required for which speed. The speed is not controlled.

WHB_4.1 Speisedruck Einzug_Vorsatz_DE

35

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2. Intake / Header Hydraulics: Intake Overview M9 : p = 24 – 435 bar

Variable displacement pump

Speed sensor B 26

Hydraulic motor with flush valve

M

Quick-stop valve

M11 : p = 24 – 400 bar Diagnostics intake drive: The intake high-pressure circuit can be checked on measurement connections 9 and 11.

Observe supply and return line arrangement!

WHB_4.1 Hochdruck Einzug_DE

36

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2. Intake / Header Hydraulics: Quick Stop Quick-stop valve Speed sensor B26

Valve (1) connects supply and return so that oil is sent directly back to the pump.

1 3

Valve (2) closes the return line of the motor to prevent overtravel and to stop the motor immediately. The pressure peak which occurs briefly is reduced by the pressure limiting valve (3).

2 Hydraulic motor with flush valve

Y 35 is grounded I.e. if the metal detection detects metal in the intake, the ground of valve Y 35 is switched.

The pressure behind the throttles in the high-pressure circuit can escape into the housing line The pressure difference causes both main valves (1) and (2) to switch 37

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2. Intake / Header Hydraulics: Overview header M10 : p = 24 – 435 bar

Variable displacement pump

Speed sensor B 27

M

Hydraulic motor with flush valve

M12 : p = 24 – 435 bar Diagnostics header drive: The header high-pressure circuit can be checked on the measurement connections 10 and 12.

Observe supply and return line arrangement!

WHB_4.1 Hochdruck Vorsatz_DE

38

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3. Fan Drive Hydraulics: BiG X MAN High pressure measurement connections 6

Mode of operation:

- Drive runs in closed system - Pump is actuated in one direction only - > fan has only one direction of rotation -If the plug is disconnected, the pump swivels out completely -> maximum fan speed (fail-safe function) - Fan speed is controlled depending on the temperature of charge air, cooling water and oil

7

5

1 3

2 4

39

(1)

Fixed displacement motor with flush valve

(2)

High-pressure limiting valve / feed valve

(5)

Charge pressure limiting valve (25 bar)

(3)

Pressure cut-off

(6)

High-pressure measurement connections

(4)

Charge pressure pump (integrated)

(7)

Actuator valve Y 82

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3. Fan Drive Hydraulics: BiG X MAN

4

3

1

5 M

2

3

Pump adjustment function As soon as the diesel engine starts, the pump is driven and the charge pressure pump (1) starts to deliver oil. The oil is then on the charge pressure limiting valve (2) and on the combination valves (3) and the highpressure lines are filled.

At the same time, charge pressure is sent directly to the set piston (5) through the control valve (4). Due to this, the pump swivels out completely and a high pressure builds up in the supply line.

As soon as the electronics are turned on, the valve Y82 is powered. Due to this, a pressure, depending on the height of the current, is on the other side of the set piston (5).

The 4/2 directional valve (reverse valve) is not used for the BiG X.

Diagnostics The emerging high pressure depends on the load (air resistance of the fan wheel).

BiG X 600/700: 25…295 bar BiG X 850/1100: 25…325 bar 40

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Pressure supply brake and working hydraulics circuit (1) Triple pump (2) High pressure filter

4

(3) Pressure limiting valve (p = 240 bar) (4) Accumulator charging valve

3 1 2

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Working hydraulics component overview

WHB_4.4 Ventilblock Arbeitshydraulik_DE

8

5 9

4

7

11

(1)

Accumulator charging valve

(2)

Parking and foot brake hydraulic accumulator

(3) (4) (5)

Lifting gear hydraulic accumulator (vibration damping) Working hydraulics valve block (with oil circulation function) ELC (electronic lifting unit control)

(6)

2/2-way seat valves pendulum frame

(7)

Lifting unit accumulator connection block

(8)

Discharge chute rotation gearbox

(9)

Foot brake valve and measurement connection

(10)

Wheel gearbox with integrated brake

(11)

Cylinder grinding device

(12)

Cylinder pendulum frame

6

10 1 42

2

3

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Pump work hydraulics (1) High pressure filter (2)

3

Pump arrangement has been changed from year of manufacture 2009! The work hydraulics pump is located directly on the power take-off gear.

