KRONE BiG X TT Basic 2014 Forage Harvester Service Training Manual - PDF DOWNLOAD

Forage Harvester BiG X

Training

2014 Season

Name:

________________________________

Company:

________________________________

Training dates: __.__. 2014 to __.__. 2014 BiG X Service Training 2014 Basic

No. 150 331 448 06 EN BiG X TT Basic 2014

Update level: Januar 2014

© KRONE Training Team, Spelle, Germany

Contents 1. Program Overview

4

2. BiG X Design

13

3. Accessories

20

4. Cab/Console/Joystick

26

5. Terminal

51

6. Feed Drive

72

7. Foraging Unit

83

8. Corn Conditioner

106

9. Discharge Accelerator/Discharge

115

10. Engine

122

11. Chassis

129

12. System Technology/Calibration

133

13. Settings/Use in the Field

167

14. Hydraulics

179

15. Electrical System/Electronics

228

16. Software

258

17. Maintenance

262

2

SI_PDF-BA_2 safety sticker_EN

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.

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

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

Introduction Symbols and Links 1.

Link to a pdf file.

In Presentation mode, the appropriate file can be opened by clicking on the symbol.

SI_PDFWHB_5.1 charge pressure_EN

e.g.

In the print version, the document and the chapter can be found in the designation under the link.

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. = Section 5.1

2.

Link to an Animation.

In Presentation mode, the appropriate file can be opened by double clicking on the symbol.

Changeover

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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BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

1. Program Overview 2014: Forage Harvester BiG X Fuel Tank (l) Urea Tank (l)

Additional tank (l)

Cutting Drum

480

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

6 – groove

MTU BR 1300 12.8 /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 16.16 l/V8

Bosch Rexroth

960

330

700

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

7 – groove

MAN D 2868 LE 16.16 l/V8

Bosch Rexroth

960

330

850

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

8 – groove

MAN D 2862 LE 24.24 l/V12

Bosch Rexroth

960

330

1100

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

8 – groove

MAN D 2862 LE 24.24 l/V12

Bosch Rexroth

960

330

Type

4

Travelling Gear System

Composite Belt Main Drive

Engine

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

(Fuel and/or silage agent)

1. Program Overview 2014: Forage Harvester BiG X Performance Data - Overview

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

Principle of PowerSplit on BiG X 700/850/1100

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

Eco Power – X Power Eco Power is used where you can manage on less machine performance. If you require more power, switch to X-Power on the BiG X 700, 850 and 1100 by pressing a button. Optionally this switchover can also occur 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.

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BiG X Service Training 2014 Basic

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1. Program Overview 2014: Forage Harvester BiG X Performance Data - Overview Applications of Different Characteristic Lines With BiG X 700-I only

= Torque = Power

= Torque = Power

= Torque = Power

ECO POWER for frugal…

• Easy conditions • Low yields • e.g. small grass swaths

X POWER full power • Larger areas • Uniform yields

TRI POWER torque boost • Large torque reserves • Highly changeable and difficult conditions • For small areas • On slopes

=

=

=

Diesel savings

6

Maximum throughput t/h

BiG X Service Training 2014 Basic

Less readjustment by the driver

© KRONE Training Team, Spelle, Germany

1. Program Overview 2014: Forage Harvester BiG X Overview of the ICAN Components

RockProtect: Rock detection

ISOBUS: Autopilot system

NIR – Humidity measurement

CropControl: Yield recording

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BiG X Service Training 2014 Basic

AutoScan: Automatic maturity measurement

AutoCalibrate: Automatic calibration of yield recording

© KRONE Training Team, Spelle, Germany

1. Program Overview 2014: Forage Harvester BiG X Overview of the ICAN Components

LaserLoad: Automatic control of the discharge chute

Data fleet management: For additional information, visit www.krone.de

of the discharge chute

ForageCam: Screen transmission to transport vehicles that drive parallel 8

BiG X Service Training 2014 Basic

KRONE AgriNir: For determining the content of the crop and for calibrating the NIR sensor.

© KRONE Training Team, Spelle, Germany

1. Program Overview 2014: Forage Harvester BiG X Pick-Up Working width (mm)

Operating elements

300

3,000

Uncontrolled pick up

300s

3,000

Uncontrolled pick up

380

3,800

Type

Easy Flow 300/380

9

Uncontrolled pick up

Easy Flow 300s (new generation 480/580)

BiG X Service Training 2014 Basic

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1. Program Overview 2014: Headers Direct Cutting System Type

6200

10

Working width (mm)

Operating elements

6,200

Disc mower

BiG X Service Training 2014 Basic

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1. Program Overview 2014: Headers Corn Front Attachment Working width (mm)

Operating elements

Transport position

6000(FP)

6,000

Circulating collector

Vertically folded (2-part)

603

6,000

Circulating collector

Horizontally folded (3-part)

753

7,500

Circulating collector

Horizontally folded (3-part)

903

9,000

Circulating collector

Horizontally folded (3-part)

1053

10,500

Circulating collector

Horizontally folded (3-part)

Type

11

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

1. Program Overview 2014: Headers Corn Front Attachment (New Generation 480/580) Working width (mm)

Operating elements

Transport position

450-2

4,500

Circulating collector

Vertically folded (2-part)

600-2

6,000

Circulating collector

Vertically folded (2-part)

750-2

7,500

Circulating collector

Vertically folded (2-part)

600-3

6,000

Circulating collector

Horizontally folded (3-part)

750-3

7,500

Circulating collector

Horizontally folded (3-part)

900-3

9,000

Circulating collector

Horizontally folded (3-part)

Type

12

BiG X Service Training 2014 Basic

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2. BiG X Design: Machine Concept Machine Concept

The engine (2) is 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 center of gravity, guaranteeing safe working on slopes. The forage harvester is driven fully hydraulically by wheel motors without speed gearbox.

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, the weight can be distributed optimally on the front and rear axles of 60%: 40%.

Image: _BiG X

2

3 4 1.

2.

3.

4.

5.

Frame Engine Diesel tank Planetary gearbox at front Planetary gearbox at rear

13

1

5 4

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

2. BiG X Design: Crop Flow Theoretical Crop Flow Rates/ Rotation Speeds Big X 500, 650 Big X 600, 700 BiG X 850, 1100

Crop Flow Optimum construction:

2,187 rpm -> v = 64 m/s 2,361 rpm -> v = 69 m/s 2,475 rpm -> v = 73 m/s

- No power loss due to major diversion of the crop flow.

- Smooth crop flow thanks to six pre-compression rollers and individual balancing of the individual unit speeds.

- High flow speed > 200 km/h at the discharge.

- High pre-compression of crop with four tension springs and up to 4,600 kg of pressure force.

2

Crop flow

- The base with the counterblade adjusts to the wear condition of the blades.

- The drum base and rear wall are spring-mounted (1), (2) and are able to avoid large forage masses to ensure that the machine runs smoothly.

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

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

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

BiG X Service Training 2014 Basic

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

1,100 rpm -> v = 38 m/s 1,188 rpm -> v = 41 m/s 1,245 rpm -> v = 43 m/s

© KRONE Training Team, Spelle, Germany

2. BiG X Design: Drive Drive of the Operating Units

In the case of the BiG X 600, 700, 850 and 1100, the drive train of the intake and header pump is mechanically connected to the main coupling, via which it is connected and disconnected.

The operating elements are hydraulically and mechanically driven.

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

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

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

Graphic_BiG X

1. Power take-off gear 2. Transfer gearbox

Closed Hydraulic Circuit

5

3. Hydraulic motor intake 4. Hydraulic motor header 5. Quick-stop valve 15

1 2

3 4 BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

2. BiG X Design: Drive Drive of the 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 elements. The drive is conveyed by composite V-belts directly to the blade drum and to the discharge accelerator. The discharge accelerator shaft conveys the drive to the right side of the machine where the corn conditioner drive is positioned.

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

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

On all machines equipped with Bosch travelling gear, the hydraulic cylinder for tensioning the main belt is therefore doubleacting.

1 Graphic_BiG X

1. Main coupling

3

2. Composite belt of the main drive BiG X 500

5 – groove

BiG X 600/650/700

7 - groove

BiG X 850/1100

8 - groove

3. Composite belt of the corn conditioner Optional 7 - groove

16

2

If the driver then presses and holds the button for reversing the intake / header with the main coupling switched off, the belt is slackened, the main coupling is switched on and the pumps are then activated. As a result, reverse can be selected again even if the crop flow is blocked.

6 - groove SI_150399606reversing_intake_EN

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

2. BiG X Design: Travelling Gear Poclain Travelling Gear Poclain The travelling gear is fully hydraulic and is driven by two axial piston variable displacement pumps and four radial piston motors. All-wheel drive is included as standard on all models.

Type

Wheel Motors

I. Road

II. Field front axle

III. All-wheel drive

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

III

IV

Changeover

Road/field front axle 17

All-wheel drive BiG X Service Training 2014 Basic

Axle separation © KRONE Training Team, Spelle, Germany

2. BiG X Design: Travelling Gear Bosch Rexroth Travelling Gear Bosch Rexroth The BiG X travelling gear 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 travelling gear is identified by planetary gearboxes (1), which are installed in the wheels as an end power take-off on front and rear axles.

Another feature are 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

BiG X Service Training 2014 Basic

2

3

1 © KRONE Training Team, Spelle, Germany

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

II.Field mode: The machine is driven by front and rear drive motors. The drive motors are adjusted steplessly according to conditions.

Travelling speeds: forwards 25 km/h, backwards 14km/h TC Traction Control: Traction Control (traction control, ASR) is active in field travel mode. If required, this can be switched on or off. Complete deactivation is not possible to protect the engines from overspeeding.

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

TC II is the traction control 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 (grass/corn) set in the terminal. The stage can therefore be adjusted to conditions.

Animation TC

19

BiG X Service Training 2014 Basic

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

Additional weights

LED working floodlight

Xenon working floodlight for cab roof

Track

Service wagon for cutting drum

20

Service wagon for intake unit

Additional axle

BiG X Service Training 2014 Basic

Fender enlargement (front and rear)

Xenon working floodlight for cab platform

© KRONE Training Team, Spelle, Germany

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

Rocks are detected by an acceleration sensor in the area of the front, upper intake roller. The sensor is attached by a plate to the upper roller gear on the right side of the machine.

Functional principle: If there is a foreign object, such as a stone in the crop and it strikes the front intake rollers, the upper roller pack will be accelerated strongly upwards. If the acceleration sensor now outputs a value which is above an adjustable level, the drive of the intake is abruptly stopped. This occurs via the so-called quick-stop valve in the hydraulic drive of the intake.

Rock detected!!

The intake is switched off the same as if metal is detected!

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BiG X Service Training 2014 Basic

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3. Accessories: Crop Control Crop Control - Yield Recording (optional) Inductive path recorder

In the cab: Pressure sensor

As an option, Crop Control can also be operated by the CCI Terminal.

Functional principle:

Based on the data of the 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 specified by control weighing. The harvested volume is converted to a 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 determined data can be printed out on the associated CAN BUS printer.

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BiG X Service Training 2014 Basic

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

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

4

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

23

1 BiG X Service Training 2014 Basic

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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

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

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

Plug

Function

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 additional tank

Signal to KMC 2

above the right front wheel

*) external: KRONE silage agent device uncontrolled or other manufacturer (variant 1230) internal: KRONE silage agent device controlled (yield-dependent, B 154) 24

BiG X Service Training 2014 Basic

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3. Accessories: NiR Sensor - Humidity-Measuring Device Humidity-Measuring Device with NIR Sensor (optional) The NIR sensor supplies precise data on the humidity of the crop. This recorded data is 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.

(Warranty claims do not arise in the case of damage caused by foreign bodies) The humidity content is measured on the discharge chute of the BiG X. The continuous crop flow at this point is the basis for reliable data recording. The sensor is easy to install and is safely protected from damage by a cover.

Functional principle:

A Near Infra Red light beam is transmitted to the foraged crops. NIR light has the exact wavelength to excite the water molecules.

NIR light can be reflected only by the water molecules in the grass or corn (the other molecules absorb the light). The difference between transmitted and reflected light is measured and the humidity content and therefore the DS content can then be determined from this difference.

The sensor is automatically calibrated at fixed intervals.

To optimize measurements, the NIR sensor should be recalibrated before every crop rotation  Krone AgriNir box

NIR sensor arranged in the back of the discharge chute 25

BiG X Service Training 2014 Basic

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4. Cab: Operation Cab Controls

1

3 2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Climatronic/ISO compartment for radio Roof Panel 2 free compartments, e.g. for two-way radio Reversing monitor (option) Front windscreen wiper Side window wiper Steering column Cool box (under passenger seat) Terminal Multi-Function joystick Control panel

6 5

9

4

10 11

7 8 26

BiG X Service Training 2014 Basic

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4. Cab: Roof Panel 2

3

1

6

4

5a

5 4

7

8

11

12

10

5a

9

Roof Panel Switch Group 1.

2.

3.

4.

5.

5a.

6.

7.

8.

9.

10.

11.

12.

Working floodlight on side of cab Cab roof working floodlight Working floodlight front bottom Working floodlight rear Transport floodlight I - Parking light II - Dipped beam Top floodlight for 3-part. EasyCollect Mirror adjustment (right rear view mirror only) Warning lights Warning flashers Windshield wipers Windshield washer unit LED spotlight joystick lighting Working floodlight upper discharge chute

27

2 11

BiG X Service Training 2014 Basic

2 1

1 3

5

© KRONE Training Team, Spelle, Germany

3

4. Cab: Roof Panel Radio 1.

ISO compartment for radio

Climatronic 2. Button to switch Climatronic on and off 3. Button to switch air conditioning on and off 4. Button to increase the desired cab temperature.

Alternatively: Manual settings "Up" 5. Button to reduce the desired cab temperature.

