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

Forage Harvester BiG X

Training

Season 2014

No. 150 331 449 05 EN

Name: ________________________________ Company:

BiG X TT 2014 Advanced

________________________________

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

Update level: January 2014

© KRONE Training Team, Spelle

Contents Ongoing number

2

Chapter

Page

1.

Programme Overview

4

2.

BiG X Design

13

3.

Accessories

20

4.

Terminal

26

5.

Intake

36

6.

Foraging Unit

46

7.

Corn Conditioner

64

8.

Discharge Accelerator

72

9.

Hydraulics: Traction Drive

77

10.

Hydraulics: Intake/Header

106

11.

Hydraulics: Fan Drive

112

12.

Hydraulics: Open Circuits

114

13.

Hydraulics: Leakage Oil and Cooling Circuits

152

14.

Hydraulics Maintenance

156

15.

System Technology Sensors

166

16.

System Technology Calibration

188

17.

Electrical System/Electronics

222

18.

Software

262

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

Possible changes due to technical developments are reserved.

All safety precautions mentioned in the operating instructions apply for the training! The trainer will carry out a safety instruction at the start of the course.

BiG X Service Training 2014 Advanced

© KRONE Training Team, Spelle

Introduction Symbols and links 1.

WHB_5.1 Speisedruck_DE

Link to a .pdf file. In Presentation mode the appropriate file can be opened by clicking on the symbol. In the print version the document and the chapter can be found in the designation under the link.

e.g.

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

2.

Link to an animation. In presentation mode, the appropriate file can be opened by double clicking Changeover

on the symbol. This is used only for a more detailed explanation during training and is not available in the print file.

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

Presentation mode is started by pressing the F5 button.

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1. Program Overview 2014:

Additional tank (l)*

Cutting drum

Composite belt main drive

Engine

Traction drive system

Fuel tank (l) Urea tank (l)

480

V-shaped / 11 ° Ø 660 mm; 630 mm 28 blades (20, 40 blades) *

6 – groove

MTU BR 1300 12.8 l / R6

Bosch Rexroth

1330 130

170/200

580

V-shaped / 11 ° Ø 660 mm; 630 mm 28 blades (20, 40 blades) *

6 – groove

MTU BR 1500 15.6 l / R6

Bosch Rexroth

1330 130

170/200

600

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

7 – groove

MAN D 2868 LE Bosch Rexroth 16.16 l / V8

960

330

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

7 – groove

MAN D 2868 LE Bosch Rexroth 16.16 l / V8

960

330

850

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

8 – groove

MAN D 2862 LE Bosch Rexroth 24.24 l / V12

960

330

1100

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

8 – groove

MAN D 2862 LE Bosch Rexroth 24.24 l / V12

960

330

Type

700

4

Forage Harvester BiG X

BiG X Service Training 2014 Advanced

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(Fuel and/or silage agent)

1. Program Overview 2014:

Forage Harvester BiG X

Overview of performance data Machine performance

Red line: X-Power: heavy use for use with maize Green line: Eco-Power: e.g. for use with grass Principle of PowerSplit on BiG X 700/850/1100

V 8 engine with 16.16 l capacity (MAN D 2868 LE) BiG X 600 Continuous cutting output X-Power: 441 kW / 600 HP BiG X 700 Continuous cutting output X-Power: 492 kW / 669 HP Continuous cutting output Eco-Power: 374 kW / 509 HP

V 12 engine with 24.24 l capacity (MAN D 2862 LE) BiG X 850 Continuous cutting output X-Power: 607 kW / 825 HP Continuous cutting output Eco-Power: 469 kW / 638 HP BiG X 1100 Continuous cutting output X-Power: 760 kW / 1.034 HP Continuous cutting output Eco-Power: 469 kW / 638 HP

Eco Power – X Power Eco Power is used when maximum machine performance is not required. When additional performance is required, on BiG X 700, 850 and 1100, press the X-Power button to activate full power mode. Optionally this switchover can also be made automatically depending on the engine capacity. This mechanism gives you flexibility and reduces diesel consumption. The use of big, powerful forage harvesters is therefore more economical even in case of weak or highly changeable mowing conditions.

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1. Program Overview 2014:

Forage Harvester BiG X

Overview of performance data Fields of application of different characteristic lines Only for BiG X 700-I

Machine performance Eco-Power

Machine performance X-Power

= Torque = Power

= Torque = Power Engine speed rot./min.

ECO-Power for economical...

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

=

6

Fuel savings

Engine speed rot./min.

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

=

Maximum throughput t/h

BiG X Service Training 2014 Advanced

Machine performance Buffalo Power

= Torque = Power

Engine speed rot./min.

TRI-Power torque boost • big torque reserves • strongly varying and difficult conditions • for smaller areas • on slopes

= Relaxed working It is not necessary to carry out many readjustments. © KRONE Training Team, Spelle

1. Program Overview 2014: Overview of the ICAN components

RockProtect: Rock detection

ISOBUS: ISOBUS steering system

AutoScan: Automatic degree of maturity recording

AutoCalibrate (Calibrating the yield recording)

NIR moisture measurement

7

CropControl: Yield recording (Data collection is also possible via CCI terminal)

BiG X Service Training 2014 Advanced

AutoCalibrate: Automatic calibration of yield recording

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1. Program Overview 2014: Overview of the ICAN components

LaserLoad: Automatic spout control

Data fleet management: Further information www.krone.de

KRONE AgriNir: Determination of the ingredients in the crop and for calibration of NIR sensor

ForageCam: Screen transmission to transport vehicles that drive parallel

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BiG X Service Training 2014 Advanced

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1. Program Overview 2014:

Headers

Pick-up Working width (mm)

Working organs

300

3000

Uncontrolled pick-up

300s

3000

Uncontrolled pick-up

380

3800

Uncontrolled pick-up

Type

EasyFlow 300s (new generation 480/580)

EasyFlow

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1. Program Overview 2014:

Headers

Direct cutting system Type

6200

10

Working width (mm)

Working organs

6200

Disc mower

BiG X Service Training 2014 Advanced

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1. Program Overview 2014:

Headers

Maize headers BiG X 600-1100 Working width (mm)

Working organs

Transport position

6000(FP)

6000

circulating collector

vertically folded (2-part)

603

6000

circulating collector

horizontally folded (3-part)

753

7500

circulating collector

horizontally folded (3-part)

903

9000

circulating collector

horizontally folded (3-part)

1053

10500

circulating collector

horizontally folded (3-part)

Type

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1. Program Overview 2014:

Headers

Maize headers BiG X 480/580 Working width (mm)

Working organs

Transport position

450-2

4500

circulating collector

vertically folded (2-part)

600-2

6000

circulating collector

vertically folded (2-part)

750-2

7500

circulating collector

vertically folded (2-part)

600-3

6000

circulating collector

horizontally folded (3-part)

750-3

7500

circulating collector

horizontally folded (3-part)

900-3

9000

circulating collector

horizontally folded (3-part)

Type

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BiG X Service Training 2014 Advanced

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2. BiG X Design: Machine Concept Machine concept The engine (2) is transverse mounted across the frame (1). This ensures a direct drive with maximum efficiency. As the diesel tank is positioned low down in the frame, the machine has a low centre of gravity. This ensures safe working on slopes. The forage harvester is driven fully hydraulically by wheel motors without shifting gear. This design provides space for a large foraging unit over the front axle.

Thanks to the good arrangement of the foraging unit and the positioning of the engine behind the rear axle, an optimal weight distribution of 60% on front and rear axle is created: 40%.

Graphic_BiG X

2

3

4 1.

2.

3.

4.

5.

13

Frame Engine Diesel tank Planetary gearbox front Planetary gearbox rear

1

5 4

BiG X Service Training 2014 Advanced

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2. BiG X Design: Crop Flow Theoretical crop flow rates / speeds Crop flow BiG X 500, 650 BiG X 600, 700 BiG X 850, 1100

Optimum construction:

2187 rpm -> v = 64 m/s 2361 rpm -> v = 69 m/s 2475 rpm -> v = 73 m/s

- No power losses as the crop flow is diverted smoothly - Smooth crop flow thanks to six pre-compression rollers and individual coordination of the single unit speeds - High flow speed > 200 km/h at discharge - High pre-compression of the crop with four tension springs and a baling force up to 4600 kg

2 Crop flow

- Using the counterblade, the base is set to the wear condition of the blades - Drum base and rear wall are spring-mounted (1), (2) and are able to avoid large forage masses to ensure the smooth run of the machine.

BiG X 500, 650 BiG X 600, 700 BiG X 850, 1100

1 V = 1 – 5.5 m/s n = 190 – 950 rpm 14

v = 42 or 46 m/s v = 44 or 50 m/s v = 47 or 52 m/s

BiG X 500, 650 1100 rpm -> v = 38 m/s BiG X 600, 700 1188 rpm -> v = 41 m/s BiG X 850, 1100 1245 rpm -> v = 43 m/s

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2. BiG X Design: Drive Drive of operating units

On BiG X 600, 700, 850 and 1100, the drive train of intake pump and header pump is connected mechanically with this main clutch and it is turned on and off via this main clutch.