Accumulator charging valve

< 70 bar

4 5

1

43

Power take-off gear

2

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

The hydraulic accumulators (3) serve as pressure accumulators. A pressure balance is activated by control lines.

This ensures that both brake circuits are constantly filled.

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

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

The manometric switch B 18 (opener) monitors the pressure on both brake circuits. If the pressure drops below 70 bar, an alarm is sent by the SmartDrive.

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Brake cylinder

Poclain traction drive

Parking brake cylinder

Parking brake valve

The parking brake valve Y18 is powered to release the parking brake. The single-action parking brake cylinders are opened against spring force.

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

Pressure sensor

Pedal switch B40

Brake valve WHB_4.1 Betriebsbremse_DE

2 Work hydraulics

1 44

Hand pump

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

Safety function!!

From a specific pedal travel the brake pedal switch B40 recognizes that the brake has been applied. The pressure sensor B16 must measure a brake pressure between p = 70 90 bar at the point where the pedal position sensor changes state. Otherwise a hydraulic full braking will be triggered. The switchover point can be set by moving the switch in the oblong hole B40.

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Overview of the Bosch drive brake system

6

3 4

5

Components

1 2 45

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1

Gear pump work hydraulics

2

High pressure filter work hydraulics

3

Accumulator charging valve

4

Pressure accumulator - service brake

5

Pressure accumulator - parking brake

6

Foot brake valve

© KRONE Training Team, Spelle

Bosch traction drive concept brake system (service brake)

The deceleration of the machine functions differently, depending what means the driver has used to issue the deceleration command to the machine:

1. Decelerating the machine using control lever -

Absorption volume on the drive motors is increased Pump is supported on the diesel engine (support moment of the diesel engine is used)

2. Decelerating the machine using brake pedal

-

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

Brake system concept (parking brake)

The parking brake is applied by the same blades as the dynamic brake.

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Function of Bosch drive brake system Parking brake released, service brake is not actuated

If pressure is applied to port S (static brake), piston (1) moves to the left against spring tension (2). This releases piston (3) so no force is exerted on brake package (4).

S

2 1 3

4

3

4

Parking brake released, service brake activated

The parking brake is released via connection S as described above. If the connection D is pressurized now (dynamic brake), the piston (3) presses against the brake package (4). As a result, a braking effect that depends on the pressure is set.

D

2 1

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Manually releasing the parking brake / towing the machine 1.

Connect minimess port line from hand pump to parking brake (1) measurement connection

2.

Reverse the stop cock (2)

3.

Using the hand pump, pressurise the system

4.

Switch off ignition (as a result drive motors have

2

virtually no intake volume) 5.

Maximum distance: 8 km

6.

Maximum speed: (10 km/h)

To tow the machine, the ignition must be turned off to ensure the wheel motors do not have any absorption volume. In this process, the steering hydraulics are depressurized.

Therefore, do not tow the machine quicker than it can be safely controlled by the driver!

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1

© KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics Measurement connections brake system Bosch traction drive

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

D

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

S The respective brake can also be vented via the respective measurement connection!

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Brake valve Bosch traction drive The brake valve is installed at the front under the cab (directly under the brake pedal). The position of the brake pedal is measured by an angle sensor (B109), the brake pressure is measured by the pressure sensor (B16).

R B N FB 1 2

= = = = = =

B16

B16

FB

N

Set the set screw (1) so that there is still a gap of approx. 1 mm to the brake valve when the brake pedal is not depressed.

Turn the set screw (2) back as far as possible to ensure that it does not have any influence if the brake pedal is depressed completely.

FB

2

FB

B109

1

50

B

R

Accumulator charging valve pressure Dynamic brake wheel gearbox Tank line Service brake pressure sensor Set screw start braking Set screw max. brake pressure

B109

B109

N

B

R

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N

B

© KRONE Training Team, Spelle

R

4. Open Circuit Hydraulics: Working and Brake Hydraulics Accumulator charging valve The accumulator charging valve is a priority valve that ensures that the pressure accumulators have been permanently filled for the parking brake circuit and for the service brake circuit. The brake circuits have priority over the working hydraulics.