Alternatively: Manual settings "Down" 6. Button to switch REHEAT mode on and off (demoisturizing the cab air) 7. Button to toggle blower speed between Manual/Automatic 8. Concealed button to switch the temperature display to ° Fahrenheit

28

1

3

4

2

5

BiG X Service Training 2014 Basic

6

7

© KRONE Training Team, Spelle, Germany

8

4. Cab: Console 3 4 5

5 2

only in machines from year of manufacture 2012

6

1

7

Control Panel 1.

2.

3.

4.

Release switches and pushbuttons Indicator lamps Button module Emergency Stop Switch 29

5.

6.

7.

12 V sockets Cigarette lighter Ignition key

BiG X Service Training 2014 Basic

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4. Cab: Console Engine Failure/Oil Pressure Indicator Lamp

1

Indicator lamp (1) lights up when a fault occurs in the diesel engine. In this case, switch off the engine immediately and repair the fault.

2

Charge Indicator Lamp

The charge indicator lamp (3) lights up if the output voltage of the three-phase generator is not sufficient to charge the batteries.

Coolant Level Indicator Lamp

3

The indicator lamp (2) for the coolant level lights up if the coolant level in the expansion reservoir has fallen below the minimum level. The coolant level must be restored as quickly as possible to prevent damage to the engine.

Diagnostic Socket (4) CAN bus interface

5

USB Port (5)

The USB port can be used to save the data from the customer counter to a USB memory stick.

Iso Bus Connection (6)

Additional CAN-BUS interface (series year of manufacture 2013)

Connection (7)

12-volt connection for cooler

30

4

7 6

BiG X Service Training 2014 Basic

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4. Cab: Console Emergency Stop Switch

1

When the quick-stop switch (1) or (2) is pressed, the travelling gear is deactivated and the machine stops. All working functions are stopped.

To activate the machine, turn the activated quick-stop switch (1) or (2) slightly to the right to return it to its home position.

0

I

Ignition Lock

II

The ignition lock (3) has 4 positions: 0 - Off I - Electrical circuit for electronics switched on II - The ignition is switched on III - Engine start

III

3

2

31

BiG X Service Training 2014 Basic

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4. Cab: Panel Button Function Buttons with LED:

9

1.

2.

3.

4.

5.

6.

7-8.

10

8

7

1

3

5

6

7

8

11

12

2

4

15

16

9

10

13

14

Start second diesel engine (automatic) Stop second diesel engine (automatic) Main drive on Main drive off Swivel pendulum frame on left Swivel pendulum frame on right Hydraulic connections red (fold in/fold out corn header; raise/lower roller crop guide)

32

9-10. Hydraulic connections blue (fold in/fold out EasyCollect plant divider or pick-up guide wheels) Press buttons 7+8 or 9+10 simultaneously to depressurize both hydraulic circuits!

11.

12.

13.

14.

Auxiliary hydraulics (option) Auxiliary hydraulics (option) Auxiliary hydraulics (option) Auxiliary hydraulics (option)

BiG X Service Training 2014 Basic

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4. Cab: Console 9

1

10

3

2

11

4

5a

6a

4

5b

7

6b

8

only for Bosch Rexroth travelling gear

Switches and Indicator Lamps 1.

2.

3.

4.

5a.

5b.

Road/field mode release switch Intake / header release switch Parking brake on/off Travelling gear release switch Traction Control on/off All-wheel drive on/off 33

6a.

6b.

7.

8.

Traction Control Stage I/II (corn/grass) Axle separation I/II Automatic steering system release switch Maintenance release switch (blade sharpening)

9.

Engine failure indicator lamp (for BiG X 600/700/850/1100: oil pressure and serious engine failure) 10. Coolant level indicator lamp 11. Charge indicator lamp

BiG X Service Training 2014 Basic

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4. Cab: Console Road/Field Mode Release Switch The road/field mode release switch (1) is used to switch from road travel to field mode and vice versa (only possible at standstill!)

I – Road mode II – Field mode In road mode, all functions of the work hydraulics (raise/lower discharge chute, etc.) are deactivated. Only the driving and steering hydraulics are active.

The travelling speed and engine speed are also dependent on the switch position.

II

2

1 I

Intake / Header Release Switch Pressing the intake / header release switch (2) releases the intake rollers and the corresponding attachment (safety function).

The intake / header can be activated using the multi-function joystick when the road/field mode switch is at position (II) and the intake / header release switch (2) and the main drive (3). release switches are switched on.

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BiG X Service Training 2014 Basic

3

© KRONE Training Team, Spelle, Germany

4. Cab: Driving Modes (Bosch Rexroth Travelling Gear) Driving Modes Bosch Rexroth: I. Road mode: - Travelling gear release switch (1) switched on The machine is started by front and rear drive motors.

Travelling speeds: Forwards 40 km/h, backwards up to 14 km/h.

1

II. Field mode: - Road/field release switch in position field + travelling gear release (1) switched on The machine is driven by front and rear drive motors. The drive motors are adjusted steplessly according to conditions Travelling speeds: Forwards 25 km/h, backwards 14km/h

2

On Press

3

Press

TC Traction Control on/off: - Press button (2) until the required symbol appears on the display Traction Control (traction control, ASR) is active in field travel mode. If required, this can be switched on or off. Complete deactivation is not possible to protect the engines from overspeeding.

Traction Control Stage I: - Press button (3) until the required symbol appears on the display TC I is the traction control for corn mode. This mode allows increased slip (spinning wheels). This is required to ensure adequate forward drive even under difficult conditions.

Traction Control Stage II: - Press button (3) until the required symbol appears on the display TC II is the traction control 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 (grass/corn) set in the terminal. The stage can therefore be adjusted to conditions Animation TC

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4. Cab: Driving Modes (Poclain Travelling Gear)

1 On Travelling Gear Release Switch

Pressing the travelling gear release switch (1) releases the travelling gear.

The travelling gear release switch must be switched off for the following functions: - Engine start - Manual operation on platform

Changeover

Road Mode

- Travelling gear release switch (1) switched on - Road/field release switch (2) set to the "road" position When starting up, the front hydraulic motors run at high intake volume – i.e. at maximum torque. The intake volume is reduced in stages when the machine has reached a certain speed.

BiG X 500 – approx. 13 km/h, BiG X 650/700 – approx. 11 km/h, BiG X 850/1100 (650/700 optional) – two stages approx. 10 and approx. 20 km/h.

Maximum speed 40 km/h.

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

2 Off

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4. Cab: Driving Modes (Poclain Travelling Gear)

1

3

2

On

Press

Off

Hill Mode - Travelling gear release switch (1) switched on - Road/field release switch (2) set to the "road" position - Hill mode is activated and deactivated with the axle separation button (3) when the machine is at a standstill.

In hill mode, the engine speed is also adapted automotively to the travelling speed, although when starting up it is already slightly higher. The machine responds more aggressively.

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4. Cab: Driving Modes (Poclain Travelling Gear)

1

3

2

On

Off

On Grass Mode - Travelling gear release switch (1) switched on - Road/field release switch (2) set to the "field" position (changeover only possible at standstill) - All-wheel drive switch (3) switched off In this case, the front hydraulic motors on the BiG X 500/650/700 always run at a high intake volume, i.e. at maximum traction.

On the BiG X 850/1100 (650/700 optional), the motors run in the first two stages.

(Reduction from 3/3 to 2/3) Maximum travelling speeds: BiG X 500 – 25 km/h, BiG X 650/700 – 19 km/h, BiG X 850/1100 (650/700 optional) – 31 km/h.

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4. Cab: Driving Modes (Poclain Travelling Gear)

1

3

On

On

2 On

All-Wheel Drive - Travelling gear release switch (1) switched on - Road/field release switch (2) set to the "Field" position - All-wheel drive switch (3) switched on It is only possible to activate all-wheel drive at a standstill!

In this case, the front hydraulic motors on the BiG X 500/650/700 always run at a high intake volume, i.e. at maximum traction.

On the BiG X 850/1100 (650/700 optional), the motors run in the first two stages (reduction from 3/3 to 2/3).

On all models (except the BiG X 500) the rear hydraulic motors are switched to half volume when the following speed is reached: BiG X 650/700 – approx. 9 km/h, BiG X 850/1100 – approx. 13 km/h.

Maximum travelling speeds: BiG X 500 – 17 km/h, BiG X 650/700 – 14 km/h, BiG X 850/1100 (650/700 optional) – 18 km/h.

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4. Cab: Driving Modes (Poclain Travelling Gear)

1

3

4

2

On

On

Press

On

Axle Separation - Travelling gear release switch (1) switched on - Road/field release switch (2) set to the "Field" position - All-wheel drive switch (3) switched on - Pressing the axle separation button (4) activates or deactivates axle separation.

The axle separation function can be switched at a travelling speed below 17 km/h (BiG X 500), 11 km/h (BiG X 650/700), or 10 km/h (BiG X 850/1100/650 optional/700 optional), corresponding to the maximum travelling speeds. In this case, the front and rear hydraulic motors on all models always run at a high intake volume – that is, at maximum traction.

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4. Cab: Parking Brake Operation Parking Brake (Poclain Travelling Gear)

The parking brake is engaged at "Ignition off" or when the parking brake release switch (1) is switched on. The machine is held in place by spring force. It releases on "Ignition on" provided there is sufficient pressure in the hydraulics accumulator.

The spring force forces the brake shoes of the front wheel motors apart – the parking brake is active.

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

1

Parking Brake (Bosch Travelling Gear)

The parking brake is automatically applied when the machine stops and the driver is not on the seat.

If the button (2) is pressed while driving, the machine automatically decelerates.

As soon as the machine is at a standstill, the parking brake is applied.

2

Automatic start-up: If the driver is sitting on the seat, the travelling gear

release switch is switched on and the joystick is actuated, the parking brake is automatically released To release the parking brake at a standstill, the foot brake pedal must be depressed all the way and then the button (2) must be pressed.

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4. Cab: Console

3 On

2

1

Autopilot Release Switch

Pressing the Autopilot release switch (1) releases the "Automatic steering" function. The autopilot can be switched on using the multi-function joystick when the switch (2) is set to field mode, the travelling gear release switch (3) is switched on and the Autopilot release switch (1) is activated. Also, the cab door limit switch must be actuated and the machine must be moving forwards (> 0.7 km/h).

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

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4. Cab: Console

3

1

On Release Switch Maintenance

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

2 2

5

4 Off

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4. Cab: Manual Operation from Platform 1

3

5

6

Manual Operation 1.

2.

3.

4.

5.

6.

7.

8.

9.

9

2

4

7

Approach counterblade right Move away from counterblade on the right Approach counterblade on the left Move away from counterblade on the left Close grinding flap Open grinding flap Start grinding cycle in automatic mode Move grinding stone manually Reverse intake / header

8

10

If one button on the manual control unit is enabled the LED lights up.

Off

Grinding Blades The following preconditions must be met in order to execute the "Sharpen blades" function: - engine is running - Travelling gear release switch (10) switched off - Road/field release switch (11) is in the "Field" position - "Maintenance" switch (12) switched on - Main drive (13) switched on

11 On

13

12 On

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On

4. Cab: Manual Operation from Platform Reverse Intake / Header For the intake / header reverse function (R), the following conditions must be met: - Engine is running - Travelling gear release switch (1) switched off - Road/field release switch (2) is in the "field" position - Intake / header release switch (3) switched on - Main coupling is running (4) (BiG X 700/850/1100)

2

3

On

On

1 Off

In the case of machines with Bosch travelling gear, first the main belt is slackened and the main coupling is automatically connected as soon as the "Reverse intake / header" function is implemented when the drum is at a standstill!

G

Retract Counterblade To activate the counterblade adjustment (G), the following conditions must be met: - Travelling gear release switch (1) switched off - Road/field release switch (2) is in the "field" position - "Maintenance" switch (3) switched on

4

R 45

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4. Cab: External Operation Raise/Lower Lifting Unit 1. Raise lifting unit 2. Lower lifting unit

3

The lifting unit can be raised/lowered on both sides.

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

Off

4 On

1 2

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4. Cab: Multi-Function joystick 3

1

Multi-Function joystick

6 7

2 4

11

9

5

10 8

12

17 16

13

15

14

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Activating the autopilot Start/stop intake / header Reverse intake / header Lower lifting unit manually Raise lifting unit manually Save/activate lifting unit lower position (automatic) Save/activate lifting unit upper position (automatic) Turn tower left (clockwise) Raise ejector flap Lower ejector flap Turn tower right (anti-clockwise) Reverse/lower discharge chute Memory button for adjustment process – lifting unit Travelling gear indicator lamp on Rotation speed of the discharge chute

18

16.

17.

18.

19.

20.

21.

Increase engine speed (in stages) Switch from idling speed to nominal speed and vice versa Reduce engine speed (in stages) Actuation button for travelling gear Acceleration ramp switch Activation button on small cross joystick for saving two cutting lengths and folding discharge chute extension 22. Free 47

BiG X Service Training 2014 Basic

21

19 20

22 © KRONE Training Team, Spelle, Germany

4. Cab: Multi-Function joystick Multi-Function joystick A - Accelerate (during forward travel) Deceleration (during reverse travel) Start travelling gear with activation button pressed (19) B - Multi-function joystick central position C - Accelerate (during reverse travel) Deceleration (during forward travel) Start travelling gear with activation button pressed (19) D - Decelerate to 0 km/h Fast reversing with activation button pressed (19) (only possible in Field mode) E - Multi-function joystick central position F - Activate cruise control (only in forward gear) To save current speed for cruise control, press button (19) and move multi-function joystick towards (F) Tap driving joystick twice to right in field mode to activate "Constant Power" load limit control.