The operating units are driven hydraulically and mechanically.

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

This makes it possible to adjust header speed and intake speed automatically and continuously. From the hydromotors of the drive train the force continues through the transfer gearbox (2) (change in speed and direction of rotation) and through the universal shafts to the header and to the intake.

Component arrangement BiG X 500 / 650 / 600 / 700 / 850 / 1100

1. Power take-off gear 2. Transfer gearbox

Graphic_BiG X

3. Hydraulic motor intake 4. Hydraulic motor header 5. Quick-stop valve

closed hydraulic circuit

5

1 2

3 4 15

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2. BiG X Design: Drive Drive of operating units

Reversing the intake when the cutting drum is at a standstill

Most of the power is consumed by the drive of the operating units. The drive is performed via composite V-belts directly to the blade drum and to the discharge accelerator. The power is transferred by the discharge accelerator shaft to the right-hand machine side. There the corn conditioner drive is positioned.

1

1. Main coupling BiG X 500

5– groove

BiG X 600 / 650 / 700

7 - groove

BiG X 850 / 1100

8 - groove

3. Composite belt corn conditioner

6 -groove

Optional 7-groove

The hydraulic cylinder for tensioning the main belt is double-acting on all machines with Bosch drive system.

Graphic_BiG X

2

3

2. Composite belt of main drive

As the hydraulic pumps for intake and header are connected mechanically with the main coupling via the power take-off gear on machines with MAN engine, the main coupling must always be switched on for turning these drives.

The header cannot be reversed if the crop flow is blocked.

If the driver presses and holds the button to reverse the intake / header drive when the main clutch is disengaged, the main belt tension is released, the main clutch is engaged and the pumps are powered. This allows the operator to reverse intake / header when the crop flow is blocked.

SI_150399606 Reversieren_Einzug_DE

SI_150417073 7-Rilliger_Crackerriemen_DE

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2. BiG X Design: Traction Drive Poclain Poclain traction drive The traction drive is fully hydraulically and is made via two axial piston variable displacement pumps as well as four rotary piston motors. All-wheel drive belongs to the standard equipment for all models.

Type

Wheel motors

I.Road mode

II. Field FA

III.All-wheel

IV. Axle separation

500

Front axle: 2-stage Rear axle: 1-stage

0…40 km/h Front axle: 2/2 -> 1/2

0…25 km/h

0…17 km/h

0…17 km/h

650 / 700

Front axle: 2-stage Rear axle: 2-stage

0…40 km/h Front axle: 2/2 -> 1/2

0…19 km/h

0…14 km/h Rear axle: 2/2 -> 1/2

0…11 km/h

Front axle: 3-stage Rear axle: 2-stage

0…40 km/h Front axle: 3/3 -> 2/3 -> 1/3

0…31 km/h Front axle: 3/3 -> 2/3

0…18 km/h Rear axle: 2/2 -> 1/2

0…10 km/h

Front axle: 3-stage Rear axle: 2-stage

0…40 km/h Front axle: 3/3 -> 2/3 -> 1/3

0…31 km/h Front axle: 3/3 -> 2/3

0…18 km/h Rear axle: 2/2 -> 1/2

0…10 km/h

850 / 1100

I

II

IV

III

Changeover

Road / field front axle 17

All-wheel BiG X Service Training 2014 Advanced

Axle separation © KRONE Training Team, Spelle

2. BiG X Design: Traction Drive Bosch Rexroth Traction drive Bosch Rexroth The BiG X traction drive with components from Bosch Rexroth consists essentially of a variable displacement pump and 4 adjusting motors.

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

A machine with Bosch Rexroth traction drive can be identified by the outboard planetary (1) installed in the wheels on front and rear axles.

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

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

1 18

2

3

1

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2. BiG X Design: Traction Drive Bosch Rexroth Traction drive Bosch Rexroth: I.Road mode: The machine is started by front and rear drive motors. Driving speeds: Forwards 40 km/h, backwards up to 14 km/h.

II.Field mode: The machine is started by front and rear drive motors. The drive motors are adjusted steplessly according to conditions Driving speeds: Forwards 25 km/h, reverse 14km/h TC Traction Control: Traction Control (traction control, ASR) is active in field mode. If required, this can be switched on or off. Complete deactivation is not possible to protect the motors from overspeeding.

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

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

The selection of the stages for Traction Control depends on the mode set in the terminal (grass/maize). The stage can therefore be adjusted to the conditions

Animation TC

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3. Accessories: Overview Overview of optional accessories BiG X 2014:

Additional weights

LED working floodlights

Xenon working floodlights for cab roof

Crawler chassis

Service cart for cutting drum

20

Service cart for intake unit

Additional axle

Fender enlargement (front and rear)

BiG X Service Training 2014 Advanced

Xenon working floodlights for cab platform

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3. Accessories: RockProtect RockProtect - Rock detection (optional) a

An acceleration sensor is located in the area of the front, top intake roller to detect rocks. The sensor is fastened via a plate to the upper roller gear on the right side of the machine.

Functional principle:

If a foreign object, such as a rock is in the crop and enters the intake rollers, the upper roller unit will be forced upwards at a rapid rate. If the acceleration sensor outputs a value which is above the preset level, the drive of the intake is stopped abruptly. This is done via the so-called quick-stop valve in the hydraulic intake drive.

Rock detected!!

The intake is stopped the same as if metal is detected!

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3. Accessories: CropControl CropControl - Yield recording (optional) Inductive path recorder

In the cab: Pressure sensor

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

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

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BiG X Service Training 2014 Advanced

Optionally, CropControl can also be operated via CCI terminal.

© KRONE Training Team, Spelle

3. Accessories: Yield-dependent Silage Agent Dosage Yield-dependent silage agent dosage The system operates with the values obtained from the yield recording CropControl. An additional flow rate sensor (3) determines the volume of silage additive actually applied. Depending on the application amount set in the terminal, the silage additive pump is controlled accordingly.

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

3

5 4 2 1. Auxiliary tank (optional) 2. Silage additive pump and filter 3. Flow sensor 4. Quick coupling 5. Nozzle unit 23

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3. Accessories: Connection of Silage Agent Devices in General Location of the plug connections (as standard) for the connection of silage agent devices Plugs with pin assignment to control the pump:

Plug XB 77, behind the cab

XY 60 Pin 1: +12 volts switched max. 15 A via fuse 22-F74 XY60 Pin 2: Earth XY60 Pin 3: +12 volts continuous voltage, max.

15 A via fuse 22-F74 XM16 Pin 1: +12 volts continuous voltage, max.

15 A or PWM signal to regulate the flow rate via fuse 22-F80 XM16 Pin 2: Earth

Plug XY60, XB 60 and XM 16 On some machines, the plugs are located in the right lamp carrier.

If the machine is already fitted with an auxiliary tank, the plug connections can already be extended to the rear of the machine!

Plug

Function

KMC output / input

Position

XM 16

Silage agent pump

KMC 3: controlled internally* / uncontrolled externally*

above the right front wheel

XY 60

Pump silage agent / molasses

DIOM: uncontrolled externally*

above the right front wheel

XB 77

Flow sensor

Signal to KMC 3

behind the cab

XB 60

Filling level of auxiliary tank

Signal to KMC 2

above the right front wheel

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

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3. Accessories: NIR Sensor - Moisture Measurement Moisture measuring with NIR sensor (optional) The NIR sensor supplies precise data on the moisture of the crop. This recorded data can be assigned to the harvested area in the customer counter. The sensor is protected by highly wear-resistant materials and can therefore be used universally for any crop. (No warranty claims in case of damage because of foreign bodies). The moisture content is measured at the spout of the BiG X. Continuous crop flow is required for reliable data. The sensor is easy to install and is safely protected from damage by a cover.

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

The sensor automatically performs the internal calibration at fixed intervals.

In order to optimize the measurement values, the NIR sensor should be calibrated each time before the crop is changed  KRONE AgriNir kit

NIR sensor arranged in the back of the spout 25

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4. Terminal: Basic Screen Variable measuring units

Blow-off valve intake

Colored display of the speed under load

ISOBUS steering system Change of the load display

Driving strategy / Traction Control mode

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4. 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 27

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4. 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

28

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.

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

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

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.

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4. Terminal: AutoScan Settings

(as standard)

2

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

3 10

7

8

9

1 4 5

6

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

30

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

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4. 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

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4. Terminal: PowerSplit (optional) BiG X 700/850/1100 1.

Diesel engine speed when machine automatically changes

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.

from ECO-Power to X-Power (i.e: 1600)

Characteristic

: Abrupt change when speed is reached

Characteristic

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

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4. 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)

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

4

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).

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4. 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%

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BiG X Service Training 2014 Advanced

100 %

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4. 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

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5. Intake: Design Design

The intake consists of six rollers, the lower roller pack is fixed and the upper roller pack is spring-mounted. The level of the spring force is 4.6 t which then exerts a prebaling pressure of 1.6 kg/cm² on the crop. The length of the intake is 820 mm. The front upper roller (1) and the bottom roller (4) are made of stainless steel allowing the metal detector to function properly.