P F B R N R4 X1 B110 X Y18

B18

= = = = = = = = = =

Working pump supply line Manometric brake tank pressure switch (B18) Working hydraulics valve block Service brake and brake valve accumulator Tank line Parking brake accumulator Manometric parking brake switch connection Manometric parking brake switch (B110) Drive motor parking brake connection Parking brake solenoid valve R

P

B

F

X1

N

R4

R

X

B P

Y18 B110

N

B110

X1

X1

F X Y18

X P R4

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B

N

Y18

© KRONE Training Team, Spelle

R4

4. Open Circuit Hydraulics: Working and Brake Hydraulics Accumulator charging valve function

Pump Work hydraulics

Valve block Work hydraulics

Brake system

When starting the diesel engine, the pump conveys oil to the system for the working hydraulics (1).

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

As soon as both accumulators have been filled to approx. 150 bar, the accumulator charging valve (2) switches over to supply the working hydraulics. The pressure is limited to approx. 30 bar on the parking brake valve (3) by a pressure-reducing valve (4).

B110

Work hydraulics valve block

3

4

1 2

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4. Open Circuit Hydraulics: Working and Brake Hydraulics

1

Parking brake function

Pump Work hydraulics

Valve block Work hydraulics

Brake system

The machine is braked as soon as the parking brake (1) is depressurized.

Braking is carried out by spring force.

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

Service brake function 3

1

B110

Work hydraulics valve block

53

2

BiG X Service Training 2014 Advanced

The position of the foot brake valve (3) is evaluated by an angle sensor on the brake valve. If the driver presses the brake pedal, hydraulic braking is initially actuated by drive motors and the drive pump. The more the pedal is depressed, the more the machine is hydraulically braked.

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

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

© KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics Plausibility checks braking systems To monitor the function of the brake systems, two function monitoring systems are integrated in the electronics of the traction drive: 1.

Foot brake valve plausibility check The position of the brake pedal is measured by an angle sensor (B109). At the same time a pressure sensor (B16) checks the pressure in the brake lines. If the measured brake pressure is not compatible with the position of the brake pedal, an error is shown and the machine stops.

To ensure that this monitoring functions properly, an error-free calibration of the angle sensor B109 is required.

2.

Plausibility check parking brake valve The pressure for releasing the parking brake is monitored by a manometric switch B110. If valve Y18 for the parking brake is powered, the respective signal is expected from brake pressure switch B110. If there is no signal, an error message appears and the machine stops.

B16

B109

54

B110

Y18

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Working hydraulics: Hydraulic block Bosch SB12 External LS line for raising the lifting unit*

01 01 06 03 04

03 07

05 06 07 08

04 08

09

05

11 10 11

Return “T” Supply „P“ 55

BMK

01

EMR-valve

Y32/Y33

02

Intermediate plate with PLV and ext. LS*

03

Autopilot

Y39/Y40

04

Grinding device

Y31/Y30

05

Pendulum frame

Y37/Y38

06

EF: Guide wheels EC: Plant divider

Y28/Y29

07

09

12

Designation

02

02

10

Pos

12

BiG X Service Training 2014 Advanced

EF: Holding-down device Y26/Y27

EC: Flaps

08

Lift/lower spout

Y24/Y25

09

Spout-flap

Y22/Y23

10

Rotate spout

Y20/Y21

11

Intermediate plate with shuttle valvel*

12

Input plate

*Part has been changed or added up to year of manufacture 2014.

From YOM 2014, valve blocks from the spare parts storage are of the same level. © KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics Work hydraulics valve block

Individual pressure balances

PLV: 230 bar

WHB_4.4 Ventilblock Arbeitshydraulik_DE

From YOM 2014 on, an external LS line is installed for the lifting unit to ensure that it functions properly.

From YOM 2014, valve blocks from the spare parts storage are of the same level.

LS-PLV: 210 bar 56

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Valve block function with individual pressure balances in case of parallel actuation As long as no directional valve has been actuated, the pressure in the total LS line (Y) is at the same level than in the return line (T).

m 2 >> m 1

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

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

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

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

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

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

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

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Connection plate valve block work hydraulics

4

3

1

2

M M 3

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

58

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Bosch_Reparaturanleitung

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Intermediate plate for external feeding LS signal

M

3 2 1

The additional intermediate plate (2) shown here is only installed on machines from year of manufacture 2014. On all machines until YOM 2014, the connection plate (1) is directly connected with the first directional valve plate (3).