F

E

19 D А

B

C G - Retrieve cutting length value 1 (to left) When the button 21 is pressed and the joystick is moved beyond the pressure point, the cutting length set in the Info Center is saved under value 1 H - Central position J - Retrieve cutting length value 2 (to right) When the button 21 is pressed and the joystick is moved beyond the pressure point, the cutting length set in the Info Center is saved under value 2 K - Lower discharge chute (move joystick beyond pressure point) L - Central position M - Raise discharge chute (move joystick beyond pressure point) 48

BiG X Service Training 2014 Basic

M

J

L K

H G

21 © KRONE Training Team, Spelle, Germany

4. Cab: KRONE - Multi-Function joystick 3

4

KRONE - Multi-Function joystick

5

2 1

6 7

9

16

11 10 8

17 18

1. Lifting unit multi-way button Top: Lower lifting unit manually Bottom: Raise lifting unit manually Left: Lower lifting unit automatically Right: Raise lifting unit automatically 2. Start/stop intake / header 3. Reverse intake / header 4. Memory buttons M1/M 2 – freely configurable 5. Activating the autopilot 6. Reverse/lower discharge chute 7. Discharge chute multi-way button Top: Discharge chute flap up Bottom: Discharge chute flap down Left: Discharge chute rotat. left Right: Discharge chute rotat. right 8. Discharge chute rotation speed 9. Free 10. Lifting unit adjustment memory button 11. Indicator lamp – travelling gear on

16.

17.

18.

19.

20.

21.

Increase engine speed (in stages) Switch from idling speed to nominal speed and vice versa Reduce engine speed (in stages) Activation button for travelling gear Acceleration ramp switch Activation button on small cross joystick for saving two cutting lengths and folding discharge chute extension 22. X-Power/Tri-Power/EcoPower changeover 49

BiG X Service Training 2014 Basic

19

21

20

22 © KRONE Training Team, Spelle, Germany

4. Cab: KRONE - Multi-Function joystick KRONE - Multi-Function joystick

F

E

D

19

C B А

A - Accelerate (during forward travel) Deceleration (during reverse travel) Start travelling gear with activation button pressed (19) B - Multi-function joystick central position C - Accelerate (during reverse travel) Deceleration (during forward travel) Start travelling gear with activation button pressed (19) D - Decelerate to 0 km/h Fast reversing with activation button pressed (19) (only possible in Field mode) E - Multi-function joystick central position F - Activate cruise control (only in forward gear) To save current speed for cruise control, press button (19) and move multi-function joystick towards (F) Tap driving joystick twice to right in field mode to activate "Constant Power" load limit control.

G - Retrieve cutting length value 1 (to left) When the button 21 is pressed and the joystick is moved beyond the pressure point, the cutting length set in the Info Center is saved under value 1.

H - Central position J - Retrieve cutting length value 2 (to right) When the button 21 is pressed and the joystick is moved beyond the pressure point, the cutting length set in the Info Center is saved under value 2.

K - Lower discharge chute (move joystick beyond pressure point) - Fold in discharge chute extension (with button 21 pressed) L - Central position M - Raise discharge chute (move joystick beyond pressure point) - Fold out discharge chute extension (with button 21 pressed) 50

BiG X Service Training 2014 Basic

M

J

L K

H G

21 © KRONE Training Team, Spelle, Germany

5. Terminal 1

Info Center:

+ 2

1.

2.

3.

4.

5.

Display Buttons from 1 to 8 Buttons A, B, C, D Rotary potentiometer Menu button

Buttons 1-8 (2)

Buttons 1-8 are used to activate the softkeys located in the righthand column. For the assignment of the keys, see the illustration.

If there is no softkey next to the button, it has no function.

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

3 5

4

Buttons A-D (3)

The buttons A-D are used to activate the softkeys located in the line just above them. For the assignment of the keys, see the illustration.

If there is no softkey above the button, then the button has no function.

Rotary potentiometer (4)

The rotary potentiometer has two functions: 1. The rotary potentiometer can be turned to change settings and to select the required menu in the menu level.

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

Menu button (5)

You can use the button next to the rotary potentiometer to open or close the menu level, or to go to the previous menu level. Holding the button down slightly longer takes you back to the home screen.

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5. Terminal Basic Screen Layout The display is divided into the following areas: I–

Status line Time, number of active errors, central lubrication status, pendulum frame position.

II – Info areas for engine data III – Info area for travelling gear and for status of lifting unit and autopilot IV – Setting and display for functions Working width, header speed, status of metal detection, cutting length and header working height.

V – Setting and display for functions Corn conditioner gap adjustment, counter menu, menu and status display for silage agent system, menu for general machine settings.

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5. Terminal: Basic Screen 1

2

1

4 3

I – Status line: 1.

2.

3.

4.

53

Time/date, fuel consumption, speed of cutting drum, area capacity, Throughput, yield, humidity of the crop (NIR sensor)/field is freely configurable Number of active errors Status of central lubrication and of compressed-air valve for cleaning intake and grinding device Beige field – idle state Green field – lubrication interval/blow out active Red field – central lubrication/blow-off valve fault Pendulum frame position -

Pendulum frame free. Pendulum frame position as shown.

-

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

-

Pendulum frame locked. Pendulum frame position as shown.

BiG X Service Training 2014 Basic

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5. Terminal: Basic Screen II – Info areas for engine data

1. Engine speed Road mode: 0 - 1,700 rpm Field mode: 0 - 1,950 rpm on MAN/0 - 2,100 on MB 2. Machine performance or or 3. Engine capacity as % 4. Coolant temperature display. If the cooling water temperature reaches the critical range, the background of the temperature display changes to red 5. Diesel tank fuel level 6. Engine fault lamp (red = serious failure, switch off engine, yellow = engine failure)

6 1

2 3

5

4

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5. Terminal: Basic Screen (Poclain Travelling Gear) III – Info area for travelling gear 1. Travelling speed Road mode: Field mode:

0 - 40 km/h 0 - 19 km/h (BiG X 650/700) 0 - 31 km/h (BiG X 800-1100, 650/700 optional)

4

8.0

2. Direction of travel

1

Forward travel Neutral (standstill)

3

Reverse travel 3. Acceleration ramp 1 - Lowest acceleration ramp 4 - Highest acceleration ramp 4. Cruise control, Constant Power status The number beside the icon is the saved speed for cruise control operation in km/h. When cruise control is active, the icon changes to green. When Constant Power is active, the icon changes to 5. Travel mode: - Front-wheel drive

2

5

- All-wheel drive

- Parking brake applied

- Quick stop console activated

- Axle separation

- Limp mode (emergency mode)

- Quick stop manual operation activated

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5. Terminal: Basic Screen (Bosch Travelling Gear) III – Info area for travelling gear 1. Travelling speed Road mode: Field mode:

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

4

8.0

2. Direction of travel

Forward travel

1

Neutral (standstill) Reverse travel 3. Acceleration ramp 1 - Lowest acceleration ramp 4 - Highest acceleration ramp 4. Cruise control, Constant Power status The number beside the icon is the saved speed for cruise control operation in km/h. When cruise control is active, the icon changes to green. When Constant Power is active, the icon changes to

3

2

5. Travel mode: if the TC icon has a green background, Traction Control is active - Traction Control on/off

5

- Traction Control Stage I for corn

- Parking brake applied

- Traction Control Stage II for grass

- Limp mode (emergency mode)

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- Quick stop console activated - Quick stop manual operation activated © KRONE Training Team, Spelle, Germany

5. Terminal: Basic Screen III – Info area for travelling gear 6. Autopilot Status Display

(display is adjusted when center scanning is programmed) - Autopilot active, left or right row tracer being evaluated

4

- Autopilot active, both row tracers are evaluated

1

- Autopilot active, discharge chute side row tracers being evaluated - Autopilot active, row tracers on side opposite discharge chute being evaluated

3

2

7. Status of Lifting Unit Control - Lifting unit ground pressure control active

- Lifting unit distance control (header contour) active

7

2 6

- Lifting unit position control active

8

- Isobus Autopilot active

8.

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5. Terminal: Basic Screen IV – Working functions setting and display

The value in the window can be altered using the rotary potentiometer or the buttons next to it. The left-hand button (-) decreases the value; the right-hand button (+) increases the value. А. Working width and operating mode The working width must be set in order to calculate the area. This area shows the icon for the selected header and the programmed working width or number of rows.

If the header is not working to full capacity across the entire width, the value in the window must be reduced in order to obtain a correct area measurement. When the "raise lifting unit" button on the multi-function joystick is pushed all the way up, the default value is reset.

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

The set operating mode is indicated by the header symbol:

- Pick-up (grass) - EasyCollect (corn)

A

B

C

D

X-Disc (all-plant silage)

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+

5. Terminal: Basic Screen IV – Working functions setting and display

-

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

The header speed can be changed during operation.

A

Status of header Colorless icon – header not active; red icon – error; green icon – header OK and active.

B

Header forward inactive/active Header reverse inactive/active Status of metal detection and the Rock Protect system (optional)

C

Metal detection inactive Metal detection or Rock Protect system defective Both systems, metal detection and Rock Protect defective

Metal detected in intake

59

D

Rock detected

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+

5. Terminal: Basic Screen IV – Working functions setting and display

-

C. Cutting length The cutting length is determined by the speed of the intake rollers and the number of blades that are used. In field mode, the cutting length menu area shows the current cutting length and the status of the "AutoScan" system.

Depending on the set number of blades and installed cutting drum, the cutting length can be set within a range of 2.0 mm (minimum) – 58 mm (maximum).

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

Two different cutting lengths (value 1/value 2) can be saved and retrieved using the small joystick.

When the "AutoScan" system is active, the symbol (S) is green. When "AutoScan" is active, the display indicates the current cutting length. The "AutoScan" system is switched off as soon as the cutting length is changed manually.

A

B

S

C

D

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5. Terminal: Basic Screen IV – Working functions setting and display

-

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

Display for the set value (II):

A

- Setpoint ground pressure as percentage of the header's own weight. It is adjustable between -5% (header sways above the ground) to a maximum of 70% (header presses on to the ground with 70% of its own weight).

B

- Pre-set height in % of glide skid sensors control travel with header contour programmed. Adjustable between min. 10 % and max. 90 % to ensure the header has adequate pendulum travel.

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

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

The setpoint ground pressure or the setpoint height can also be saved using the multifunction joystick.

C I

D

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5. Terminal: Basic Screen V – Function setting and display, menu access 1.

2.

3.

4.

Corn conditioner gap adjustment Counter menu Menu and status display for silage agent system. Auxiliary tank filling level (T).

General machine settings menu

When "Corn" or "X-Disc" mode is set, the field (1) shows the current actual value of the corn conditioner gap. The gap is changed using the rotary potentiometer.

The respective menus are accessed by pressing the buttons (В), (С) or (D). (Quick access)

1

62

2

3

Т

4

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5. Terminal: Machine Settings Pick up Easy Flow:

When using Easy Flow, select the lifting unit ground pressure control (Р) in the "General machine settings" menu.

Setpoint value (А) for operation with the Easy Flow should be within the range 20-30 % according to operating conditions.

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

Recommendation: 400 - 420 rpm as a basic speed.

P

Direct cutting system X-Disc:

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 unit position mode (α).

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

U А 63

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5. Terminal: Machine Settings EasyCollect corn attachment:

When using EasyCollect without sensing skids, select lifting unit position control (α) in the "General machine settings" menu.

α

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

d

64

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

Recommendation: 380 - 420 rpm as a basic speed.

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

5. Terminal: Joystick Settings Driving joystick - Memory - Buttons: The buttons M1 and M2 on the joystick can be freely configured as of complete software version 200814613.

When delivered, the buttons M1 and M2 on the joystick have not been assigned any functions.

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

M1

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

M2

- Increase/reduce working width ± - Retrieve saved cutting lengths (from the small cross switch joystick) 1 or 2 1/2 - Increase/reduce header speed ± - Turn pendulum frame left/right If buttons M1/M2 have already been assigned functions, the illustrated settings mask appears whenever the machine is started.

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

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5. Terminal: AutoScan Settings

(as standard)

2

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

3 10

7

8

9

1 4 5

6

"AutoScan setting" menu within the machine settings range

1.

Setting min./max. cutting length

2.

Graphic representation of the settings

3.

Setting for degree of maturity sensor available/not available

4.

AutoScan status automatic adjustment of the cutting length active

6.

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

7.

Current cutting length

8.

Current position on the characteristic line within the working range

9.

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

10.

Max. cutting length set by the driver. The associated degree of maturity can be changed in AutoScan expert mode (DEF = 67%).

manual adjustment of the cutting length active 5.

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

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

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

2.

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

3.

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

4.

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

5.

Current performance mode

6.

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

Characteristic

: Abrupt change when speed is reached

Characteristic

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

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5. Terminal: Constant Power Settings Constant Power – Load Limit Control

On the BiGX 1100, Constant Power can only be adjusted depending on the speed (1)

(optional)

The Constant Power load limit control controls the forward speed of the machine depending on the diesel engine load and provides constant machine load at a lower fuel consumption.

Software prerequisites for Constant Power: Terminal: min. 150 200 104-08 4 KMC3: min. 150 200 103-08 1 2 SmartDrive greater than A16939C (e.g. A22823H, A33789C.H86, ) 5 DRC on each software Activation of Constant Power: Tilt joystick 2x to the right (only possible in Field mode)

6

3

1.

Setting for speed reduction depends on the speed (button "1") e.g.: 10%  2,000 rpm – 10% = 1,800 rpm

2.

Setting for speed reduction depends on utilzation (button "2") e.g.: 80% 

69

3.

Setting for the min./max. speed.

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

4.

Actual engine speed

5.

Actual engine load

6.

Diesel engine nominal speed

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

5. Terminal: Settings for Rock Protect RockProtect - Rock Detection (optional) Setting the sensitivity from 0-100 % by the driver. Due to different conditions (variable or irregular swath shape), it may be necessary to adjust the sensitivity several times a day. To ensure that the system functions optimally, the sensitivity must be adjusted to the given conditions. To do this, adjust parameter 27500 according to the graphic.