They are equipped with replaceable strips (9). The metal detection is installed in the roller (4).

8

5 4 3

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

1

7

Front upper intake roller Middle upper pre-compression roller Rear upper pre-compression roller Front lower intake roller Lower middle pre-compression roller Rear lower flat roller Bearing plate lower roller unit Bearing arm upper roller unit Toothed bars (changeable for grass/maize) Wear strips (bottom as an option)

9 10

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

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5. Intake: Design Upper Roller Unit 1

6 7

4 2

8

9

3

10 5

1 2 3 4 5 37

Upper net rollers Middle baling roller Rear baling roller Bearing arm upper roller unit Rocker arm left

6 7 8 9 10

Support axle net roller Upper roller gear Support axle middle baling roller Support axle rear baling roller Right rocker arm

BiG X Service Training 2014 Advanced

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5. Intake: Upper Bearings Bearing roller unit top left (from BiG X Bosch YOM 2012 on)

The upper rollers are mounted on fixed axles (4) on the left-hand side. The axles are connected with each other via a bearing arm (2). This bearing arm is guided rear by a rocker arm (1). The upper rolls are forced down by tension springs. Central lubrication supplies the bearings with grease.

1 2

7

7

3

6

38

7

6

6 4

4 1 2 3 4

5

5

5

Left rocker arm Left bearing arm Radial spherical plain bearing Fixed axle

4 5 6 7

Fixed sleeve Pendulum roller bearing Labyrinth seal

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5. Intake: Upper Bearings Roller gear top right (from BiG X Bosch YOM 2012 on)

The upper rollers are mounted on the right-hand side on fixed axles (1). The both front axles are fastened outside in the gearbox housing (2) with clamping elements (3). The rear axle is mounted in the gearbox. It is fastened by a profile sleeve (4) in a rocker arm (5) that guides the entire gearbox. The rollers are driven by profile flanges (6). They are inserted in the gearbox.

5

1

6

6

6

2 3

1

3

4 1 2 3 4 39

Fixed axles Gearbox housing Clamping element Profile sleeve

5 6

Right rocker arm Profile flanges

BiG X Service Training 2014 Advanced

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1

5. Intake: Top Bearings (from BiG X Bosch YOM 2012) 1

6

4

8 5

3

9

2 13

14

10 11 12

4

7 1 2 3 4 5 40

Profile sleeve Gearwheel on hollow shaft Grooved ball bearing Rotary shaft sealing ring Quad ring

6 7 8 9 10

Blade ring Reducer ring with O-ring seal Fixed axle Socket Cover washer with thread

BiG X Service Training 2014 Advanced

11 12 13 14

Taper roller bearing Rotary shaft sealing ring Labyrinth seal Ring seal

© KRONE Training Team, Spelle

5. Intake: Upper Bearings Bearing lower right roller unit

The journals (1) of the lower rollers are attached by pendulum roller bearing (2) in a bearing plate (3). The central lubrication supplies the bearings with grease. The front roller has a fixed shaft (4). The metal detector is mounted to this axle. The shaft sealing rings (5) are installed so that the grease can leak away from bearing. However, the bearing seals protect against dirt and moisture from the outside.

1

1

4

3

2

5 6

Journal Pendulum roller bearing Bearing plate Fixed axle

5

2

5 6

1 2 3 4 41

2

5

6 5 6 7

Shaft sealing rings O-ring seal Clamp axle metal detection

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5. Intake: Lower Roller Gear Bearing lower roller gear (left)

1

3

2 5 4

1 2 3 4 5

42

Taper roller bearing 2x Rotary shaft sealing ring O-ring seal Gearbox sealing flange Fastening screws 3x

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5. Intake: Drive BiG X 600/700/850/1100 The intake drive

The intake is driven by the hydraulic motor via universal shaft on the lower intake roller gearbox (2). From there, power is sent to the lower intake and pre-compression rollers and via double joint (BiG X 600/700/850/1100) or tower gearbox (BiG X 500-1000) to the angular gearbox (3). The upper roller gear (5) on the right-hand side of the machine is driven from the angular gearbox via universal shaft (4). The possibility to infinitely vary the speed of the intake from the cab enables the cutting length to be infinitely adjusted manually or automatically.

3 6

2 From year of manufacture 2011, the intakes on BiG X 600 / 700 / 850 / 1100 are equipped with a modified drive.

A new lower roller gear (2) is available as the rear springs have been newly arranged.

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

1.

2.

3.

4.

5.

6.

1

Input shaft of the lower roller gear Lower roller gear Angular gear Universal shaft Upper roller gear Double joint

SI_150371257 Antrieb_Einzug_Drehrichtung_DE

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BiG X Service Training 2014 Advanced

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4

5

5. Intake: Settings Settings

The upper roller pack is pulled downwards by four springs. The springs must be pretensioned equally right and left. When the crop passes the intake, the upper roller unit is raised against spring force.

BiG X 700/850/1100 BiG X 600-I/700-I/850-I/1100-I

Big X 500/650

v

h

h

3 v

h = 490 mm

44

v = 530 mm

On BiG X with Bosch traction drive, the front springs cannot be set!

BiG X Service Training 2014 Advanced

h = 450 mm

© KRONE Training Team, Spelle

v = 416 mm

5. Intake: Settings Settings scraper and flat roller

D

2

Make certain that there is no collecting edge between scraper (1) and counterblade (4).

This must be checked before every season !

1

The scraper (1) should be adjusted as close as possible to the flat roller (3) (0 – 0.3 mm).

The distance between the roller shell of the pre-compression roller (2) and scraper (1) should be equal externally on the right and left approx.

8 mm. The setting is made via distance plates under the rubber pads.

Furthermore, it is very important that the dimension (D) is not below 24mm. Then at the latest the scraper (1) must be replaced.

4

1

5

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3

6. Foraging Unit: Design Cutting drum

3

1

The cutting drum (1) has a closed body on which the blades (4) are arranged in a V-shape, offset at 11° to the counterblade (6). The bearing journals (2) are fastened via screws on the drum body. The cutting drum is driven via composite V-belts (3). The composite Vbelt pulley and the bearing journal diameter vary depending on the model. The cutting blades (4) are screwed in place with five hexagonal head screws which are tightened to 270 Nm.

4

2

2 Whenever a blade is changed, use new screws!

5 Composite V-belts: BiG X 500 BiG X 650, 600, 700 BiG X 850,1100

11°

7 8

8 46

7

5– groove 7-groove 8 -groove

The cutting drum is mounted in the cutting drum housing by two pendulum roller bearings (7). The cutting drum housing in turn is mounted in the machine frame by sliding bearings (8). The sliding bearings represent the pivot about which intake and header are raised and lowered.

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6. Foraging Unit: Blade / Counterblade Readjusting the cutting blades The blades must be adjusted optimally to the grinding device to sharpen the blades with the fewest grinding cycles possible.

Sharp tools - risk of injury!

Wear gloves when working on the blade drum.

1. Grind the blades of the cutting drum 2. Move away the counterblade (3) on both sides using the setting motors via manual operation on the platform. Extend both setting motors again approx. 5 mm to ensure that there is enough play to the counterblade after setting the blades.

3. Align counterblade (3) parallel to the ground blade backs on the counterblade support (refer to chapter “Turning / Changing Counterblade”).

4. Loosen all hexagonal head screws (2).

5. Set blades to the counterblade.

6. Tighten all hexagonal head screws (2) with torque wrench (tightening torque 270 Nm).

7. Loosen the blade drum locking, turn the blade drum by one row of blades further and lock it in place again.

8. Readjust the next row of blades.

9. Continue until all row of blades on the drum have been adjusted equally.

10. Loosen the locking of the blade drum.

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

12. Attach or folding in intake housing 2 13. Grind the cutting blade 14. Readjust the counterblade.

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6. Foraging Unit: Blade / Counterblade Replacing cutting blades Blades must always be replaced in pairs to prevent an imbalance in the drum. The two blades which are offset by 180° on the drum (e.g. blade 1 and blade 8, blade 1 and blade 6, blade 1 and blade 11).

The blade drum must always be fitted with the same blades; please observe the art. no. on the replacement blades (refer to the spare parts list)!

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

Whenever a blade is changed, use new screws!

1. Screw out hexagonal head screws (2) and (3).

2. Remove cutting blade (1) to the front.

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

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

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

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

When installing the cutting blades (1), observe installation direction of the threaded bars (5). The surface (a) with the rounded corners must be placed toward the drum (6), the flat surface (b) must face away from the drum (6). Install the wider surface of the threaded bars to the top in the direction of the blade carriers!

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6 4

1

5

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BiG X Service Training 2014 Advanced

a © KRONE Training Team, Spelle

b

6. Foraging Unit: Blade / Counterblade Turning or replacing counterblade Install the counterblade on the cleaned holding surface only. The skid surface area must be flat. If required, rework or replace skid surface area. When turning the counterblade, clean the underside of the counterblade.