The LS signal pressure of the lifting unit can be measured on measurement connection (M). As soon as the lifting unit is not actuated, the tank pressure should be present here.

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4. Open Circuit Hydraulics: Working and Brake Hydraulics 5/3-way valve plate work hydraulics valve block

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

1

2 3

1

(1) Magnetic coil (2) Return spring

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

(3) Valve spool Emergency manual operation: Each valve can be actuated manually.

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4. Open Circuit Hydraulics: Working and Brake Hydraulics 5/3-directional valve with hydraulically unlockable non-return valve (seat valve) work hydraulics valve block

Locking block (1):

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BiG X Service Training 2014 Advanced

If problems arise, non-return valves can be replaced. They are available individually as a spare part.

© KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics Working hydraulics valve block: Intermediate plate with PLV

Up to year of manufacture 2013

From year of manufacture 2014 An additional PLV is mounted directly at the gear pump.

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

The LS-PLV in the input plate should also be tested!

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Maize / maintenance

(1) EMR valve

Grass

Y 32 - lifting valve

4

Y 33 - lowering valve (2) Accumulator switching block

3

(3) Three-way valve grass / maize (4) Safety stop valve

4

1

(5) Pressure sensor

5

2

5 63

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Working hydraulics valve block: EMR

1

2

5 Lifting unit cylinder

4 6

3 (1) Pressure balance (2) Lifting spool

2

4

3

(3) Lowering valve insert (4) Lock valve (5) Lifting set unit (6) Lowering set unit 64

Each ELC valve is tested on a test rig after assembly. Any adjustment on individual parts on the valve is therefore forbidden!

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4. Open Circuit Hydraulics: Working and Brake Hydraulics EMR - Electronic mowing table control

Grass / maize

Pressure sensor B49 (1): The pressure sensor permanently measures the pressure in the lift line. The signal goes to the EMR. Correct calibration is a prerequisite for error-free lifting gear control.

Function valve Y34 (2):

2

1

Function valve Y53 (3):

3

65

The valve is energized permanently so it is always open and is independent of the grass/maize mode. The hydraulic accumulator damps vibrations. The valve has to be switched only when actuating the lifting unit in order to access a direct function in the hydraulic system. The valve closes for 3 seconds and opens automatically afterwards

By switching the valve, the smaller hydraulic accumulator can be connected or disconnected. Due to the lower pretension (35 bar), even lower pressure peaks of the pick-up can be recorded. In grass mode, the hydraulic accumulator is therefore connected. Valve Y53 is energized in this case.

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Throttle valves for setting the speed Raise spout flap Lower spout flap

Lift/lower spout

Grinding cylinder off Grinding cylinder on

2/2 - way seat valves for locking the pendulum frame

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

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Work hydraulics valve block: Intermediate plate with PLV The extension is folded by the “Raise spout” (Y24) and “Lower spout (Y25) valves.

Y76

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

1

Y24

0.075l 45 bar

Y25

1 From year of manufacture 2013 on, an additional hydraulic accumulator is installed on all machines with Bosch traction drive.

This hydraulic accumulator dampens the vibrations on the discharge chute.

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

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BiG X Service Training 2014 Advanced

The lowering brake valve ensures an even folding process.

From YOM 2014 on, the both throttle non-return valves (1) are integrated in the connections on the hydraulic cylinders. Up to YOM 2013, they are installed externally in the line (on the discharge chute slewing ring)

© KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics Checking the maximum pressure in the work hydraulics: First of all, the lifting unit / header must be fully lowered to the ground. Close both stop cocks on the lifting cylinders. Field switches must be switched on and the diesel engine should be at low idle speed. Actuate joystick key for “Lift lifting unit manually”. The pressure can be measured at the following connections at p = 200 / 210 bar.

Alternatively for all machines:

Pressure measurement on the plug-in connectors for the pendulum frame cylinder or for the front attachment

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

Measurement connection on the input valve block (before ELC), if available (since 2008, series since 2009) Additional LS measurement connection (series since 2014)

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Components steering hydraulics (1)

Pump steering hydraulics

(2)

High-pressure filter

(3)

Steering unit

(4)

Steering cylinder

(5)

Valve autopilot

(6)

2/2-way seat valves autopilot

(7)

Measurement connection

(8)

Steering pressure sensor

3

8

1 5

2

6

7

4 WHB_4.1 Lenkung_DE

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4. Open Circuit Hydraulics: Steering Hydraulics From automatic steering valve

Y67

If steering is not actuated, the oil is returned at zero pressure back to the tank.