Sensitivity 100 %

0%

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5. Terminal: Submenu Structure (Software 200814619) 1. Settings 2. Counter

3. Calibration

4. Diagnostics 5. Close submenu

1-1-22

1-1-25

1-1-26

4-4-4

4-4-5

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6. Intake: Drive The Intake

The intake is driven by the hydraulic motor by means of a cardan shaft on to the lower intake roller gear (2). From there the force is distributed on to the lower intake and pre-compression rollers and by means of the double joint (BiG X 700/850/1100) or tower gearbox (BiG X 500-1000) on to the angular gearbox (3). From the angular gearbox the cardan shaft (4) drives the upper roller gear (5) on the right side of the machine. 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

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

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

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

1.

2.

3.

4.

5.

6.

4

1

Input shaft of bottom roller gear Lower roller gear Angular gearbox Cardan shaft Upper roller gear Double joint

SI_150371257Feed drive_ direction_EN

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6. 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 tonnes 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 lower roller (4) are made of stainless steel in order to detect metal. They are fitted with replaceable strips (9). The metal detection is installed in the roller (4). The intake unit is cleaned cyclically with compressed air (see parameters 33651 and 33652).

8

5

3

2

7

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

Intake roller top front Pre-compression roller top middle Pre-compression roller top rear Intake roller bottom front Pre-compression roller bottom middle Smooth roller bottom rear Bearing plate lower roller pack Bearing arm upper roller pack Toothed plates (can be rotated for grass/corn) 10. Wear strips (optional at bottom)

4

9 10

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

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6. Intake: Layout of the Upper Roller Pack 1

6 7

4 2

8

9

3

10 5

1 2 3 4 5 74

Top feed rollers Middle baling roller Rear baling roller Bearing arm upper roller pack Left rocker arm

6 7 8 9 10

BiG X Service Training 2014 Basic

Supporting axle for feed roller Upper roller gear Supporting axle for middle baling roller Supporting axle for rear baling roller Right rocker arm © KRONE Training Team, Spelle, Germany

6. Intake: Top Bearings Bearing for Roller Pack at Top Left (from BiG X Bosch year of manufacture 2012)

The upper rollers are mounted on the left-hand side on fixed axles (4). The axles are connected to one another by a bearing arm (2), which is guided from behind by a rocker arm (1). Both are then pulled downwards by the tension springs. The bearings are supplied with grease by the central lubrication.

1

2

7

7

3

6 4

4

75

7 6

6 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

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

6. Intake: Top Bearings Roller Gear at Top Right (from BiG X Bosch year of manufacture 2012)

The upper rollers are mounted on the right-hand side on fixed axles (1). The two front axles are externally attached in the gearbox housing (2) by means of clamping elements (3). The rear axle is mounted in the gearbox and is attached by a profile sleeve (4) in a rocker arm (5) that guides the entire gearbox. The rollers are drive by profile flanges (6), which are inserted into the gearbox.

5

1

6

6

6

2 3

3

1

4 1 2 3 4 76

Fixed axles Gearbox housing Clamping element Profile sleeve

5 6

Right rocker arm Profile flanges

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

1

6. Intake: Top Bearings (from BiG X Bosch Year of Manufacture 2012) 1

6 8

4

5

3

9

2 13

14

10 11 12

4 7 1 2 3 4 5 77

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

6 7 8 9 10

Lamellar ring Reducing ring with O-ring seal Fixed axle Bushing Cover disk with thread

BiG X Service Training 2014 Basic

11 12 13 14

Taper roller bearing Rotary shaft sealing ring Labyrinth seal Ring seal

© KRONE Training Team, Spelle, Germany

6. Intake: Layout of Lower Roller Pack Lower Roller Gear 1

3

2 5 4

1 2 3 4 5

78

2x taper roller bearings Rotary shaft sealing ring O-ring seal Gearbox sealing flange 3x fastening bolts

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

6. Intake: Lower Bearings Bearing for Roller Pack Below Right

The pins (1) of the lower rollers are mounted by means of pendulum roller bearings (2) in a bearing plate (3). The bearings are supplied with grease by the central lubrication. The front roller is also equipped with a continuous fixed axle (4), to which the metal detection system is attached. Each of the shaft sealing rings (5) are installed in a way that allows grease to escape from the bearing, while providing external protection to the bearing against dirt and moisture.

1

1 4

3

2 5

6 1 2 3 4 79

2

5

6

Pin Pendulum roller bearing Bearing plate Fixed axle

5

2

5

6 5 6 7

Shaft sealing rings O-ring seal Clamp on axle for metal detection

BiG X Service Training 2014 Basic

© KRONE Training Team, Spelle, Germany

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6. Intake: Metal Detection Metal Detection

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

3

4

3

2

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6. Intake: Settings Settings

The upper roller pack is pulled downwards by four springs. The springs must be pre-tensioned equally on the right and left. When the crop runs through the intake, the upper roller pack is lifted against the spring force.

BX 600/700/850/1100

BX 650

v

3 h

h = 490 mm

v

h

v = 530 mm

h = 450 mm The front springs cannot be set on BiG X with Bosch travelling gear!

(BX 600-I, 700-I, 850-I, 1100-I)

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v = 416 mm

6. Intake: Settings Setting the Scraper and Smooth Roller

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

The distance between the roller shell of the pre-compression roller (2) and scraper should be approx. 8 mm externally on the right and left.

The setting is made by spacer plates under the rubber pads (3).

At regular intervals, check the thickness (D) of the scraper: D ≥ 24 mm, otherwise the scraper must be replaced!

2

D

1

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

This must be checked before every season!

See below

3

4

1

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7. Foraging Unit: Cutting Drum Variants Overview of BiG X Cutting Drums

Blade drum

BiG X 500/650 = 1,100 rpm BiG X 600/700 = 1,200 rpm BiG X 850/1100 = 1,250 rpm

Rotation speed, (rpm)

660/800

Diameter/width, (mm) Number of blades

20

28

40

48

Chop length range, (mm)

5.0 – 29

4.0 - 21

2.5 – 15

2.0 - 12

Cuts/min

11,000 12,000 12,500

15,400 16,800 17,500

22,000 24,000 25,000

28,800 30,000

Applications

83

Overseas markets, Lucerne Grass insert

Universal application

BiG X Service Training 2014 Basic

Biogas products High throughput despite short cutting length on account of more cuts/min.

Biogas products, only in BiG X 850/1100 Chop length recommendation for optimum throughput and machine functions: 2 - max. 9 mm

© KRONE Training Team, Spelle, Germany

7. Foraging Unit: Design Cutting Drum 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 attached to the drum body with screws.

The cutting drum is driven via composite V-belts (3). The composite V-belt 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.

3

1

4

2

2

Whenever a blade is changed, use new screws!

5 Composite V-belts:

11°

BiG X 500 BiG X 600 BiG X 650, 700 BiG X 800, 850, 1000, 1100

7 8

8

7 84

5 - groove 7 - 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 the intake and header are raised and lowered.

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© KRONE Training Team, Spelle, Germany

7. Foraging Unit: Bearing Design Cutting Drum Bearing Big X 700 on left (Floating Bearing)

10

1. 20 023 283 0 Slide ring

9

6

4

3

2. 00 911 609 0 Retaining ring I 160x4 3. 20 021 884 0 Sealing 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 - on 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-cutting drum bearing_EN

1

2

3

4

5

9

10

Cutting Drum Bearing Big X 700 on right (Fixed Bearing) 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

7

5. 00 224 030 1 Support washer, rd. 85/75x5 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 washer, rd. 109.9/95x3 10. 00 911 691 0 Retaining ring 110x4

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7. Foraging Unit: Blade/Counterblade Readjusting the Cutting Blades To sharpen the blades completely with as few grinding cycles as possible, the blades must be adjusted optimally to the grinding device.

Sharp tools - risk of injury!

Always wear gloves when working with the blade drum.

1. Grind the blades of the cutting drum.

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

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.

3. Align counterblade (3) parallel to the ground blade backs on the counterblade support (see chap. Turning/Replacing the Counterblade).

4. Unscrew all hexagonal head screws (2).

5. Set blades to the counterblade.

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

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

8. Readjust the next row of knives.

9. Continue in this way until all rows of knives on the blade drum have been re-adjusted equally.

10. Loosen the locking of the blade drum.

11. Set grinding stone until there is a gap of 0.5 mm between blade 2 back and grinding stone.

12. Attach the intake housing and fold it in.

13. Grinding the cutting blade.

14. Readjust the counterblade.

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7. Foraging Unit: Blade/Counterblade Replacing the Cutting Blades To avoid imbalances in the blade drum, the cutting blades must always be replaced in pairs. The two blades which are offset by 180° on the blade 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, observe art. no. on the replacement blades (see also 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. Unscrew the hexagonal head screws (2) and (3).

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

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

4. Replace pressure plates (4) if they are damaged or heavily worn.

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

5. Install new cutting blade and, using new screws, screw it hand-tight on to the blade holding surface and pressure plate (4).

When installing the cutting blades (1), observe installation direction of the threaded strips (5). The surface (a) with the rounded corners must be placed on the blade drum (6); the surface (b) must be turned away from the blade drum (6). Mount the wider surface of the threaded strips facing upwards towards the blade carrier!

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1

5

2

a © KRONE Training Team, Spelle, Germany

b

7. Foraging Unit: Blade/Counterblade Turning or Replacing the 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. Using the setting motors, by manual operation on the platform, move counterblade (1) away from the blade drum (must rotate) on both sides.

After setting the blades, ensure that there is still play between the blades and counterblade by 350 Nm extending, both setting motors again by approx. 5 mm.

425 Nm* 3. Remove hexagonal head screws (2), detent edged washers (3) and washers (4).

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

Then re-tighten spring assembly to a torque of 75 Nm. 5. Pull the counterblade (1) forwards out of the supports. !

6. Clean skid surface area and underside of the counterblade.

210 Nm 7. Turn counterblade or install new counterblade.

!

! = Loctite medium strength Installing a new Counterblade *) applies only to machines without VariStream 1. Place new counterblade (6) on the counterblade support and attach hand-tight in the middle at bottom using 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 tension plate (7). m 4. Tighten all three screw connections on the counterblade to the specified torque (see Fig.).

2 3 4 88

7

1

2 5

3

4

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7. Foraging Unit:

From year of manufacture 2010

4 VariStream_1

1

3

ET_manual drum base 700_1100_EN

2 2

3

Drum Base

Distance between blade and drum base (1) is changed automatically with the counterblade in the front area (drum inlet). 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 Using washers, align the drum base central to the housing.

89

Hexagonal head screw (5): Md = 350 Nm, Use detent edged washer and 5 medium-strength screw retention.

6 BiG X Service Training 2014 Basic

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

© KRONE Training Team, Spelle, Germany

7. Foraging Unit:

From year of manufacture 2011

Drum Base

1

The springs of the drum base have been rearranged on the BiG X 700/850/1100 year of manufacture 2011.

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

On the drum bases from year of manufacture 2011 the centering pivots (1) of the VariStream springs can be screwed on.

This facilitates installation/removal of the drum base.

With these drum bases, it is also possible to screw husk comb (3) directly onto the drum base.

Furthermore, the pivots of the drum base have also been fitted with wear sleeves (2).

2 3

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ET_manual drum base 700_1100_EN

7. Foraging Unit: Blades 1

Cutting Blades

There are two types of blades: (A) – grass cutters and (B) - corn cutters.

They differ in shape. Both blades come in standard and HD versions. The HD blade has a thicker hardening layer, thereby increasing the service life.

The standard blades are fitted as standard, and better suited to stony conditions. Blades must always be changed in pairs, set at an 180° offset on the drum, so as to avoid imbalance and vibration. To achieve longer cutting lengths in grass, it is possible to operate the cutting drum with half the number of blades. The removed blades are then replaced by blanks (3) and (4) to protect the drum body from damage and wear.

6

7 5

3

4

2 6 7 5

A "Standard"

"Special"

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B

7. Foraging Unit: Counterblade Counterblade

3

The counterblade is attached (1) to the anvil (2) on the right and left by means of bolts (3) and nuts (4). There is also a bolt in the middle of the counterblade (5).

1

Two Counterblade Versions

А - "Standard". This counterblade is usually used in combination with standard grass cutters.

B - "Special". This counterblade is usually used in combination with "special" grass cutters and corn cutters.

3 4

2 5

A

"Standard"

B

"Special"

4

Tightening torques without VariStream (until year of manufacture 2009): Nut (4) on side Bolt (5) in center

425 Nm 210 Nm

Tightening torques with VariStream (machines manufactured in 2010 and later): Bolt (3) on side: 350 Nm + medium-strength threadlocker + SKM 20 Bolt (5) in center: 210 Nm 92

BiG X Service Training 2014 Basic

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7. Foraging Unit: Counterblade Counterblade Adjustment

6

1

9 7

2

The distance from the blade (1) to the counterblade (2) can be adjusted via the anvil (3) on which the counterblade is mounted. The anvil (3) pivots in sliding bearings (4) around the axis (X). When the button (5) is pressed, the counterblade is adjusted by means of the electric motors (6), the rocker arm (7), the joystick (8) and the fixing bolts (9). The long rocker arm (7) permits fine adjustment of the counterblade.

Anvil attachment: Pre-tension the disc spring package (A) with the crown nut until a torque of 65 – 75 Nm is attained on the crown nut.

8 X

3 4

6

9 A 93

5

BiG X Service Training 2014 Basic

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© KRONE Training Team, Spelle, Germany

7

7. Foraging Unit: Counterblade 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 mounted. The anvil (6) rotates in sliding bearings at the pivot (1). When the button (9) is pressed, the counterblade is adjusted by means of adjustment motor units (5). The small number of pivots (1),(3),(4), two of which (1),(4) are pre-tensioned with springs (8),(9), permits fine and direct adjustment of the counterblade.

The pre-tensioned pivots cause fewer vibrations to occur, which protects the bearings.