1. Grind the blades on the cutting drum 2. Move the counterblade (1) away from the blade drum on both sides using the setting motors via manual operation on the platform.

After setting the blades, ensure that there is still play between the blades and counterblade by extending both setting motors again by approx. 5 mm.

350

Nm 425 Nm*

3. Remove hexagonal head screws (2), detent edged washers (3) and discs (4).

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

Then tighten spring assembly to a torque of 75 Nm. 5. Remove the counterblade (1) out the front side of the supports.

6. Clean the mounting surface and bottom of the counterblade.

7. Turn counterblade or install new counterblade.

!

!

210 Nm

! = Loctite medium strength Assembling a new counterblade *) applies only to machines without VariStream 1. Place the new counterblade (6) on the counterblade support and install hand-tight centre bottom with hexagonal head screw (2), detent edged washers (3) and washers (4).

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

3. Move setting motors until the outer hexagonal head screws (2) with detent edged washers (3) and washers (4) can be screwed tension-free through the draw shackle (7).

4. Tighten all three screw connections of the counterblade with the specified torque (refer to the figure).

m

2

3 4 49

7

1

2

5

3

4

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6. Foraging Unit: Bearing Design Cutting drum bearing BiG X 700 left (floating bearing) 1. 20 023 283 0 Slide ring

10

9

6

4

3

1

2. 00 911 609 0 Circlip I 160x4 3. 20 021 884 0 Seal ring protection

7

4. 90 000 106 0 Shaft sealing ring A 130x160x12 5. 00 931 922 0 Bearing 22216 E 6. 20 023 284 0 Thrust ring

5

80.1x95.2x15

8

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

11

2

9. 00 214 286 0 Intermediate ring 10. 00 911 696 0 Retaining ring 130x4 11. 20 023 294 0 Flange on left

WHB_3.2.3.1.

Häckseltrommellagerung_DE

Cutting drum bearing BiG X 700 right (fixed bearing)

1

2

3

4

5

9

10

1. 00 911 696 0 Retaining ring 130x4 2. 00 224 028 2 Cover Rd. 150x30 3. 00 937 534 0 O-ring seal 130x4 4. 00 911 570 0 Retaining ring A 75x2.5 5. 00 224 030 1 Support disc Rd.85/75x5

7

6. 00 931 920 0 Pendulum roller bearing 22215 E

6

7. 00 215 483 0 Bearing housing on right

8

8. 00 936 061 0 Shaft sealing ring A 85x110x12

9. 00 224 128 2 Intermediate disc Rd. 109.9/95x3 10. 00 911 691 0 Retaining ring 110x4

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6. Foraging Unit: Counterblade Adjustment Changed counterblade adjustment

A modified counterblade adjustment is installed in all machines from YOM 2014 on as well as in the machines built at last in YOM 2013.

The bolts (1) form the lower pivot point, the lever (2) is screwed firmly with the counterblade support (3). The adjustment is made via the servomotor unit recorded in the pivot point (4) that shifts the threaded piece (5) via the threaded spindle. The threaded piece is mounted so as to be rotatable in the lever (2).

A parking brake (6) pretensioned via disc springs provides damping of the vibrations on the entire adjustment.

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SI_150385506Gegenschneidenverstellung_DE

© KRONE Training Team, Spelle

6. Foraging Unit: Counterblade Adjustment Counterblade adjustment from year of manufacture 2014 The distance from the blades to the counterblade (7) can be adjusted via the anvil (6) on which the counterblade is fastened. The anvil (6) turns in the plain bearings on the pivot point (1). The counterblade is adjusted via adjusting motor units (5) if the key (9) is actuated. A sensitive and direct adjustment of the counterblade is possible as there are less pivot points (1),(3),(4) and two of this pivot points (1),(4) are pretensioned via springs (8),(9). The pretensioned pivot points ensure that there are less vibrations.

Furthermore the bearings are protected.

As before, the fastening of the anvil is pretensioned via disc spring assemblies and crown nuts. The pretension is reached if a tightening torque of 65 – 75 Nm is reached on the crown nuts.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Pivot point anvil Parking brake (no pivot point) Pivot point threaded piece on threaded spindle Pivot point adjusting motor braked Adjusting motor unit Anvil with screwed adjusting lever Counterblade (screwed with anvil) Disc spring for setting motor pretension Disc springs anvil

9 5

4 8

SI_150385506Gegenschneidenverstellung_DE

3

2

7 6 9

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BiG X Service Training 2014 Advanced

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6. Foraging Unit: Counterblade Adjustment Counterblade adjustment from year of manufacture 2014 Tightening torques: 1.

2.

3.

4.

5.

6.

7.

8.

Nut anvil on cutting drum 65-75 Nm Screw centre counterblade on anvil 210 Nm Screw outside counterblade on anvil 350 Nm Screw parking brake on cutting drum 85 Nm Screw adjusting lever on anvil 210 Nm Crown nut adjustment unit on cutting drum 40 Nm Cover of the gap on anvil 49 Nm Adjustment limitation on adjusting lever 25 Nm

Installation counterblade adjustment

5

6

3

1. First the anvil is installed and tightened with nuts 1.

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

3. The adjusting lever is preassembled now. This means that the adjusting motor unit is connected with the adjusting lever so that it can be mounted now.

4. Then the parking brake screws right and left (4) are tightened with the prescribed torque.

5. Afterwards the screw connections for the adjusting lever right and left on the anvil (5) are tightened.

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

53

8

7

For the function of the counterblade adjustment, it is very important that it is installed free of tension. To do this, observe the following procedure:

2 1

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5

© KRONE Training Team, Spelle

4

6. Foraging Unit:

YOM 2010 or Later

4 1

VariStream_1

3

ET_Handbuch

2

Trommelböden 700_1100_DE

2

3

Drum base

The clearance between blades and drum base (1) in the front area (drum input) is adjusted automatically by adjusting the counterblade. In the rear area (drum outlet), set a gap of 6 mm using adjusting screws (2). Then set spring tension (3) to 46 mm (spring length only).

Using the spacer (4), set a distance of 823±3 mm between the insides of the drum housing.

5 Align the drum base central to the housing by using washers.

54

Hexagonal head screw (5): Md = 350 Nm, edged washer and medium 5 Use detenttight screw locking.

6 BiG X Service Training 2014 Advanced

Middle bolt (6): Md = 210 Nm, Use detent edged washer

© KRONE Training Team, Spelle

6. Foraging Unit:

YOM 2011 or Later

Drum base

The position of the drum base springs has been modified on BiG X 600 / 700 / 850 / 1100 from YOM 2011.

The default setting gap between blade and drum base (6mm) and the setting dimension of the springs of 46mm remain unchanged (see previous page).

6mm

These drum bases also offer the possibility to screw a husk directly on the drum base.

Holes for screwing on the husk comb 55

BiG X Service Training 2014 Advanced

ET_Handbuch Trommelböden 700_1100_DE © KRONE Training Team, Spelle

6. Foraging Unit: Grinding Device Grinding device The blades are grinded by a cylindrical grinding stone. If the drum moves forward, the grinding stone moves horizontally back and forth over the drum. The grinding stone is held in the grinding slide by a clamping device (1). This clamping device is located in a threaded sleeve (2). The height of the grinding stone is set using this threaded sleeve. The grinding slide is moved by a synchronization hydraulic cylinder (3). Witch each grinding cycle, the adjusting ratchet (4) turns the toothed wheel (5) one gear and the grinding stone is moved a little further to the drum. An adjusting ratchet can optionally be installed on both sides.

The visible threading length of the threaded sleeve (A) should be at least 5 mm. Reset grinding stone, if necessary.

The grinding flap (9) is opened as soon as the maintenance switch is turned on. Otherwise, it is closed via a hydraulic cylinder (6). The grinding flap always opens if the diesel engine is switched off. The throttle non-return valves (7) next to the valve block can be used to set the speed of the synchronised cylinders (3). The grinding slide is guided at the rear with a ball bearing on a rail. From YOM 2012, a spring-loaded ball bearing (8) is installed additionally from the top.

3

6 4 9

8 SI_150388056

5

Schleifsteinführung_DE

А 2

The grinding stone speed should be set so that the grinding stone needs approx. 5 seconds to move from one side to the other. Based on past experience, we furthermore recommend to drive with an adjusting ratchet (4).

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6. Foraging Unit:Grinding Device 2

Grinding cycle counter The Namur sensor on the right side as well as the Namur sensor on the left side recognizes the end of the grinding path. Grinding cycles are also counted via theses pulses. The driver gets an information message in the terminal when a number of grinding cycles determined by the parameter is reached. Grinding in automatic mode is no longer possible.

1

The maintenance menu of the terminal includes a field with a grinding cycle counter (1), a bar graph with the possible cycles (2) as well as a softkey for resetting the counter (3). (From software version 200 814 617).