Y66

2 3

As the steering wheel is rotated, a pressure develops in the lines to the steering axle.

The maximum pressure can be checked on measurement connection 9. To do this, turn steering all the way in and hold steering wheel. A pressure of p = 200 bar should be measured at low idle. The pressure limiting valve (2) is located in the steering orbitol. The shock valves (3) are for the safety of the orbitol and open with a pressure of p = 250 bar.

WHB_4.1 Lenkung_DE Measurepoin t minimess 9

70

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

Power take-off gear

1

Connection autopilot: The steering of the machine is taken over by the automatic steering valve. The seat valves Y67 / Y66 open simultaneously as soon as one of the main valves Y39 / Y40 is actuated.

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4. Open Circuit Hydraulics: Working and Brake Hydraulics The rear axle suspension is a separate system. The hydraulic pretension of the suspension can be adjusted with a hand pump according to the front attachment weight and the rear ballast.

When adjusting, the machine should be fully equipped for the respective use (front attachment, rear weights, diesel tank full, kernel processor installed etc.)

Hydraulic cylinder

Damping element

Hydraulic accumulator 1.4 l / 60 bar

2 a

Pressure gauge

Measurepoint minimess line for the connection to the hand pump

Axle suspension setting: Between rear axle and main frame, there should be a spring path of a = 30…40 mm. The pressure in the system must be set accordingly.

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1

© KRONE Training Team, Spelle

4. Open Circuit Hydraulics: Working and Brake Hydraulics

(1) Additional axle accumulator charging valve (2) Additional Axle valve block

3 2

(3)

Additional axle pressure limiting valve

(4)

Axle with lifting cylinders

1

4

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Description of functions additional axle: Additional axle function is active in maize mode only!

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

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

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

Pressure limiting valve (1) set to 90 bar.

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

1

Standard settings parameters comp. current list in the Download Center.

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4. Open Circuit Hydraulics: Working and Brake Hydraulics 1

3

4

2

Hydraulic connection for molasses pump - Additional gear pump (1) on the main gearbox - High-pressure filter (2) in the supply - Valve block (3) for single-action function in the rear of the machine - Couplings (4) for pressure line and depressurised return 74

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4. Open Circuit Hydraulics: Working and Brake Hydraulics 1

3

2 Double-action control unit - Additional gear pump (1) on the main gearbox - High-pressure filter (2) in the supply - Valve plate Bosch 5/3 directional valve SB 12 (3)

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4. Open Circuit Hydraulics: Working and Brake Hydraulics 1

2

3 Two double-action control units - Additional gear pump (1) on the main gearbox - High pressure filter (2) - Valve block (3) from Hydac with two 4/3 directional valves

76

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Wheel motor brake connections

2

3 Parking brake valve

9

4 1

8 5 7

Accumulator charging valve

Return line

Hydraulics

6

Pneumatics

(1) Foot brake valve

(6) Pressure control valve 7.3 bar

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

(7) Air compressor

(3) Actuating cylinder parking brake

(8) Air filter

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

(9) Connections compressed air brake trailer

(5) Compressed air storage tank 77

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4. Open Circuit Hydraulics: Working and Brake Hydraulics Compressed air supply from the reservoir

Parking brake valve signal

Parking brake actuating cylinder

To the trailer connection coupling (reserves line) 3/2-way valve

Foot brake valve signal

(Trailer brake valve)

To the trailer connection coupling (brake line)

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5. Cooling and Leakage Hydraulics: Poclain Leakage Oil Circuits and Cooling Circuits BIG X 700 / 850 / 1100

2

3

2

1

(1)

Tank

(2)

Suction return air filter

(3)

Tank return air filter

(4)

Radiator

3 4

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

• A collector is not required for the leakage oil.

• The flush oil from the traction drive and from the intake and header drive runs by the radiator.

Parallel to the radiator, there is a bypass to protect the radiator.