The attachment of the anvil is pre-tensioned as before by means of the disc spring packages and crown nuts. The pre-tension is achieved when the tightening torque at the crown nuts reaches 65 – 75 Nm. 1.

2.

3.

4.

5.

6.

7.

8.

9.

9 5

4

Pivot point of anvil Holding brake (no pivot!)

Pivot point of threaded piece on the threaded spindle Pivot point of adjusting motor braked Adjusting motor unit Anvil with adjusting joystick bolted on SI_150385506_Counterblade Counterblade (bolted to anvil) adjustment_EN Disc spring for pre-tensioning setting motor Disc springs for anvil 7

8

3

2

6 9 94

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1 © KRONE Training Team, Spelle, Germany

7. Foraging Unit: Counterblade Counterblade Adjustment from Year of Manufacture 2014 Tightening Torques: 1.

2.

3.

4.

5.

6.

7.

8.

Nut for anvil on cutting drum 65-75 Nm Bolt in center of counterblade on anvil 210 Nm Outer bolts of counterblade on anvil 350 Nm Bolt on holding brake on cutting drum 85 Nm Bolts on adjusting joystick on anvil 210 Nm Crown nuts for adjustment unit on cutting drum 40 Nm Gap cover on anvil 49 Nm (on BiG X 500 only) Adjustment limit on adjusting joystick 25 Nm (on BiG X 500 only)

Installation of Counterblade Adjustment

5

1

6

3

To ensure that the counterblade adjustment functions, it is very important that it is mounted tension-free. To do this, proceed as follows: 1. Mount the anvil and tighten it with nut (1).

2. Fit the counterblade and tighten with the bolts at position 2 and 3.

3. Pre-install the adjusting joystick i.e. connect the adjusting motor unit to the adjusting joystick so that it can now be attached.

4. Screw the holding brake at the right + left Tighten with the prescribed torque (4).

5. Tighten the bolts for the adjusting joystick right+ left on the anvil (5).

6. Tighten the crown nuts on the adjusting motor units with the specified torque.

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7

5

4

© KRONE Training Team, Spelle, Germany

6. Foraging Unit: Grinding Device Grinding Device The blades are ground by a cylindrical grinding stone, which moves horizontally back and forth across the drum as it rotates forwards.

The grinding stone is secured by a clamping device (1) in the grinding slide. This clamping device is located in a threaded sleeve (2), which is used to adjust the height of the grinding stone. The grinding slide is moved by a synchronized hydraulic cylinder (3).

For each grinding cycle, the adjustment ratchet (4) turns the toothed wheel (5) one tooth further and the grinding stone is moved slightly closer to the drum. An adjustment ratchet can be mounted on both sides as an option.

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

The grinding flap (9) is opened as soon as the maintenance switch is switched on. Otherwise, it is closed via a hydraulic cylinder (6). If the diesel engine is switched off, the grinding flap always opens. The throttle non-return valves (7) beside the valve block can be used to set the speed of the synchronized cylinder (3). The grinding slide is guided at the back by a ball bearing on a rail. From year of manufacture 2012, a spring-loaded ball bearing (8) is also mounted from above.

3

6

4 9

8 5

SI_150388056 Grinding stone guide_EN

А 2

The speed of the grinding stone should be set so that the grinding stone takes approx. 5 sec. to move from one side to the other. Based on experience, we also recommend using an adjustment ratchet (4).

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© KRONE Training Team, Spelle, Germany

1

6. Foraging Unit: Grinding Device 2

Grinding Cylinder Counter

One Namur sensor on the right and one on the left-hand side detect each end of the grinding path. These pulses are also used to count the grinding cycles. After a number of grinding cycles specified by parameters has been counted, the driver receives an information message in the terminal and automatic grinding is no longer possible.

In the maintenance menu of the terminal, there is a field containing a grinding cycle counter (1), a bar graph showing the number of cycles still possible (2) and a softkey for resetting the counter (3). (from software version 200 814 617 on) .

1

After you have adjusted or replaced the grinding stone, you must always reset the cycle counter on the terminal!

Parameter

Designation

Meaning

33590

Grinding cycles total counter

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

33657

Grinding stone adjuster

Number of adjustment ratchets per grinding cycle

34014

Grinding stone adjuster number of teeth

Number of teeth on the toothed wheel

34023

Number of grinding cycles until information displayed

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

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7. Foraging Unit: Grinding Device Blade Sharpening Menu

1

1. Display engine speed The engine speed is set as standard to 1,100 rpm (applies to machines from software 200814613 and an adjuster).

2. Display for conditions not met (yellow) 3. Warning symbols 4. Cycle counter

4 5

2

3

6

When the maximum number of cycles has been reached, automatic grinding is no longer possible.

Press the button 1 to reset the cycle counter to zero.

8

7

9

5. Grinding flap position display The grinding flap can be opened and closed manually using buttons 3 and 4 on the terminal or using the buttons (T) on the manual control unit.

10

11

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

7. Number of completed grinding cycles 8. Setpoint values for number of grinding cycles to be performed 9. Status display for electric motors for counterblade adjustment 10. Counterblade adjustment parameters menu 11. Start automatic grinding 12. Start manual grinding 98

BiG X Service Training 2014 Basic

T

11

© KRONE Training Team, Spelle, Germany

12

7. Foraging Unit: Grinding Device Changing Grinding Stone/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 detent pin (8) 90° so that it can engage later.

Unscrew the adjustment wheel (7) together with the threaded sleeve (2) until the detent pin engages in the threaded sleeve. Unscrew the adjustment wheel from the threaded sleeve. The clamp of the grinding stone is then loosened. Using a suitable tool, set the new grinding stone to a distance of 3 mm from the blades. When installing a new grinding stone, observe the correct position of the clamping, thrust and intermediate rings. After adjusting a grinding stone which has already been used (reset), check dimension "X".

The adjustment wheel (7) is tightened to 180+10 Nm. Pull detent pin and rotate by 90° (parking position). Re-attach pawl (9) and close grinding device flap protection.

Reset grinding cycle counter!

After you have adjusted or replaced the grinding stone, you must always re-tighten the grinding stone with 180 Nm after the first grinding cycle.

9

1 1.

2.

3.

4.

5.

6.

7.

8.

9.

Grinding stone Threaded sleeve Clamping ring Intermediate ring Support washer Sleeve Gearwheel (Z = 36) Detent pin Pawl 99

7

8

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7. Foraging Unit: Grinding Device

5

7

4

6

2 5

3

max.

3

100 mm

6

Md = 180+10 Nm

6

2 22

1

5 1

4

1

3 1.

2.

3.

4.

5.

6.

7.

Grinding stone Threaded sleeve Clamping ring Intermediate ring Support washer Sleeve Gearwheel (Z=36) 100

5

4

Note the position of the beveled edges!

Beveled edge is face down!!

BiG X Service Training 2014 Basic

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7. Foraging Unit: Grinding Device Different Clamping Rings

There are 2 different clamping ring variants. If the machine is fitted with an adjustment ratchet (1), you should fit transparent/brown (2) clamping rings. If the relevant machine is equipped with two adjustment ratchets (1), you should fit black clamping rings (3) (softer).

After you have adjusted or replaced the grinding stone, you must always re-tighten the grinding stone with 180 Nm after the first grinding cycle.

1

Intermediate ring (4) is not installed in every machine.

3 101

2

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7. Foraging Unit: Installing and Removing the Foraging Unit Dismounting the Foraging Unit

The foraging unit can be dismounted onto the specially made trailer (1). The trailer is adjusted using a jack (2).

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

A complete description for dismounting and mounting the foraging unit can be found in chapter 3.2.3. of the BiG X workshop manual.

Trailer for the foraging unit no. 20 023 186.0

1

2 WHB_3.2.3_Removing and Installing the Cutting Drum Housing_EN

SI 150393896 Service cart cutting drum_EN

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

Sharpening does not do any good unless the counterblade is readjusted as well. As the corn cutters sharpen themselves very effectively, there is no need to "sharpen them until they shine" at every grinding interval. In corn mode, we recommend that you only adjust the counterblade several times a day between the grinding processes without having sharpened it beforehand. In doing so, the sharpness of the blades must be monitored continuously. In the case of grass cutters, 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 machine, lower the attachment by pressing the button (1) until it is completely on the ground.

1

2. Move the maintenance release switch to the "on" position.

The maintenance menu appears on the Info Center display.

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

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

Readjusting the counterblade

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

5. Press the "Move counterblade right to blade drum" button and the "Move counterblade left to blade drum" button alternately and very lightly.

6. If there is a noise when readjusting one side (right/left) (cutters striking the counterblade!), release the button immediately and very briefly press the appropriate button "Move counterblade away from blade drum".

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: Adjust the Counterblade The most Important factors influencing wear and fuel consumption The Influence of the cutting blade – self-sharpening effect On genuine counterblades and cutting blades for cutting corn, the very high-quality coatings result in a self-sharpening effect.

This means that the basic material wears faster than the coating on the cutting edge! The coating forms an aggressive edge, known as the mouse tooth! The self-sharpening effect is clearly visible and, on genuine parts, can easily be felt with your fingernail. Excessively frequent and intensive grinding will cause the expensive coating and the self-sharpening effect to be worn away unnecessarily. All too often, the quality advantage, difference in performance and added value of genuine parts is not exploited due to incorrect handling.

A very well developed "mouse tooth" on the corn cutter!

--> this is what it should look like!!

The self-sharpening effect is clearly visible on the reverse side of the cutter!

Excessively frequent and intensive grinding will cause the expensive coating and the self-sharpening effect to be worn away unnecessarily!!

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6. Foraging Unit: Adjust the Counterblade The most important factors influencing wear and fuel consumption  The influence of the counterblades

The counterblade is subjected to the greatest stress during harvesting and is largely responsible for the cutting quality. The different crop and usage conditions result in different wear patterns on the cutting components. The wear patterns form the basis for selecting the most suitable quality and variant of counterblade.

"Smooth surface" – no pronounced impacts by foreign bodies visible.

 The influence of the cutting gap setting

"Crater-shaped surface" – countless impacts by foreign bodies and deformations in the surface.

--> A harder counterblade design would be the wrong choice in this case!

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

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

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

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8. Corn Conditioner: Design Design and Drive

L

The operating elements are designed as serrated rollers. The rollers are mounted on pendulum roller bearings (L) and rotate at different speeds with respect to each other. The bearing housings of the rear roller (3) on the right and left are permanently attached and have a fixed installation position. The bearing housings (4) of the front rollers swivel about 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 from the cab by a joystick (8) and electric motor (7).

From year of manufacture 2011 the BiG X 700/850/1100 feature lubricatable deflection rollers on the corn conditioner.

X 4

8 3

6

1 5 2 7 9

1 2

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SI_150376068_lubricatable idler pulley_EN

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

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8. Corn Conditioner: Differential Speed Accessories Pack B045: Differential Speeds on the Corn Conditioner

To optimize cracking of the grain in the corn conditioner, it is possible to increase the speed difference of the rollers. 3 differential speed variants are possible. These are set by exchanging the drive pulleys and are available for all serrated roller shells. 20 % differential speed is the standard version.

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

Spare-part numbers marked in blue refer to corn conditioners with lubricatable deflection rollers. Before converting, please check carefully whether the deflection roller can be lubricated 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 roller (1) can be replaced with the diameter 204 mm (20020769.0, 20027147.0).

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

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SI_150371189 Adjustments crop flow Varistream _EN

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A

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

1. Rollers with 123 teeth: Optimum equipment configuration for corn silage with over 18 mm cutting length.

This ensures maximum throughput allied to optimum grain working and long cutting lengths. These rollers are usually used in combination with the 20-blade drum. A roller with chrome-plating and a saw tooth profile is also optionally available.

2. Rollers with 144 teeth: This standard equipment is well suited to cutting lengths up to 20 mm – ideal for almost all conditions. The rollers are optionally also available with chrome-plating and a saw tooth profile. The rollers can be used in conjunction with any 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 friction surface 2.3 times larger than the standard conditioner.

This allows an even higher throughput with optimum conditioning of the grain. The disc rollers operate at the same speed, however a differential speed occurs automatically on account of the disc shape on the circumference.

5

1.

2.

3.

108

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

BiG X Service Training 2014 Basic

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8. Corn Conditioner: Roller Conditioner Settings 2

3

A

4 1

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

In doing so, the joystick (3) must be 12 mm in front of its mechanical stop (A) (housing). The minimum gap (X) of the rollers should now be 0.5 mm (if required adjust). The two hexagonal nuts (4) are the mechanical safety stop to prevent the rollers coming into contact with one another in the event of incorrect calibration. When the spring tension has been set again (dimension Y=93 mm) and the hexagonal nuts (4) have been tightened, the minimum gap must be checked again (if required, re-adjust). When the default setting has been made, the display must be calibrated in the terminal (see chapter Calibration).

Y X Gap (X) for mechanical limit = 0.5 mm Dimension Y = 93 mm WHB_3.4.2 Basic adjustment cc_EN

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8. Corn Conditioner: Roller Conditioner Settings Corn Conditioner Motor for Adjusting the Gap The Dunker electric motor (1) replaces the Valeo engine (2) and has been fitted as standard since year of manufacture 2008. The motor type is specified by a parameter setting and may have to be adjusted if the motor is replaced.

3

Parameter 33607 (Service): 0

Parameter 33607 (Service): 1

2

1

Valeo engine

110

Dunker engine

Type of engine

Corn conditioner variant

Wedge (3)

Impulse 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, stronger springs

20 029 728 0

39

Dunker

Roller conditioner, stronger springs

20 029 728 0

69

Dunker

Disc conditioner

20 029 201 0

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8. Corn Conditioner: Disc Conditioner Settings General aspects:

On account 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 corn conditioner housing.

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

4

Y

Disc Roller

A

2 3

The disc rollers consist of individual segments (S) which can be replaced if required. The connection to the shaft is made by a fit-in 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. If all disc segments have to be replaced, the housing, the shafts, etc. can still be used. When installing the discs, ensure that the direction of rotation is correct!