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

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3

Parameter

Designation

Meaning

33590

Total counter grinding cycles

Current state of the grinding cycle counter (only for information)

33657

Grinding stone adjuster

Number of adjusting ratchets per grinding cycle

34014

Grinding stone adjuster number of gears

Number of gears of the toothed wheel

34023

Number of grinding cycles up to the note display

Number of total grinding cycles until the information message appears that informs you to reset the grinding stone. (Default value is calculated from 34014 and 33657)

BiG X Service Training 2014 Advanced

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6. Foraging Unit: Grinding Device Replacing / resetting grinding stone

7

6 3 5 3 2

4

The grinding stone must be replaced as soon as the dimension “X” is more than 100 mm!

Then loosen the pawl (9) and rotate the locking bolt (8) 90° so that it can engage later.

Unscrew the adjustment wheel (7) together with the threaded sleeve (2) until the locking bolt engages in the threaded sleeve. Unscrew the adjustment wheel from the threaded sleeve. The clamp of the grinding stone is thus released. Set the new grinding stone to a distance of 3 mm to the blades using suitable aids. When installing a new grinding stone, observe the correct position of clamping rings, thrust rings and intermediate rings. After adjusting a grinding stone that has already been used (reset), check dimension “X”. The adjustment wheel (7) is tightened with 180+10 Nm. Pull detent pin and rotate by 90° (parking position). Fasten pawl (9) again and close grinding unit flap protection.

Reset grinding cycle counter!

After the grinding stone has been reset or replaced, it is absolutely necessary to tighten the grinding stone again to 180 Nm after first grinding.

9

1 1.

2.

3.

4.

5.

6.

7.

8.

9.

58

Grinding stone Threaded sleeve Clamping ring Intermediate ring Support washer Sleeve Gearwheel (Z = 36) Locking bolt Pawl

7

8

BiG X Service Training 2014 Advanced

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x

6. Foraging Unit: Grinding Device 3

5

7

4

6

2

5

6

2

3 1

5

3 1.

2.

3.

4.

5.

6.

7.

59

Grinding stone Threaded sleeve Clamping ring Intermediate ring Support washer Sleeve Gearwheel (Z=36)

5 1

4

1

max.

6

100 mm

Md = 180+10 Nm

4

Observe the position of the bevelled edges!

Bevelled edge faces down!!

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6. Foraging Unit: Grinding Device There are two different clamping ring versions. If an adjusting ratchet (1) is installed in the machine, then you should mount transparent / brown (2) clamping rings. If the respective machine is provided with two adjusting ratchets (1), then you should install black clamping rings (3) (softer).

After the grinding stone has been reset or replaced, it is absolutely necessary to tighten the grinding stone again to 180 Nm after first grinding.

1

The intermediate ring (4) is not installed in each machine.

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6. Foraging Unit: Setting the Counterblade General information regarding the setting of the cutting blades to the counterblade Dull cutting blades and a too great distance between the cutting blades and the counterblade will result in an unnecessarily high requirement of force, poor chop quality and high wear and tear on the cutting elements.

Sharpening does not do any good unless the counterblade is readjusted as well. The maize blades sharpen themselves very effectively, so there is no need to “sharpen them till they shine” at every grinding interval. In maize operation, it is recommended to merely readjust the counterblade several times a day between the grinding processes without having grinded before. In this process, the sharpness of the blades must always be observed. Short grinding intervals with a brief grinding duration combined with readjusting the counterblades work better than long grinding intervals with long grinding times.

1. To relieve the load on the machine, the header must be lowered by activating the key (1) until it rests completely on the ground.

1

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

In the display of the Info Center, “Maintenance” menu appears.

3. Set the number of grinding cycles taking account of the above mentioned points.

4. The engine speed is set automatically depending on software and setting (number of blades) when the grinding process is started.

Readjusting the counterblade Once the grinding process is complete, the counterblade must be readjusted while the blade drum is running.

5. Press the “Move counterblade right to blade drum” key and “Move counterblade left to blade drum” key alternately for a very short time.

6. If there is a noise when adjusting one of the sides (right/left) (blades touch the counterblade!), let go of the key immediately and press the appropriate key “Move counterblade away from the blade drum” for a very short time.

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

After you have blocked the counterblade, the blade drum must run without making any noise.

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6. Foraging Unit: Setting the Counterblade The most important decisive factors regarding wear and fuel consumption  Decisive factor counterblades

When used in harvest, the counterblade is strongest affected and it is largely responsible for cutting quality. Due to different harvesting conditions and operating conditions, there are different wear patterns on the cutting components. These wear patterns form the basis for the selection of the most suitable quality and version of the counterblade.

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

 Decisive factor cutting gap adjustment

“Crater-shaped surface” - numerous impacts of foreign bodies and deformations in the surface.

--> a harder version of the counterblade would be the wrong choice here!

In addition to the correct assembly of the counterblade, the exact setting of the cutting gap between blade and counterblade is of central importance both for the harvesting of maize and grass. The driver must always make sure that the counterblade has been optimally adjusted. There is evidence that significantly more energy is consumed with an increased cutting gap. A continuous cutting gap adjustment in between already leads to noticeable smooth running and an improvement of the cutting quality. It is more important to set the cutting gap continuously than to grind just the blades intensively. However, make sure that a start-up of the cutting blades to the counterblade must be prevented in each case during the operation!

The consequence of blade contact with the counterblade!

The coating on the back flakes off due to vibrations!

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6. Foraging Unit: Setting the Counterblade The most important decisive factors regarding wear and fuel consumption Decisive factor cutting blade - self-sharpness effect When original counterblades and cutting blades are used in maize harvesting, a selfsharpening effect is achieved due to highquality coatings. This means that the basic material wears out faster than the coating on the cutting edge! The coating forms an aggressive cutting edge - the so-called “mouse tooth”! The selfsharpening effect is clearly visible. On original parts, you can feel it with your fingernail. The expensive coating as well as the selfsharpening effect are ground off unnecessarily if grinding is carried out too frequently and too intensively. Due to incorrect handling, quality advantages, differences in performance and the added value of original parts are often not used.

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

--> It must look like this!!

On the rear side of the blade, the selfsharpening effect is clearly visible!

The expensive coating as well as the selfsharpening effect are ground off unnecessarily if grinding is carried out too frequently and too intensively.

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7. Corn Conditioner:

Design

Design and drive

L

X

The working organs are designed as toothed rollers. The rollers are mounted on pendulum roller bearings (L) and they run at different speeds. The bearing housings of the rear roller (3) on the right and left are firmly mounted and have a fixed installation position. The bearing housings (4) of the front rollers swivel around the axis (X) and are held in the working position by springs (5) and a wedge (6). Therefore the distance between the rollers can be adjusted by moving the wedge (6).

The adjustment is made via lever (8) and electric motor (7) from the cab.

From YOM 2011 on, the BiG X 700/850/1100 feature lubricated deflection pulleys on the corn conditioner.

4

8 3

6

1 5 2 9

1 2

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7

SI_150376068 abschmierbare Umlenkrolle_DE

The corn conditioner is driven via a 6-groove composite V-belt that is tightened via hydraulic cylinder. The speed difference of the rollers is 20% as standard. Optionally, the speed difference can be increased to 30 % or 40 %.

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7. Corn Conditioner:

Differential Speed

Accessories kit B045: Differential speeds on the corn conditioner

To optimize conditioning of the grain in the corn conditioner, it is possible to increase the speed difference of the rollers. Three differential speed variants are possible. These are set by exchanging the drive pulleys and they are available for all serrated roller shells. A differential speed of 20% is the standard.

Deflection roller (1) Ø mm Speed difference

20%

Mat. no.

Ø mm 30%

Mat. no. Ø mm

40%

Mat. no.

186 20026712.0 224231.4

193 20027146.0 20022939.1 186 20026712.0 224231.4

Lower roller (2) (smooth disc)

Upper roller (3)

226

186

226533.2

226532.2

226

171

226533.2

20020767.0

236

171

20020768.0

20020767.0

3

2

S

1

A

Spare parts numbers marked in blue refer to corn conditioners with lubricatable deflection pulleys.

Before converting, please check carefully whether the deflection roller is lubricatable or not!

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

SI_150371189

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

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7. Corn Conditioner:

Variants

Corn conditioner rollers The rollers are made in one piece, and are cylindrical in shape. The diameter of each roller is 250 mm. The rollers differ in their number of teeth, material properties and tooth form. The chrome-plated rollers have a very long service life and are optionally available in a "Heavy Duty" design (5) with 123 and 144 teeth in a saw tooth profile.

1. Rollers with 123 teeth: Optimum equipment for maize silage with over 18 mm cutting length. This ensures maximum throughput along with optimum conditioning in long cutting lengths. Normally, these rollers are used in combination with the 20 blade drum. A roller with chrome-plating and a saw tooth profile is optionally available.

2. Rollers with 144 teeth: This is well suited to cutting lengths up to 20 mm – ideal for almost all conditions.

The rollers are optionally available with chrome-plating and a saw tooth profile. The rollers can be used in conjunction with any cutting drum.

3. Rollers with 166 teeth: Fine intermeshing with saw tooth profile, very well suited to cereal all-plant silage.

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

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

5

1.

2.

3.