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5. Cooling and Leakage Hydraulics: Poclain Leakage Oil Circuits and Cooling Circuits

Steering valve return, work hydraulics, additional axle

Leakage oil switching valve, quick-stop valve, motors feed drive and front attachment, fan drive;

5

7

Charge pressure circuit traction drive

4

Leakage oil wheel motors front Leakage oil wheel motors at rear

6

Leakage oil pumps, traction drive, feed drive and header

1 2

80

3

Suction lines charge pressure pumps traction drive, intake / header and fan drive

(1) Suction return air filter

(4) Sieve drum drive

(2) Tank return filter

(5) Radiator

(3) Pressure sensor

(6) Manometric switch BiG X Service Training 2014 Advanced

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

© KRONE Training Team, Spelle

5. Cooling and Leakage Hydraulics: Poclain Leakage Oil Circuits and Cooling Circuits BIG X 600-I / 700-I / 850-I / 1100-I

(1) Collector unit (2) Radiator

(3) Bypass valve (4) Suction return air filter

2 4

(5) Tank

3 1

5 All the leakage oil of the closed circuits is then brought together on a collector unit (1) and flows through the radiator (2).

A bypass valve (3) is installed to protect the radiator from too high pressure. After that, the oil flows through the suction return air filter (4) back to the tank (5) and then to the charge pressure pumps.

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5. Cooling and Leakage Hydraulics: Poclain Leakage Oil Circuits and Cooling Circuits Suction return filter: The suction return filter integrates the return filter in the open hydraulic circuit and the suction filter in the closed hydraulic circuit in one filter. This filter can always be used if the volume at the filter inlet, through steering return line, work hydraulics and radiator is greater than the required suction volume of the feed pump.

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

Pressure retaining valve

Filler necks with ventilation filter

Re-suction valve

Pressure limiting valve

The air exchange between container and environment is minimized due to the use of ventilation filters with double non-return valves. This reduces the ingress of dirt and humidity. The intake conditions of the pumps are improved significantly by the defined pressure level in the tank. On account of the double valve, a pretension of 0.2 bar is reached in the tank.

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6. Hydraulics Maintenance: Pressure Filter High pressure micro filter for work hydraulics and steering hydraulic pump - With contamination indicator - Replacement of the filters as required or when hydraulic oil changed - Bypass function with contaminated filter

All machines with MAN engine do not have a high pressure filter in the charge pressure circuits!

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6. Hydraulics Maintenance: Error Messages Manometric switch suction return air filter When the permitted contamination is reached, the return line pressure in front of the filter increases to a value of more than 2 bar. In this case the manometric switch transmits an electrical signal to the job computer and a warning symbol appears on the terminal.

Pressure sensor tank return air filter wheel motors (only Poclain traction drive) When the filter is contaminated, the pressure on the sensor increases.

- If the pressure is over 1.5 bar for longer than 6 seconds, the error message "Leakage oil filter contaminated" appears - If the pressure is over 2 bar for longer than 5 seconds, the error message "Check wheel motors" appears

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

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6. Hydraulics Maintenance: Oil Change Oil change interval: 500h Tank filling capacities: BiG X 500 BiG X 650 BIG X 600 / 700 / 850 / 1100

90 litres 90 litres 120 litres

When changing the oil, always replace the hydraulic oil filter inserts, as well.

Hydraulic oil change: With the 500 h hydraulic oil service the hydraulic oil should be discharged from the tank over the quick coupler with a hose into a suitable container. In addition, the hydraulic oil filters must be replaced.

To drain the oil completely out of the system, remove the pipe (flush and leakage oil) off of the intake and header motors.

Before start-up, the complete system (wheel motors and pumps) must be vented!

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6. Hydraulics Maintenance: Bosch Maintenance Maintenance planetary gearbox Bosch Wheel gearbox at front

Oil level check • Oil level must reach inspection screw (1) in the illustrated position Oil change • Screw out oil filler screw (2) and release the pressure from the gearbox • Unscrew oil drain plug (3).

• Screw in oil drain plug (3) again.

• Add oil. Oil level must reach control bore hole (1).

• Screw in oil filler screw (2).

Wheel gearbox at rear

Oil level check • Oil level must be 40 mm below opening (1) in the illustrated position Oil change • Screw out inspection screw (1) and release the pressure from the gearbox • Move oil drain plug (2) to the lowest position and screw it out • Screw in oil drain plug (2) again • Turn the wheel by approx. 30° upwards • Screw out oil filler screw (1) • Add oil. Oil level must reach approx. 40 mm below the wheel centre.