X= 3 mm

R Direction of rotation (identical for all discs!)

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S

F

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8. Corn Conditioner: Disc Roller Design/Settings Assembly/Corn Conditioner Setting 1. Installing the adjustable shaft

The adjustable disc shaft must be completely installed, i.e. the shaft with the pre-assembled bearing housings (1) is attached to the housing via the pivot bolts (2). The couplings (8) must also be installed, however without a spring for the time being.

1

8 7

2. Installing the fixed shaft

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

Y

3. Axial alignment of the fixed shaft

The fixed shaft can be moved in the oblong holes. This is required to set an equal distance between the disc elements. Then the screws on the fixed bearing side must be fully tightened.

4. Aligning the floating bearings on the fixed shaft

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

A 4 95 ±2 mm

2 6

5

5. Parallel alignment of the disc shafts to each other

The distance between the rollers must be set the same as for the roller conditioner using the adjusting joysticks (5), the couplings (6) and the wedge (7). In doing so, set the distance between adjusting joystick (5) and housing to 15 mm at point A. The distance between the rollers must be 3 mm at the tip. The spring dimension Y must be 92 mm (just spring length).

6. Setting the mechanical minimum distance

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

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8. Corn Conditioner: Design of Bearing for Roller and Disc Cond.

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Corn Conditioner Bearing on left (Fixed Bearing)

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12

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Corn Conditioner Bearing on right (Floating Bearing) 1. 00 911 691 0 Retaining ring 110x4

WHB_3.4.1.1 renew cracker bearing_EN

1. 00 911 691 0 Retaining ring 110x4 2. 00 910 716 0 Support washer 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 washer 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 - on left 11. 00 911 686 0 Retaining ring I 100x3 12. 00 936 019 1 Shaft sealing ring BA 70x100x10 13. 00 910 746 0 Support washer S 80x100x3.5

9

2. 00 910 716 0 Support washer S 90x110x3.5 3. 00 910 851 1 Shim ring 90x110x0.1

11

10

9

6

4. 00 937 577 0 O-ring seal 110x3

5. 00 223 464 1 Ring rd. 120x23 6. 00 936 058 0 Shaft sealing ring B2 SL 80x10/12

7

7. 00 931 914 0 Bearing 22212 ES 8. 00 219 433 3 Bearing housing - on right 9. 00 911 686 0 Retaining ring I 100x3 11. 00 910 746 0 Support washer S 80x100x3.5

12

12. 00 226 462 3 Roller

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2

8

00 910 849 0 Shim ring 90x110x0.5

10. 00 936 019 1 Shaft sealing ring BA 70x100x10

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1

8. Corn Conditioner: Fitting the Corn Conditioner Conversion Corn Conditioner – Grass Chute In grass mode, the corn conditioner is removed and replaced by the grass chute (1). When removing the corn conditioner using the electric cable winch and deflection roller (3), the corn conditioner is placed on the trailer (2) supplied. Before removal, the cable must be disconnected from the adjusting motor and the central lubrication line. The procedure is detailed in the operating instructions.

6

2 5 BA_7.5.7 converting the grass channel grain conditioner_EN

3

1 4

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9. Discharge accelerator: Design Discharge Accelerator

4 2 F

1

The function of the discharge accelerator is to accelerate the crop from the corn conditioner or the cutting drum and convey it into the discharge chute.

The discharge accelerator has a diameter of 560 mm. At a speed of 2188 rpm, we obtain a theoretical crop flow rate of 64 m/s. The discharge accelerator is mounted on pendulum roller bearings. The rear wall is springmounted and 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 1.

2.

20 020 240 0 – Discharge scoop serrated on left 20 023 196 0 – Discharge scoop smooth "X-treme" 20 020 241 0 – Discharge scoop serrated on right 20 023 195 0 – Discharge scoop smooth on right "X-treme" 115

x 2. x 2. x 2. x 2.

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9. 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 on left (Fixed Bearing)

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

Discharge Accelerator Bearing on right (Floating Bearing)

14 13 12 11 10 9

8

7

6

5

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

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3

2

1

9. Discharge accelerator:

BiG X 500 - 1000

Setting the rear wall for VariStream until year of manufacture 2010

А

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

X

Dimension (X): Grass: 4-5 mm, corn: 2-4 mm Rear wall pivot on top above the 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

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

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

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

This crop flow variant can be recognized by the fact that there are NO quick release fasteners on the rear wall for locking.

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9. Discharge accelerator:

BiG X 700/850/1100

Setting the rear wall for VariStream from year of manufacture 2011 -> Grass mode 1. Adjust rear wall on top via the rubber pads until there is a jump edge of 15 mm between the rear wall and duct connection.

2. Set the gap between the rear wall and the discharge scoops to 2 mm using stop screws on the grass channel.

3. Set tension rods of the springs until there is a maximum spring travel of 10 mm to 12 mm above the step in the tension rod. As a result, there should be no stacking edge even when the rear wall has completely rebounded.

4. To exclude faults, once again manually pull back the rear wall all the way and ensure that there is no stacking edge.

Duct connection

approx. 15 mm Rubber pad

Adjusting screw grass channel

10 mm

Rear wall

This crop flow variant can be recognized by the quick release fasteners on the side of the rear wall of the discharge accelerator.

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8. Discharge accelerator:

BiG X 700/850/1100

Setting the rear wall for VariStream from year of manufacture 2011 -> Corn mode

60 mm

Adjusting screw corn conditioner

1. Using the adjusting screw on the corn conditioner, set a gap of 60 mm between the corn conditioner screw flap and discharge accelerator housing.

2. Set the gap between the rear wall and the discharge scoops to 2 mm using rubber pads.

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

4. To exclude faults, once again manually pull back the rear wall all the way and ensure that there is no stacking edge.

5. If the pivot below on one side does not grip fully in the claw of the rear wall, the corn conditioner on that side must be pulled in until the bolt is rests fully in the claw.

Duct connection

Rubber pad

10 mm

Rear wall

This crop flow variant can be recognized by the quick release fasteners on the side of the rear wall of the discharge accelerator.

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

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SI_150371189-adjustment crop flow_EN

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9. Discharge Accelerator/Discharge: Rotating the Discharge Chute

The discharge chute can be rotated through (1) 210° by the hydraulic motor. The speed sensor in the gearbox indicates the position of the discharge chute. Two 'Namur' sensors monitor the central position and top/bottom position of the discharge chute.

Automatic function of the discharge chute: - Shut down drive at end position - Reverse discharge chute - Automatically lower discharge chute into Transport position

9

X

8

7

6

5

3

Tower, Start-Up Safety Mechanism

2

5

1

6 3

Start-Up Safety Mechanism

8

The discharge chute is fitted with a start-up safety mechanism. The spring package holder (3) is connected to the bearing ring (2) by bolts (4). The spring mount (7) is attached by bolts (6) on the slewing ring (5). The disc spring package (8) pushes the cam (9) into the spring mount (7), so establishing a connection between the drive and the discharge chute. If the discharge chute encounters an obstacle, the spring-operated cam is pushed back and the connection is broken. The discharge chute is able to swing freely.

4

Adjustment dimension for start-up safety mechanism spring package (8): X = 70 +3 mm.

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9. Discharge Accelerator/Discharge: Discharge Chute Discharge Chute The discharge chute is fitted with interchangeable wear plates. To ensure even filling of the transportation trailer, the crop flow can be controlled by means of the ejector flap (1). The ejector flap (1) is moved by way of a hydraulic cylinder (2) from the cab. As from an EasyCollect working width of 7.5 meters, a discharge chute extension (3) should be fitted at position (4). On the EasyCollect 1053, a hydraulically folding discharge chute extension (5) is fitted as standard. In grass mode, the extensions should be removed.

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4

2

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10. Engine: Overview Mercedes Overview of Engines All BiG X machines are fitted with Mercedes-Benz diesel engines: ОМ 460 LA

BiG X 500 x 1

ОМ 502 LA

BiG X 650 x 1

ОМ 5 0 2 L A 1 2 3 4 5 1.

2.

3.

OM – oil engine 4 ; 5; 9 –- series Series 500: Series 900:

4.

5.

1 - 6-cylinder V–engine 2 - 8-cylinder V–engine 4 - 4-cylinder in-line engine 6 - 6-cylinder in-line engine

L – charge air cooling A – exhaust turbocharger

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10. Engine: Overview MAN Overview of Engines

The new BiG X machines are fitted with the following MAN engines: D 2868 LE 121

BiG X 600 BiG X 700

D 2862 LE 121

BiG X 850 BiG X 1100 D 2 8 6 2 L E 121 1. 2. 3. 4. 5. 6.

1.

2.

3.

4.

5.

6.

D-diesel engine 28- cylinder diameter 128 mm 6- cylinder stroke 160 mm 2- cylinder number L- supercharging with charge air cooling E- built-in engine

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10. Engine: Fuel Filter Overview MAN Engines Fuel Delivery MAN Engines 1.

2.

3.

4.

5.

6.

4

Prefilter of hand pump Prefilter with water separator Prefilter of hand pump (this vents the system) Main fuel filter (only for V 12 engines) Main fuel filter Electric fuel pumps

5

2

4

3

5 2

Caution:

3

When removing the filter ensure absolutely clean working.

Even the smallest particles (0.02 mm) may cause the failing of the common rail injection system.

6 1

1

6

Fuel schematic BiG X with MAN V12 engine. V 8 engines have one high-pressure pump and one main filter less.

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10. Engine: Cooling System Engine Cooling The cooler package (1) is located in front of the engine as viewed from the direction of travel. Cold air is drawn in behind the cab from above through the cooler package and discharged to the rear with the heat of the engine.

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

The suction blower (3) cleans the screen and blows residual dust out of the air filter cartridges. It is driven by means of the main belt.

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3

1

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10. Engine: Cooling System 500/650 Cooler Package

To ensure ease of maintenance, all radiators are arranged on one level.

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

BIG X 500

BIG X 650

Oil cooler Coolant cooler Charge air cooler

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Oil cooler Charge air cooler Coolant cooler

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10. Engine: Cooling System 700/850/1100 Cooler Package

To ensure ease of maintenance, all radiators are arranged on one level.

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

Big X 600/700

Big X 850, 1100 Oil cooler Charge air cooler

Direction of travel Coolant cooler

Oil cooler Charge air cooler

Coolant cooler

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Gearbox oil cooler The BiG X 600-1100 is fitted as standard with gearbox oil cooling for the power take-off gear.

The gearbox oil is cooled by a curved pipeline in front of the cooler package.

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10. Engine: Fuel Tank Main Tank

The main tank (1) is positioned in the center, low down in the frame to ensure a low center of gravity.

BiG X 600/650 = 960 l BiG X 700/850/1100 = 960 l

1

2

Auxiliary Tank The auxiliary tank (2) is fitted behind the rear axle, and can be used either as a fuel tank or a silage tank. The tank capacity depends on the model: BiG X 500 = 250 l BiG X 600 = 330 l BiG X 650 = 330 l BiG X 700 = 330 l BiG X 850 = 330 l BiG X 1100 = 330 l The fill level of the auxiliary tank (2) is displayed on the basic screen (4) The options on the menu (5) can be used to configure the auxiliary tank usage and to activate and deactivate the fill level display.

The menu (5) is opened by pressing button (C).

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11. Chassis: Wheel Motors Poclain Travelling Gear Front axle BiG X 500

BiG X 650 3-stage wheel motors optional

Rear axle

3,494 cm³ (1C) 1,747 cm³ (2C)

1,536 cm³

4,250 cm³ (1C)

2,099 cm³ (1C)

1,500 cm³ (2C)

1,049 cm³ (2C)

4,333 cm³ (1C)

2,099 cm³ (1C)

2,833 cm³ (2C)

1,049 cm³ (2C)

1,500 cm³ (3C)

Front axle

Wheel Motors

Changeover

The machine is driven by four radial-piston wheel motors. The intake volume of the wheel motors is varied depending on the speed, as shown in the table.

1C = full intake volume -> high torque, low speed 3C = minimum intake volume -> low torque, high speed

BiG X 700 3-stage wheel motors optional

4,250 cm³ (1C)

2,099 cm³ (1C)

1,500 cm³ (2C)

1,049 cm³ (2C)

4,333 cm³ (1C)

2,099 cm³ (1C)

2,833 cm³ (2C)

1,049 cm³ (2C)

1,500 cm³ (3C) BiG X 850 BiG X 1100

5,133 cm³ (1C)

2,808 cm³ (1C)

3,300 cm³ (2C)

1,404 cm³ (2C)

1,833 cm³ (3C)

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Rear axle

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11. Chassis: Hydraulic Motors and Bosch Wheel Gearbox Combination of Hydraulic Motors + Wheel Hub Gearboxes

The BiG X forage harvester is driven via 4 axial piston motors with an adjustable intake volume, in connection with a wheel hub gearbox.

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

On all wheel hub gearboxes, the hydraulic motors (4) are inserted and flange-mounted in the fixed part of the wheel hub gearbox in position (3).

The wheel hub gearboxes have separate oil lubrication.

2

3

3

1 4 Hydraulic motors BiG X 600, 700, 850, 1100 with Bosch travelling gear

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Gearbox

Front axle (Axial piston adjusting motor)

Rear axle (Diagonal axis adjusting motor)

V max = 115 cm³

V max = 62 cm³

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Front axle

Rear axle

GFT 0040

GFT 0013

i = 35.9

i = 37.6

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11. Chassis: Tires Tires A range of different tires are available for the BiG X models.

When selecting tires, it is essential to comply with the applicable licensing regulations.

Also, when wheels are exchanged, the relevant drive control parameter set must be adapted! For further information, contact the KRONE Service department.