66

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

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1

2

3

7. Corn Conditioner: 2

A

3

4

1

Roller Conditioner Settings

Default setting for roller conditioner If the corn conditioner is dismantled, the minimum gap between the rollers must be set. Also the minimum gap may have to be re-adjusted if the rollers are worn. The minimum gap between the rollers is set by turning the turnbuckle (2).

In doing so, the lever (3) must be positioned 12 mm in front of its mechanical stop (A) (housing). The minimum gap (X) of the rollers should now be 0.5mm (adjust as required). The two hexagonal nuts (4) represent the mechanical safety stop to prevent the rollers from clashing during an incorrect calibration.

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

Y X Distance (X) in case of mechanical limit = 0.5 mm Dimension Y = 93 mm

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7. Corn Conditioner:

Roller Conditioner Settings

Corn conditioner motor to adjust the gap The Dunker electric motor (2) replaces the Valeo motor (1) and has been fitted as standard since year of manufacture 2008. The motor type is specified by a parameter setting and must be adjusted if the motor is replaced.

3

Parameter 33607 (service): 0

Parameter 33607 (service): 1

1

2

Valeo motor

68

Dunker motor

Engine type

Corn conditioner version

Wedge (3)

Pulses per 0.1 mm (parameter 33600)

Valeo

Roller conditioner, standard

219 297 2

33

Dunker

Roller conditioner, standard

219 297 2

58

Valeo

Roller conditioner, reinforced springs

20 029 728 0

39

Dunker

Roller conditioner, reinforced springs

20 029 728 0

69

Dunker

Disc conditioner

20 029 201 0

63

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7. Corn Conditioner:

Disc Conditioner Settings

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

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

4

Y A

2 3

Disc roller The disc rollers consist of individual segments (S) which can be replaced as required. The connection to the shaft is made by a key (F). An O-ring seal between the segments (R) prevents the ingress of silage effluent.

Individual discs can be replaced if damaged or highly worn. Worn discs can even be reground once. If all disc segments have to be replaced, the housing, the shafts, etc. can still be reused. When installing the discs, ensure that the direction of rotation is correct!

X= 3mm

Direction of rotation (identical for all discs!)

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S

R F

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7. Corn Conditioner:

Disc Roller Design / Settings

Assembly / setting corn conditioner 1.Installation of the adjustable shaft

The adjustable disc shaft must be installed completely. This means that the shaft is fastened with the completely installed bearing housings (1) via the deflection bolt (2) on the housing. The couplers (8) must also be assembled.

However, perform assembly without spring first.

1

8

7

2.Installation of the fixed shaft

The fixed disc shaft must be installed with the completely installed bearing housings (4) in the housing. The fastening nuts of the bearing housing should only be in contact and they must not be tightened securely.

Y

3.Axial alignment of the fixed shaft

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

A

4.Alignment floating bearing of the fixed shaft

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

5.Parallel alignment of the disc shafts to each other

4 95 ±2 mm

2 6

5

The adjustment of the rollers is the same as for the roller conditioner: It must be set via adjusting levers (5), couplers (6) and wedge (7). In this process, the distance between the adjusting lever (5) and the housing must be set at point A to 15 mm. The distance between the rollers must be 3 mm on the tip. The spring dimension Y must be 92 mm (spring length only).

6.Setting the mechanical minimum distance

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

3 mm

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7. Corn Conditioner: 1

2

3

5

6

7

8 10

4

11 13

Design of Bearing for Roller and Disc Conditioner Corn conditioner bearing on left (fixed bearing)

11

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

12

9

Corn conditioner bearing on right (floating bearing) 1. 00 911 691 0 Retaining ring 110x4 2. 00 910 716 0 Support disc S 90x110x3.5 3. 00 910 851 1 Shim ring 90x110x0.1

WHB_3.4.1.1. Walzenlager austauschen_DE

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11

10

9

6

4

3

2

8

00 910 849 0 Shim ring 90x110x0.5 4. 00 937 577 0 O-ring seal 110x3 5. 00 223 464 1 Ring Rd. 120x23 6. 00 936 058 0 Wedi B2 SL 80x10/12

7

7. 00 931 914 0 Bearing 22212 ES 8. 00 219 433 3 Bearing housing right 9. 00 911 686 0 Retaining ring I 100x3 10. 00 936 019 1 Wedi BA 70x100x10

12

11. 00 910 746 0 Support disc S 80x100x3.5 12. 00 226 462 3 Roller

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5

1

8. Discharge Accelerator: Design Discharge accelerator

4

2 F

1

The function of the discharge accelerator is to accelerate the crop from corn conditioner or cutting drum and to transport it into the spout. The diameter of the discharge accelerator is 560 mm. At a speed of 2188 rpm we obtain a theoretical crop flow speed of 64 m/s. The discharge accelerator is mounted on pendulum roller bearings. The rear wall is spring-mounted and it is able to avoid large forage masses.

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

6

3

5

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8. Discharge Accelerator: Design of Bearing BiG X 700/850/1100 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15

Discharge accelerator bearing right (floating bearing) 1. 00 900 352 0 Screw M 20x1.5x70 2. 20 026 383 0 Cap 3. 20 024 533 1 Clamping ring 4. 00 915 004 0 Fit-in key A 18x11x70 5. 20 024 535 0 Belt pulley Rd. 300 6. 20 024 533 1 Clamping ring 7. 20 024 803 0 Raceway 8. 20 024 802 0 Cover 9. 90 000 063 0 Shaft sealing ring AS 70x100x10 10. 90 000 193 0 Pendulum roller bearing 22312 U 15-VS 11. 20 026 017 0 Bearing housing right 12. 00 936 447 2 Shaft sealing ring A 80x110x10 13. 20 024 800 0 Cover 14. 20 024 799 0 Raceway 73

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

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7

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4

3

2

1

8. Discharge Accelerator:

BiG X 500 - 1000

Setting the rear wall on VariStream up to YOM 2010

А

Setting the upper distance between the rear wall and the rotor by screwing the rubber buffer in or out.

X

Dimension (X) : Grass: 4-5 mm, maize: 2-4 mm Pivot point rear wall top via rubber pad

VariStream_4

Checking the discharge point by "extending" the rear wall

Additional raising and lowering of the rear wall Bending axis rear wall bottom

Hinge pin of the rear wall After making modifications to the stop screw (1), the discharge point and the distance between rotor and rear wall must be checked or reset!

A characteristic for this crop flow version is that there are no quick releases on the rear wall for locking.

74

1 Setting the lower distance between rear wall and rotor by adjusting the stop screw (1).

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Movement of grass channel and rear wall when adjusting the stops Grass channel hinge pin on the transfer shaft

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8. Discharge Accelerator: Old contour New contour

BiG X 600/700/850/1100

Rear wall setting for VariStream from YOM 2011 -> Grass mode 1. Adjust the rear plate top using the rubber pads so that there is a 15 mm jump step between rear wall and duct connection.

2. Adjust a 2mm distance between rear wall and discharge scoops using the stop screws on the grass channel.

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

4. To make sure that there is no fault, pull the rear wall entirely back manually and ensure that no collecting edge is created.

Duct connection approx. 15 mm Rubber pad

Set screw of grass channel

10mm

Rear wall

This crop flow version can be recognised on the quick releases located laterally in the rear wall of the discharge accelerator.

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8. Discharge Accelerator:

BiG X 600/700/850/1100

Rear wall setting for VariStream from YOM 2011 -> Maize mode

60mm

Set screw corn conditioner

1. Set a distance of 60 mm between corn conditioner screw link and spout housing using the set screw on the corn conditioner.

2. Set the distance from rear wall to discharge scoops via rubber pad to 2 mm.

3. Adjust the tension rods of the springs so that the rear wall may move back to an extent that there is no collecting edge between rear wall and duct connection (max. 10mm).

4. To make sure that there is no fault, pull the rear wall entirely back manually and ensure that no collecting edge is created.

5. If the pivot point at the bottom on one side is not completely in the claw on the rear wall, move the corn conditioner up on that side until it is completely in the claw point.

Duct connection Rubber pad

10mm

Rear wall

This crop flow version can be recognised on the quick releases located laterally in the rear wall of the discharge accelerator.

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

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9. Hydraulics Traction Drive: Charge Pressure Circuit Poclain

Charge pressure circuit overview

4 6

1

3

7 5

Changeover

2

WHB_5.1 Speisedruck_DE

8

WHB_5.1 Umschaltung_DE

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

77

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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9. Hydraulics Traction Drive: Charge Pressure Circuit Poclain High pressure circuit

Charge pressure circuit 500 - 700

4

High pressure circuit

2

Charge pressure circuit

1

3

78

(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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9. Hydraulics Traction Drive:Charge Pressure Circuit Poclain

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

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9. Hydraulics Traction Drive: Pump Adjustment Poclain 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-energised, the pilot valve (3) is always in the "throttled" position. The pump swivels back in a controlled manner.

1 80

LINDE DBV_DE

LINDE_Schaltplan E2_DE

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9. Hydraulics Traction Drive: Overview Linde Pumps 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!