• Screw in oil filler screw (1).

Perform all work while the gearboxes are warm!

Only „SHELL S4 CX 50“ may be used as the gearbox oil!

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6. Hydraulics Maintenance: Start-up 1.

On components that cannot be vented (e.g. variable displacement pumps), hydraulic oil (HLP 46, see operating instructions) recommended by KRONE must be added. Observe extreme cleanliness! For information regarding the procedure and the position of the connections, please refer to the following pages.

2. The hydraulic oil tank must be filled with hydraulic oil (HLP 46, see operating instructions) recommended by KRONE until the middle of the viewing glass is reached. Observe extreme cleanliness!

3. Vent the system as far as necessary from bottom to top (for example: if the header variable displacement pump has been replaced the wheel motors do not need to be vented). Always start with the component at the deepest point. For information regarding the procedure and the position of the connections, please refer to the following pages.

4. Connect suitable pressure gauges to the supply pressure test connections in order to monitor the charge pressure at startup. (For information regarding the charge pressures, see the respective system descriptions) 5. Start diesel engine. Look at charge pressure and hydraulic oil tank filling level through viewing glass.

6. As soon as the hydraulic oil filling level cannot be seen any more in the viewing glass, the motor must be stopped and hydraulic oil must be added. Repeat this process until the filling level of the hydraulic oil remains at constant level.

7. Check charge pressure at the same time. Within 30 seconds the charge pressure of all pumps must have reached the respective charge pressure. If this is not the case, it is absolutely necessary to interrupt the process and to search for faults! The system will be damaged seriously if the machine runs without charge pressure for a longer time!

8. Let intake / header drive turn slowly and observe whether the charge pressure remains stable.

9. Slowly move the machine forward and backward and observe whether the charge pressure remains stable. On machines with Poclain traction drive, the wheel motors must not turn without load (machine placed on blocks) for a longer time! Wheel motors are damaged!

10. Do not start the machine and load the drives until the charge pressure is stable.

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6. Hydraulics Maintenance: Poclain Ventilation Venting Poclain wheel motors Front wheel motors, hexagonal socket head screw inside

BiG X 650/700//850/1100 Rear wheel motors, hexagonal socket head screw top

Front wheel motors, hexagonal socket head screw top

BiG X 500 Rear wheel motors, hexagonal socket head screw inside The static pressure is sufficient to press the air out of the system. It is not necessary to start the motor.

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6. Hydraulics Maintenance: Ventilation Venting the components of the fan drive (MAN) Variable displacement pump fan drive The leakage oil lines must be connected and the housing of the pump must then be vented via the upper dummy plug (X).

X

Fixed displacement engine fan drive The engine must be filled as far as possible via the leakage oil connection (T). Further venting is not necessary.

T

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

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6. Hydraulics Maintenance: Bosch Ventilation Venting the components of Bosch traction drive Variable displacement pump traction drive To vent the pumps, detach the hydraulic hoses on the top of the pumps (-> leakage oil lines) until the air has escaped and the hydraulic oil runs out bubble-free.

Adjusting motor traction drive The engine must be filled as far as possible via the leakage oil connection (T). Further venting is not necessary.

X

T

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

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6. Hydraulics Maintenance: Ventilation Venting the pumps To vent the pumps, detach the hydraulic hoses on the top of the pumps (-> leakage oil lines) until the air has escaped and the hydraulic oil runs out bubble-free.

BiG X 500 / 650 / 700 / 850 /1100

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

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6. Hydraulics Maintenance: Gearbox Oil Cooling 4

6

6a 1 2

from the radiator to the radiator

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7 3

6

(1)

Gear pump

(2)

Integrated PLV

(3)

Manometric switch

(4)

Nozzle

(5)

Filter

(6)

Non-return valve

(7)

Measurement connection

5 Depending on the year of manufacture, the non-return valve (6) is installed at position (6a) above the power take-off gear or (as shown) in the hydraulic lines in the direction of the radiator (6).

On the measurement connection (7) you should always measure under 30 bar.

1

At operating temperature, there should be a pressure of approx. 1-3 bar.

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

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