Tires

/ BiG X 600

Front axle

Rear axle

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11. Chassis:

Rear Axle Suspension Rear Axle Suspension

The rear axle suspension is provided by a hydraulic cylinder (1) in connection with a hydraulic accumulator (2). The pressure in this closed system can be read from the pressure gauge (3). The system is charged via a Minimess connection (4). The hand pump is used to adjust the chassis to the dimension a of 3-4 cm between the frame (5) and axle (6).

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

3 2

1

4

The travelling gear design featuring wheel motors means that a wide steering angle of 53° is possible. This allows a very tight turning circle.

5 a

Machine Maneuverability

6

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12. System Technology Calibration: Pendulum Frame Calibrating Pendulum Frame Sensor

The pendulum frame sensor (1) must always be calibrated after repair or maintenance work on the pendulum frame. Even if the sensor or the job computer KMC3 has been replaced or removed.

General Information for Calibration of Pendulum Frame The following conditions must be met for calibration of the pendulum frame: - Release switch (2) road/field in field mode - Travelling gear release switch (3) off.

It is recommended to mount the header (EC, EF, X-Disc) on the machine so that the pendulum frame can be aligned exactly horizontally.

1 Using the buttons (4), the header can be aligned horizontally by hydraulics if the hydraulic cylinder (corn) is attached to the pendulum frame.

2 On

4

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1 Calibration only required for BiG X 500, 650-I, 800 and 1000.

Parameter 33634 = 0 (Elobau angle sensor)

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12. System Technology Calibration: Pendulum Frame

V 1

2 Calibrating the Pendulum Frame Sensor

3 D

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

When the pendulum frame is in a horizontal position, the value (1) of sensor B52 must move between 350 - 450. If required, re-align the sensor in the oblong holes.

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, indicated value as a horizontal position.

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

W

S

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12. System Technology Calibration: Pendulum Frame Intake BiG X 700, 700-I, 850, 850-I, 1100, 1100-I B87 Pendulum Frame Position at Top Left, B88 Pendulum Frame Position at Top Right (on left/right always in direction of travel) If both sensors are not alive, the pendulum frame is in the horizontal position.

If a sensor is alive by a movement of the pendulum frame, this means: B87 alive = pendulum frame + header higher on left B88 alive = pendulum frame + header higher on right As the sensors are in a fixed position in the intake 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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12. System Technology Calibration: Lifting Unit P

Sensors of the Lifting Unit

The lifting unit must be adjusted once before commissioning for the respective header or after replacement of 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.

K

Installing the Angle Sensors (V)

When installing the angle sensors (V), ensure that the notch (K) faces the plug (S). The pin (P) in the axle must face the other side.

2

1

α P

1

α

3 d

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

1.

2.

3.

d

S

2 3

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V

12. System Technology Calibration: Lifting Unit 2

1

α

Default Setting of the Lifting Unit Sensors

3

α

P

1.

2.

3.

d

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

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

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

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

W

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

- Pick Up, corn attachment or X-Disc must be attached. In the menu "General Machine Settings" of the terminal an appropriate header must be set, as the lifting unit must be calibrated for each operating mode (EasyCollect, Pick up, X-Disc) to take the different header weights into consideration.

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

- Align the header horizontally.

1

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12. 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 unit 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

Adjusting Procedure 1

В50

α

139

В47 В48

В49 P

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

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

Simultaneously hold down button (1) and button (N) for approx. 7 s until the message "EMR Adjustment 1 OK" appears in the terminal.

α d

d

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12. System Technology Calibration: Lifting Unit Checking the Calibration of the Lifting Unit

The diagnostics and the associated values from the sensors can be checked in the diagnostics menu. Firstly, the current values (I) are displayed here and secondly, the saved values for the corresponding positions (II).

At sensor B49, the value is stored in the central position during calibration (adjusting procedure 2). The values of sensors B 47, B 48 and B 50 are stored at the highest and lowest positions during calibration (adjusting procedure 1 and 3). The corresponding adjacent symbol indicates how the values are assigned to the relevant position.

I II

Menu 4-1-5

Checking the Calibration of the Pressure Sensor

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

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12. 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 - Travelling gear release switch (2) off - Header is attached and is horizontal. The corresponding operating mode in the terminal has been set.

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

1 On

2 Off

Calibrating the Upper Lifting Unit Height

Raise lifting unit until the value of the current lifting height is (3) 80%.

- If there is a pick-up, measure the distance between the ground and the lowest point of a spring tine - If there is a corn header or direct cutting system, measure the distance between the ground and the cutter blade Using the rotary potentiometer, select the field (4) "Height of the Lifting Unit at 80%" and enter the determined dimension.

4

3

5

Calibrating the Lower Lifting Unit Height

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

- Determine values as above Using the rotary potentiometer, select the field (5) "Height of the Lifting Unit at 20%" and enter the determined dimension.

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

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12. System Technology Calibration: Autopilot Calibrating the Autopilot Sensors

Starting with the complete software version 200814616, two different autopilots are available if the machine is suitably equipped. On the one hand, there is the autopilot, which operates using the mechanical row tracer. On the other hand, there is the option of using a GPS-based system that operates using a standardized ISOBUS interface. However, this is only possible if a corresponding system (Trimble, Reichhardt, Topcon or Autofarm) is installed on the machine.

The choice between the two systems is made in the machine settings menu.

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

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

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

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12. System Technology Calibration: Autopilot Calibrating the Autopilot Sensors

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

1 On

3

2 P K

On General Information on the Calibration of the Autopilot Sensors The following conditions must be met: - Engine is running - Release switch (1) Road/Field in field mode - Travelling gear 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

On

4

5

S Installing Autopilot Sensors

When installing the angle sensors (4) В65 and В61 for the row tracers, ensure that the notch (K) faces the plug (S). The pin (P) in the axle must face the other side.

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

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12. System Technology Calibration: Autopilot L 1

R

2

R

L

Calibrating the Autopilot Sensors

On the terminal, open the "Maintenance/Calibration/Autopilot" 3-4 menu.

Calibrating the row tracers on left (L) B65 and right (R) B61:

Both row tracers (on left and right) are calibrated once in their basic position without being activated.

The actual value (1) of the sensor (L) В65 must be within the range 265 ± 50; if required, re-adjust sensor mechanically in the oblong holes. Activate the row tracer as far as the limit obstruction. The current sensor value must show a difference with respect to the zero position of 300 – 320 (Important: When activated, the value must be larger!).

Select 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 the sensor (L) В61 must be within the range 590 ± 50; if required, re-adjust sensor mechanically in the oblong holes. Activate the sensor as far as the limit obstruction. The current sensor value must show a difference with respect to the zero position of 300 – 320 (Important: When activated, the value must be smaller!).

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

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12. System Technology Calibration: Autopilot Calibrating the Flexible Row Tracers The rest position must be calibrated for the flexible row tracers. To do this, drive the machine on a level surface and make sure that the row tracers can swing freely.

In the calibration screen 3-4, both sensor values B66 must have a value of 50 +/- 10 at the zero position. This value must then be stored in the same way as the mechanical row tracers.

Once the sensor has been in use for approx. 100 ha, the calibration must be performed again.

The following values are derived based on the used condition: B66 (row registration left) = 50-120 B66 (row registration right) = 50-120 If one of the sensor values in the zero position is greater than 120 or less than 40, the plastic paddle may be faulty and must be replaced.

For control: If the sensor is fully activated, the following values result: B66 (row registration left) = 450 +/-10 B66 (row registration right) = 450 +/-10

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

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

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12. 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 less than 220; if required adjust sensor or coupling rod and start calibration process from the beginning.

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

- Turn the steering wheel all the way to the right. The actual value (1) must not be greater than 630; if required adjust sensor or coupling rod and start calibration process from the beginning.

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

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12. System Technology Calibration: Autopilot Calibrating the Minimum Currents of the Steering Valves Y39 and Y40

Move steering axle to straight-ahead driving. The machine must be standing on an even asphalt surface. The calibration specifies the minimum and maximum power consumption on the electromagnetic valves Y39 and Y40 .

As of terminal software version 150 200 104 – 08, the minimum valve currents on left/right can be calibrated automatically. 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 independently to the left and right limit obstruction.

А 1

2

4 3

F

1.

2.

3.

4.

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

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

Calibration of the valves Y39 and Y40 Calibration run successfully and values are saved Stop calibration 147

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12. System Technology Calibration: Autopilot Calibration of the Turning Circle

For the GPS-based ISOBUS autopilot systems, the average turning circle when steering to the left and right must be calibrated.

To do this, you must drive the machine slowly in a circle on solid ground with the steering fully locked. You must then measure the diameter of the inside of the turning circle. Then add the width of the machine to this value. The result is the average turning circle diameter. You must then enter the turning circle diameter determined in this way into the corresponding field (A).

This operation must be carried out separately for each side.

А

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12. System Technology Calibration: Discharge Chute Discharge Chute Sensors

The discharge chute must be calibrated if e.g. the end position is not reached or changes (of an electronic, mechanical, hydraulic type) were made to the system.

Default Setting of the Discharge Chute Sensors

The sensor В30 (1) counts pulses in the gearbox of the discharge chute while it turns. The sensor (1) is screwed with the copper ring all the way into the gearbox housing at a torque of 10 Nm. The sensor В29 (2) monitors the position of the discharge chute up/down. When the discharge chute is raised, the sensor B29 detects metal and the DC is shown as raised on the calibration screen.

The sensor В28 (3) monitors the central position of the discharge chute. If the discharge chute is turned, metal is detected by the sensor B28 when the central position is overrun.

This point is used as a starting point for counting pulses to the right and left.

1

2

N

M

M

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

- Tighten hexagonal nuts (M) to a torque of 10 Nm.

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12. System Technology Calibration: Discharge Chute 1

M

E

On

2

Off Calibrating the Discharge Chute

Calibration of the discharge chute specifies the "electronic" limit obstructions (E) for the machine to prevent the discharge chute from becoming unbraked via the joystick until the mechanical stops (M) can be approached. This would eventually damage the components in the rotating drive. The calibration specifies the maximum distance the discharge chute can be turned to the right or left side using the joystick. Due to a non-symmetrical arrangement of the relevant components, the "electronic" end positions on the right and left may deviate from each other. It is therefore necessary to calibrate both sides separately. The determined values do not have to be the same! Parameter settings specify from which distance, e.g. to the calibrated end position or to the central position, the discharge chute reduces its rotation speed (see section Parameters).

General Information on Calibrating the Discharge Chute In order to be able to calibrate the upper discharge chute, the following conditions have to be fulfilled: - Engine is running - Release switch (1) road/field in field mode - Release switch (2) maintenance off - The driver sits on the driver's seat and the discharge chute must be raised

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12. System Technology Calibration: Discharge Chute 1 2 3 5

4 6

1.

2.

3.

4.

5.

6.

In the terminal, open the "Maintenance/Calibration/Discharge chute" 3-5 menu.

Current discharge chute position up/down Current discharge chute 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 discharge chute (on left or right) The saved number of max. pulses for left (electronic maximum on left) The saved number of max. pulses for right (electronic maximum on right)

Buttons (А) and (С): Saving the currently counted pulses as an electronic maximum on left and right Buttons (B) and (D): Manual actuation of the discharge chute to the left and right

Calibrating the Electronic Stops on the Discharge Chute

Move the discharge chute all the way to the left by pressing the button (L) on the joystick. The discharge chute stops when the max. number of pulses for this side has been reached.

By pressing the button (B), the discharge chute can continue turning at minimum current. Hold down button until the discharge chute is just in front of the mechanical limit obstruction (ensure that the obstruction is still not touched!).

Save this position by pressing the button (A). The new electronic maximum to the left is therefore set.

Move the discharge chute all the way to the right by pressing the button (R) on the joystick. The discharge chute stops when the max. number of pulses for this side has been reached. By pressing the button (D), the discharge chute can continue turning at minimum current. Hold down button until the discharge chute is just in front of the mechanical limit obstruction (ensure that the obstruction is still not touched!).

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

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L

R

12. System Technology Calibration: Discharge Chute Calibrating the flows from the valve for turning the discharge chute The flows for the valves that rotate (Y20 and Y21) the discharge chute are automatically calibrated. Each time the machine is restarted, the flows are calibrated once. This takes place automatically the first time the discharge chute is reversed in the corresponding direction.

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

However, complete software versions 20 081 461 7 and higher provide the parameters "Rotate discharge chute left factor Imin" (25228) and "Rotate discharge chute right factor Imin" (25229). With these two parameters, you can increase or reduce activation of the discharge chute if necessary. This means that you can adjust the speed of rotation for the respective direction.

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

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12. System Technology Calibration: Corn Conditioner 1

Calibrating the Corn Conditioner The calibration should be run when you re-install the corn conditioner or if the actual value of the roller spacing deviates markedly from the setpoint value.

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

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

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

On

General Information on Calibrating the Corn Conditioner The following conditions must be met to perform the calibration: - Release switch (1) road/field in field mode - Corn conditioner installed.

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12. System Technology Calibration: Corn Conditioner 1 S

3

4 F

2

Calibrating the Corn Conditioner (Roller Conditioner)

Before you commence the calibration, you must use parameters to set the corresponding type for adjusting the corn conditioner. (see description of corn conditioner adjustment layout) On the terminal, open the "Maintenance/Corn Conditioner Calibration" 3-6 menu.

To ensure a precise calibration, it is necessary to measure the exact distance between the rollers (1) and (2) using a sensor 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 color. 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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12. System Technology Calibration: Corn Conditioner 3

1

4 X

S

2

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

On the terminal, open the "Maintenance/Corn Conditioner Calibration" 3-6 menu.

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.

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

Select the field (S) with the rotary potentiometer. The input field is highlighted in color. 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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12. System Technology Calibration: Header Drive Calibrating the Header

The header should only be calibrated if the actual speed deviates markedly from the setpoint speed or after replacement of the KMC2 job computer. The calibration must also be run after working on components of the header drive (pump or hydraulic motor).

Even if overspeeding (n > 750 rpm) has been detected, recalibration is required.