81

(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

Holding washer for pivoting angle potentiometer

(10) Proportional solenoids pump control Y1 to Y4

6

3

(1)

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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9. Hydraulics Traction Drive: Stage Switchover Poclain 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-energised 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 depressurised and the wheel motor is in the large intake volume.

Diagnostics: On measurepoint minimess 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

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Changeover

9. Hydraulics Traction Drive: Stage Switchover Poclain 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

83

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

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9. Hydraulics Traction Drive: Stage Switchover Poclain 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 measurepoint minimess 6, measurepoint minimess 7 or measurepoint minimess 8 the switching function and the pressure in the low-pressure circuit can be checked.

WHB_5.1 Observe switch logic!!

Umschaltung_DE

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Changeover

9. Hydraulics Traction Drive: Stage Switchover Poclain Circuit logic stage switchover wheel motors Poclain

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

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9. Hydraulics Traction Drive: 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 is only possible if the machine is at standstill!

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9. Hydraulics Traction Drive: 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) 87

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)

BiG X Service Training 2014 Advanced

Outputs © KRONE Training Team, Spelle

9. Hydraulics Traction Drive: Poclain High Pressure Circuit 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) 88

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9. Hydraulics Traction Drive: Poclain High Pressure Circuit

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!

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9. Hydraulics Traction Drive: 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.

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9. Hydraulics Traction Drive: Charge Pressure Bosch 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 91

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9. Hydraulics Traction Drive: Overview Bosch 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

92

Components

9

BiG X Service Training 2014 Advanced

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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9. Hydraulics Traction Drive: Functions Bosch Function description Bosch traction drive 1.

Acceleration forwards 0 - Vmax in road mode As soon as the driver has given the drive command via the drive lever, 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 forwards 0 – Vmax in field mode The sequence for the acceleration process is the same as for road mode. The only difference is that the maximum speed here is limited to 25 km/h. The maximum reverse speed is approx. 14 km/h (electronically limited).

93

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9. Hydraulics Traction Drive: Functions Bosch Function sequences of Traction Control 3.

Function 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

94

TC for use in practice

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9. Hydraulics Traction Drive: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

95

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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9. Hydraulics Traction Drive: 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.

96

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9. Hydraulics Traction Drive: 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 rising. 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.

97

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9. Hydraulics Traction Drive: Bosch Terminal Diagnostics Bosch terminal diagnostics

1. Valve drive pump forward Y101 2. Valve drive pump backward Y102 3. Pivoting angle sensor B108 4. Steering angle sensor B107 5. High-pressure sensor forward B101 6. High-pressure sensor backward B102 7. Parking brake manometric switch B110 8. Parking brake valve Y18 9. Brake pedal angle sensor B109 10. Service brake pressure sensor B16 11. Valve currents wheel motor Y103-Y106 12. Speed sensors wheel motor B103-B106

98

1 2 3

11 12

4 5

7

6

8

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9 10

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9. Hydraulics Traction Drive: Control Circuit Bosch Pump 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 via 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!

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9. Hydraulics Traction Drive: Bosch Drive Pump Components of drive pump

12

10

9

Components

8

11

7

13 1 14 3

2

100

4

5

6

BiG X Service Training 2014 Advanced

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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9. Hydraulics Traction Drive: Bosch Drive Pump Components of drive pump 5

Components

4

3

2

6

1

7

10

8

101

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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9. Hydraulics Traction Drive: Wheel Motor Bosch 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

2 102

Currents =

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approx. 5.5 ohm

9. Hydraulics Traction Drive: Wheel Motor Bosch M1

Hydraulic motor A6VE

Mode of operation:

3

Pump

2 Pump

G

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

103

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9. Hydraulics Traction Drive: Wheel Motor Bosch 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 the both shuttle valves.

Thus it is possible to measure the actual high pressure here.

Target value forward: 30…490 bar Target value backward: 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. 104

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9. Hydraulics Traction Drive: Wheel Gearbox Bosch Planetary gearbox GFT 40

3

2

1

4

10

6

7

8

5

9

Components

105

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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10. Hydraulics Intake / Header: 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

106

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10. Hydraulics Intake / Header: Quick Stop 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.

107

Stop valve

Pilot valve

(Main valve)

(Y 35, conducts to earth)

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10. Hydraulics Intake / Header: 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

108

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10. Hydraulics Intake / Header: Overview Intake 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

109

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

Valve (1) connects supply and return so that oil is converted 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 via the pressure limiting valve (3).

2 Hydraulic motor with flush valve

Y 35 conducts to earth.

I.e. if the metal detection detects metal in the intake, the earth contact 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 110

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10. Hydraulics Intake / Header: 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

111

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11. 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 (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

112

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11. 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 builts up in the supply line.

As soon as the electronics is 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 113

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Pressure supply brake and work hydraulics circuit (1) Triple pump (2) High pressure filter

4

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

3 1 2

114

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Work hydraulics component overview

WHB_4.4 Ventilblock Arbeitshydraulik_DE

8

5 9

4

7

11

(1)

Accumulator charging valve

(2)

Hydraulic accumulator parking and foot brake

(3) (4) (5)

Hydraulic accumulator lifting gear (vibration damping) Valve block work hydraulics (with oil circulation function) ELC (electronic lifting unit control)

(6)

2/2-way seat valves pendulum frame

(7)

Lifting unit accumulator connection block

(8)

Rotate discharge chute gearbox

(9)

Foot brake valve and measurement connection

(10)

Wheel gearbox with integrated brake

(11)

Cylinder grinding device

(12)

Cylinder pendulum frame

6

10 1 115

2

3

12 BiG X Service Training 2014 Advanced

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12. Hydraulics Open Circuits: Work and Brake Hydraulics 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

116

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 work 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 via control lines, releases the oil flow to the work hydraulics (EF connection). At the same time, a nonreturn 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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12. Hydraulics Open Circuits: Work and Brake Hydraulics 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

1 117

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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12. Hydraulics Open Circuits: Work and Brake Hydraulics Overview of brake system Bosch traction drive

6

3 4

5

Components

1 2 118

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

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12. Hydraulics Open Circuits: Work and Brake Hydraulics 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.

119

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Function brake system Bosch traction drive 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 blade package (4). As a result, a braking effect that depends on the pressure is set.

D

2 1

120

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Manually releasing the parking brake / towing the machine 1.

Connect measurepoint minimess 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 is depressurised.

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

121

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1

12. Hydraulics Open Circuits: Work 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!

122

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12. Hydraulics Open Circuits: Work 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 via an angle sensor (B109), the brake pressure is measured via 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

123

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

BiG X Service Training 2014 Advanced

N

© KRONE Training Team, Spelle

B

R

12. Hydraulics Open Circuits: Work 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 work hydraulics.

P F B R N R4 X1 B110 X Y18

B18

= = = = = = = = = =

Work pump supply line Brake tank pressure manometric switch (B18) Work hydraulics valve block Accumulator service brake and brake valve Tank line Parking brake accumulator Connection manometric switch parking brake Manometric switch parking brake (B110) Connection parking brake in the drive motor Solenoid valve parking brake R

P

B

F

X1

N

R4

R

X

B P

Y18 B110

N

B110

X1

X1

F X Y18

X P R4

124

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B

N

© KRONE Training Team, Spelle

Y18

R4

12. Hydraulics Open Circuits: Work 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 work hydraulics (1).

The accumulators for the parking brake and the foot brake valve are filled via 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 work hydraulics. The pressure is limited to approx. 30 bar on the parking brake valve (3) via a pressure-reducing valve (4).

B110

Work hydraulics valve block

3

4

1 2

125

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12. Hydraulics Open Circuits: Work 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 depressurised.

Braking is carried out via spring force.

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

Service brake function 3

1

B110

Work hydraulics valve block

126

2

BiG X Service Training 2014 Advanced

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

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

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

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12. Hydraulics Open Circuits: Work 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 via 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

127

B110

Y18

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Work 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

11 10 11

Return “T” Supply „P“ 128

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 05

09

12

Designation

02

02

10

Pos

12

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.

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12. Hydraulics Open Circuits: Work 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 129

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work 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

131

2

Bosch_Reparaturanleitung

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work and Brake Hydraulics 5/3-directional valve with hydraulically unlockable non-return valve (seat valve) work hydraulics valve block

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

Locking block (1):

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Work 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 work 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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12. Hydraulics Open Circuits: Work 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

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Work 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 137

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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12. Hydraulics Open Circuits: Work 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

138

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 energised in this case.

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work and Brake Hydraulics Work hydraulics valve block: Intermediate plate with PLV The extension is folded via 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).

140

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)

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Steering 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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12. Hydraulics Open Circuits: Steering Hydraulics From automatic steering valve

Y67

2 3

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

Y66

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 orbitrol. The shock valves (3) are for the safety of the orbitrol and open with a pressure of p = 250 bar.

WHB_4.1 Lenkung_DE Measurepoin t minimess 9

143

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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12. Hydraulics Open Circuits: Work and Brake Hydraulics The rear axle suspension is a separate system. The hydraulic pretension of the suspension can be adjusted via 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, corn conditioner installed etc.)

Pressure gauge

Hydraulic cylinder

Damping element

2 a

Hydraulic accumulator 1.4 l / 60 bar 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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12. Hydraulics Open Circuits: Work and Brake Hydraulics

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

Pressure limiting valve Additional axle

3

(4)

2

Axle with lifting cylinders

1

4

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work 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 147

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12. Hydraulics Open Circuits: Work 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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12. Hydraulics Open Circuits: Work 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

149

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Wheel motor brake connections

2

3 Parking brake valve

9

4 1

8 5 7

Accumulator charging valve

Return line

Hydraulics

Pneumatics

6

(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 150

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12. Hydraulics Open Circuits: Work and Brake Hydraulics Compressed air supply from the reservoir

Parking brake valve signal

Actuating cylinder parking brake

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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13. Hydraulics: Leakage Oil Circuits and Cooling Circuits Poclain 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 via the radiator.

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

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13. Hydraulics: Leakage Oil Circuits and Cooling Circuits Poclain Return steering valve, 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

153

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

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

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13. Hydraulics: 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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13. Hydraulics: 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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14. 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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14. 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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14. 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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14. Hydraulics Maintenance: Maintenance Bosch 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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14. 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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14. Hydraulics Maintenance: Venting Poclain 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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14. Hydraulics Maintenance: Venting 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

T

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.

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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14. Hydraulics Maintenance: Venting Bosch 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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14. Hydraulics Maintenance: Venting 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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14. Hydraulics Maintenance: Gearbox Oil Cooling 4

6

6a 1 2

from the radiator to the radiator

3

6

(1)

Gear pump

(2)

Integrated PLV

(3)

Manometric switch

(4)

Nozzle

(5)

Filter

(6)

Non-return valve

(7)

Measurement connection

165

7

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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15. 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:

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

166

+ 8.2 V

Diagnostic s

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15. 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

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15. System Technology Sensors: Namur Sensor Brake 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 Pin 1 (brown) Pin 2 (black) – Signal Pin 3 (blue)

NPN - normally open contact

– 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.

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15. System Technology Sensors: Angle Sensor Intake 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 169

70°

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

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15. System Technology Sensors: Angle Sensors Bosch 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).

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15. 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

0°

2.5V→7.5V

72° (82°)

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3 2 1

15. 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

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15. 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.

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C

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A

15. 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 Measuring range:

120°

Power supply voltage:

12 V

Signal:

4…20 mA

174

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

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15. 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

175

U 3

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

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15. System Technology Sensors: Pressure Sensor Lifting Gear

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 20 176

40

60

80 100 120 140 160 180 200

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15. 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

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15. 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

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15. 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 Measuring range:

0…600 bar

Supply voltage:

10 volts

Signal voltage:

0.5…4.5 V

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15. System Technology Sensors: Leakage Oil Filter 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

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15. System Technology Sensors: Speed Wheel Motor Poclain

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.

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15. System Technology Sensors: Speed Bosch Wheel Motor

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).

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15. System Technology Sensors: Intake / Header Speed 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.

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Parameter 25492

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15. System Technology Sensors: Hydraulic Oil Temperature

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

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15. 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!

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15. System Technology Sensors: Seat Switch Poclain 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

186

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

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

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15. System Technology Sensors: Seat Switch Bosch 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

187

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

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

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16. System Technology Calibration: Pendulum Frame 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 188

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

Parameter 33634 = 0 (angle sensor Elobau)

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16. System Technology Calibration: Pendulum Frame

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)

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S

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16. System Technology Calibration: Pendulum Frame 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)

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16. 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

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V

16. 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 192

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16. 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

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16. 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

194

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.

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16. 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).

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16. 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.

196

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.

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16. 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.

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16. 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.

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16. 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).

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16. 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.

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16. 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).

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16. 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

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16. 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

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А

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16. 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

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16. 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

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16. 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.

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16. 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).

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16. 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.

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16. 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.

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16. System Technology Calibration: Spout S

1

4 X

3

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.

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16. 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!

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16. 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!

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16. System Technology Calibration: Intake / Header 6 2

1

3

4 5

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 213

16. 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.

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16. 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.

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16. 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

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16. 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.

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16. System Technology Calibration: Bosch Traction 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

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16. System Technology Calibration: CropControl 1

2

4

3 9

5

8

6 7

Control unit CropControl 219

1 2, 3, 4 5 6 7 8 9

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

B73

B72

Inductive displacement transducer on intake

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Pressure sensor in intake drive

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16. 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

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16. 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.

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17. 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.

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17. 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

223

D6

D7

D8

E6

E7

E8

F6

F7

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17. 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

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17. 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.

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17. Electrical System/Electronics: Circuit Diagram Layout 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

1

2

3

Wire colors BX 500 / 650 / 800 / 1000:

Wire designation BX 700 / 850 / 1100: Power supply Signal line / switch circuit Earth (white) 226

CAN high CAN low

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

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17. 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) 6X... DIOM (A 6) 9X... EMR (A 9)

a – Pin contact b - Socket contact

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) 227

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17. Electrical System/Electronics: 1

Input - output job computer

Engine corn conditioner rollers Voltage V2 / LD 12

2 3 4 5

5 4

2

228

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

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17. 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.

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17. 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 230

CAN MB,

CUC

A16

MFR (MAN), ADM 2 (MB)

A14

A7

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CAN MAN

A8 © KRONE Training Team, Spelle

Sensors Actuators EDC (MAN), PLD (MB)

17. Electrical System/Electronics: Part Overview Console 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

A1

Part designations see circuit diagram!

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A7

A2

A17

A6

A5

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17. Electrical System/Electronics: Part Overview Console 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!

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17. Electrical System/Electronics: Basic Information CAN12 V

Bus

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.

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17. 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

234

Blue lead: CAN HIGH Green lead: CAN LOW

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17. 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.

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17. 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

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17. 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

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17. 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

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 120 Ω terminating resistor

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

17. 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)).

 120 Ω terminating resistor

STLP_CAN 3_MAN_DE

239

120Ω

Diagnostics

120Ω

CAN low

A14

120Ω

2

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

17. 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.

240

CAN 2

120Ω

A2 KMC 2 120Ω

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With AutoScan: Resistor disconnected in the KMC 2

120 Ω ║~150 Ω

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

17. 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 241

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

17. 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)

242

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17. 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. 243

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17. 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

Header speed

A2

KMC 2 Spout rotat. right

Spout rotation pulses Header left

120Ω *

Raise spout flap

120Ω

switched!

Lower spout flap

Cutting drum speed

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)

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!

244

Header forward

Spout rotat. left

Spout position bottom

Stop signal metal

Intake backward

Header backward

Spout position centre

Level of silage agent

Intake forward

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

17. Electrical System/Electronics: KMC 3 B20 B36 B37 B42 B43 B44 B46 B52 B59 B70 B77 B87 B88 B85 B92 245

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

* 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!

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)

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Counterblade left Counterblade right Corn conditioner distance Silage additive pump Smart Drive release

© KRONE Training Team, Spelle

Y28 Y29 Y30 Y31 Y54 Y55 M9

M10 M11 M16 GAL

17. 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) 246

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A6

© KRONE Training Team, Spelle

K15 K18

K28 K39 K41 GAL

17. 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

Reversing light / horn Brake light

A1

Life signal (toggle)

Tasks Smart Drive controls and monitors driving hydraulics

247

Y10

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

Wheel speed

Y4

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Y69 Y70 M12 K29 K30 KMC3

17. Electrical System / Electronics: S3 S 69

B101 B102 B18 B110

B16 B109 B108 B107 B103 B104

B105 B106 248

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

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K29 K30

Y101 Y102 Y103 Y104 Y105 Y106

17. 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

Row registration left

Steering to the right

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.

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17. 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.)

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17. 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 251

EMR

Y32

Supply 12V

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17. 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 252

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

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17. 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!

253

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17. 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

254

A8

CAN 3

MR Engine control

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

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17. 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:

MFR

Power supply

CAN MAN

EDC (Electronic Diesel Control)

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)

255

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17. 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 256

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17X21

17X4

17X20

17X7 17X2

17. 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

257

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.

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17. Electrical System/Electronics: Logic Power Supply + 12 volts

Voltages

Release switch Road / field

22F78 Voltage V3 KMC3

Quick stop switch 22K32 Maintenance release switch

22LD32

IN9

IN7

IN13 F12

GAL-Logik -IC1

-A22

0V

KMC 3

LD40

OUT 6

PWM_LA8

Relay circuit board Console

LD31

Grinding stone valve on left

-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.

258

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17. Electrical System/Electronics: Overview Job Computers

259

(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)

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17. 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

260

Relay circuit board console

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17. 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

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18. Software: KRONE Download Center

3

2

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) 262

SI_150369998 Komponenten Softwareupdate_DE

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WHB_7.10.1.KRONE Download Center_DE

© KRONE Training Team, Spelle

18. 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: 27004132.0 263

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18. 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)

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18. 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

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18. 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!!

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18. 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

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18. 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!

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18. 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.

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18. 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

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18. 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

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18. 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 272

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