2

1 On

On

4

3 Off

General Information on Calibrating the Header The following conditions must be met to calibrate the intake/header: - Release switch (1) road/field in field mode - Intake/header release switch (2) on - Diesel engine speed: 2,000 rpm (BiG X 650), 1,900 rpm (BiG X 600/700/800/850/1000/1100) - Maintenance release switch (3) off - Travelling gear switch (4) off - The intake is not turning - The header is not turning - The driver must be sitting on the driver's seat - In the case of BiG X 700/850/1100 the main coupling must be switched on!

Calibrate intake / header only when oil is warm!

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12. System Technology Calibration: Header Drive Calibrating the Intake

The intake should always be calibrated if the actual cutting length differs from the displayed cutting length. Calibration is also necessary if the KMC2 job computer has been replaced or after work on components of the intake (pump or hydraulic motor).

1 On

2 On

4

3 Off

Mode of Operation for Activating the Intake From the complete software version 20 081 461 6, the speed of the header is actively regulated in operation. This means that the chop length is always maintained at the value set by the driver irrespective of the pressure and other outside interferences. In this case, overloading the diesel engine is taken into account. If the speed sensor for the header does not work, the system acts as a controller.

Active regulation can be activated using parameter 25507.

General Information on Calibrating the Header The following conditions must be met to calibrate the intake / header: - Header in working position!

- Release switch (1) road/field in field mode - Intake / header release switch (2) on - Diesel engine speed: 2,000 rpm (BiG X 650), 1,900 rpm (BiG X 600/700/800/850/1000/1100) - Maintenance release switch (3) off - Travelling gear switch (4) off - The intake is not turning - The header is not turning Calibrate intake / header only when oil is - The driver must be sitting on the driver's seat warm!

- In the case of BiG X 700/850/1100 the main coupling must be switched on!

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12. System Technology Calibration: Intake / Header 6 2

1

3

4 5

A

B

C

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

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

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

D

In the terminal, open the "Maintenance/Intake and Header Calibration" 3-7 menu.

Progress bar of the intake or header calibration: 1. Progress bar of the intake calibration (support value 1 and support value 2) 2. Progress bar of the header calibration (support value 1 and support value 2) 3. Actual value 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 – starting current; Imin – current at minimum speed; Imax – current at maximum speed 6.

Speed of diesel engine Softkey button (A) and (C): Start the calibration of intake or header Softkey button (B) and (D) Stop the calibration of intake or header Softkey button (E): Automatic engine speed setting, 2,000 rpm (BiG X 500/650), 1,900 rpm (BiG X 700/800/850/1000/1100)

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12. System Technology Calibration: Intake Drive E 2

1

3

4 5 A

B

C

D

The button (E) can be used to increase the engine speed to the required speed.

Calibrating the Header

Press the button (C) to start the calibration process. The valve Y7 „Header in front" is actuated. The header should start turning after a short time. The calibration process lasts up to 120 seconds. If the necessary data cannot be determined during this time, the calibration process is interrupted. Press the button (D) to end the calibration process. The progress bars can be used to track the current state of the programming.

Calibrating the Intake

Press the button (A) to start the calibration process. The valve Y5 „Intake in front" is actuated. The intake should start turning after a short time. The calibration process lasts up to 120 seconds. If the necessary data cannot be determined during this time, the calibration process is interrupted. Press the button (B) to end the calibration process. The progress bars can be used to track the current state of the programming.

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12. System Technology Calibration: Rock Protect Calibrating Rock Protect

The calibration of the Rock Protect determines the value of the signal voltage of the acceleration sensor В76 at rest.

The Rock Protect should be calibrated before it is used for the first time or after replacement of components relevant for the system.

In the terminal open the "Maintenance/Calibration/Rock Protect" 3-9 menu.

Before starting the calibration, ensure that the header is in the harvest position. In addition, the intake must be free from crop and the precompression rollers must rest against the bottom limit stop. The intake may not be switched on. Press the button (A) under the softkey to start the calibration. The calibration runs fully automatically.

1 2 A 1. Current value of the signal voltage of the sensor В76 2. Stored value of the signal voltage of the sensor В76 А - Start calibration of Rock Protect

The system sensitivity can be set in the menu of the terminal "Settings/Parameters/Rock Protect" 1-1-21. Ex works the value is set to 50. As the value increases, the system becomes more sensitive and therefore reacts to smaller stones.

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12. System Technology Calibration: Main Coupling 1

Calibrating the Main Coupling

As of terminal software version 150 200 104-08 the valve current can be calibrated for the main coupling. The switching behavior is affected in this way.

The calibration should be run for hard switching of the main drive, after repairs or replacement of system components or after replacement of the KMC 3 job computer.

On

2

3 Off

General Information on the Calibration of the Main Coupling To calibrate the main coupling, the following conditions must be fulfilled: - Engine is running - Release switch (1) road/field in field mode - Release switch (2) travelling gear off - Release switch (3) maintenance off - The driver must be sitting on the driver's seat and the door must be closed

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Off

12. System Technology Calibration: Main Coupling 3 1 2

1.

5

6

2.

3.

5.

6.

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

Calibrating the Main Coupling In the terminal open the "Maintenance/Main Coupling Calibration" 3-10 menu.

Press the button (5) to start the calibration which runs fully automatically. If no speed is detected on the cutting drum, the automatic calibration process is stopped at 1400 mA. If the calibration process is successful, a green tick appears.

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12. System Technology Calibration: Bosch Travelling Gear Calibration of the Bosch Travelling Gear

Installation and production tolerances as well as component fluctuations ensure that the values of sensors differ slightly in defined positions and that actuators (valves) have a slightly different behavior. It is therefore necessary to save these component-specific properties once in the control unit and after each relevant change in the system. The following components are therefore calibrated for the Bosch travelling gear:

1

• Angle sensor brake pedal B109 (1) - Signal current when brake pedal not depressed (0 bar) - Signal current when brake pedal fully depressed (80 bar) • Steering angle sensor B107 (2) - Setting the sensor for straight-ahead driving (5.0 +/-0.1 V)

2

3 - Pivoting angle sensor B108 (3) - Setting the sensor when pump is in the central position (2.50 +/-0.02 V) - Saving the difference from the setpoint value (offset) - Maximum values of the sensor at full intake volume - Proportional valves pump Y101 + Y102 (4) + (5) - Minimum current (respond threshold) - Maximum current (end of the control range) - Proportional valves drive motors Y103, Y104, Y105, Y106 (e.g. (6)) - Maximum current (respond threshold) - Minimum current (end of the control range) 163

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4 5

6 © KRONE Training Team, Spelle, Germany

12. System Technology Calibration: Crop Control 1

2

4

3 9

5

8

1 2, 3, 4 5 6 7 8 9

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

6 7

B73

B72 Crop Control control unit 164

Inductive path recorder on the intake

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Pressure sensor in the intake

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12. System Technology Calibration: Crop Control Calibrating Path Recorder B 72: Before starting up the machine for the first time and after any assembly work on the path recorder, the path recorder must be calibrated. Ensure that no crops are in the intake and that the upper pre-compression 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 the excursion of the pre-compression rollers from which the measurement starts. The higher the minimum excursion setting, the more crops must flow through the rollers to activate the yield counter.

Guide value for minimum excursion: 5 mm, to be set by pressing 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 the minimum excursion

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12. System Technology Calibration: Crop Control The pressure sensor must be calibrated before starting up the machine for the first time, after any assembly work and weekly during operation. For this, it must be ensured that no crops are in the intake and that the pre-compression rollers have been moved to the bottom limit stop.

Calibrating Pressure Sensor B 73:

The following conditions must be met for calibration: • Cutting drum switched on • Feed drive switched on • Engine at working speed (~2,000 rpm)

1

2

• Feed drive must be in the working position (-> not too high)

3

U Menu level 1 - 2 Calibrating pressure sensor

A

O

• Chop length set to smallest possible value (depending on number of cutting blades) (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 "Calibrating" symbol is displayed inversely. An arrow appears under the left hatched area. The chop length must now be increased until the black bar is in the hatched area. After a short time the value is placed in the temporary storage (~40-70 bar) and the arrow symbol jumps under the right hatched area.

2. Calibrating the drive pressure for the upper intake speed:

After the arrow symbol is to be detected under the right hatched area, the chop length must be increased further 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 "Calibrating" symbol is no longer displayed inversely.

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

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13. Settings: Machine Settings Pick up Easy Flow:

When using Easy Flow, select the lifting unit ground pressure control (Р) in the "General machine settings" menu.

Setpoint value (А) for operation with the Easy Flow should be within the range 20-30 % according to operating conditions.

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

Recommendation: 400 - 420 rpm as a basic speed.

P

Direct cutting system X-Disc:

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 unit position mode (α).

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

U А 167

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13. Settings: Machine Settings EasyCollect corn attachment:

When using EasyCollect without sensing skids, select lifting unit position control (α) in the "General machine settings" menu.

α

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

d

168

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

Recommendation: 380 - 420 rpm as a basic speed.

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13. Settings: Joystick Driving joystick - Memory - Buttons: The buttons M1 and M2 on the joystick can be freely configured as of complete software version 200814613.

When delivered, the buttons M1 and M2 on the joystick have not been assigned any functions.

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

M1

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

M2

- Increase/reduce working width ± - Retrieve saved cutting lengths (from the small cross switch joystick) 1 or 2

1/2 - Increase/reduce header speed ± - Turn pendulum frame left/right

If buttons M1/M2 have already been assigned functions, the illustrated settings mask appears whenever the machine is started.

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

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13. Settings: AutoScan

(as standard)

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

3 10

7

8

9

Setting min./max. cutting length

2.

Graphic representation of the settings

3.

4.

"AutoScan setting" menu within the machine settings range

6.

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

Setting for degree of maturity sensor available/not available

7.

Current cutting length

AutoScan status

8.

Current position on the characteristic line within the working range

9.

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

10.

Max. cutting length set by the driver. The associated degree of maturity can be changed in AutoScan expert mode (DEF = 67%).

automatic adjustment of the cutting length active manual adjustment of the cutting length active 5.

4 5

6 1.

1

Activation of the automatic cutting length adjustment via button "D" 170

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13. Settings: 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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13. Settings: PowerSplit (optional) BiG X 700/850/1100 1.

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

2.

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

3.

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

4.

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

5.

Current performance mode

6.

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

Characteristic

: Abrupt change when speed is reached

Characteristic

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

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13. Settings: Constant Power (Optional) Constant Power – Load Limit Control

On the BiGX 1100, Constant Power can only be adjusted depending on the speed (1)

(optional)

The Constant Power load limit control controls the forward speed of the machine depending on the diesel engine load and provides constant machine load at a lower fuel consumption.

Software prerequisites for Constant Power: Terminal: min. 150 200 104-08 KMC3: min. 150 200 103-08 SmartDrive greater than A16939C (e.g. A22823H, A33789C.H86,) DRC all software versions Activation of Constant Power: Tilt joystick 2x to the right (only possible in Field mode)

1.

2.

4

1

2

5 6

3

Setting for speed reduction depends on the speed (button "1") e.g.: 10%  2,000 rpm – 10% = 1,800 rpm Setting for speed reduction depends on utilzation (button "2") e.g.: 80% 

3.

4.

5.

6.

173

Setting for the min./max. speed Constant Power controls forward speed only until min./max. limits are reached.

Actual engine speed Actual engine load Diesel engine nominal speed

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13. Settings: Rock Protect (Optional) RockProtect - Rock Detection (optional) Setting the sensitivity from 0-100 % by the driver. Due to different conditions (variable or irregular swath shape), it may be necessary to adjust the sensitivity several times a day. To ensure that the system functions optimally, the sensitivity must be adjusted to the given conditions. To do this, adjust parameter 27500 according to the graphic.

Sensitivity 100 %

0%

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13. Settings: Parameter Setting Parameter Press the Menu button (button next to the rotary potentiometer) to enter the menu level. Under settings 1  Parameter 1-1, you can enter the individual parameter settings 1-1-1 to 1-1-15. These are allocated into individual groups for a better overview.

1

1-1

1-1-1

Press the rotary potentiometer to enter the individual groups. Parameters belonging to the group are listed in the individual groups. The rotary potentiometer can be used to switch between the individual parameters.

Parameter_Service_ENBiG X 700_1100

Press the potentiometer again to adjust the top parameter highlighted in blue. The input screen indicates again the parameter number (A), the minimum (B) and maximum (C) setting, the factory default (D) and the recommended unit (E). The actual and setpoint values are indicated in the "Value" field. The setpoint value can be changed there via the rotary potentiometer or the corresponding softkeys and saved by pressing Enter (Softkey B) or by pressing the rotary potentiometer again.

A B C D E

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13. Settings: Dynamic Speed Adjustment Dynamic Speed Adjustment – SynchroSpeed The parameters for dynamic speed adjustment can be used to adjust the mode of operation. The parameter 25478 specifies in which operating mode the adjustment (dynamics) is active. The parameters 25476 and 25477 are used to set the start speed and the increase in the straight line (=aggressiveness).

25478 0 = Dyn. header speed adjustment deactivated 1 = Dyn. header speed adjustment activated for corn only 2 = Dyn. header speed adjustment activated for grass/X-Disc only

3 = Dyn. header speed adjustment activated for grass/X-Disc and corn

E.g.

Header speed set in the terminal nSetpoint = 400 RPM (is simultaneously minimum speed) In this example the header speed is increased accordingly from a travelling speed of 6 km/h.

25476

176

= 25477

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13. Settings: Hydraulic Functions Throttle Valves for Setting the Speed Raise DC flap Lower DC flap

Raise/lower discharge chute

Grinding cylinder off Grinding cylinder on

Throttle non-return valves (A): Setting of the pendulum frame speed to prevent the header from "rocking".

А 177

Setting: It should take 7s to manually swivel the pendulum frame from right to left.

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13. Settings: Blade/Counterblade General information on setting the cutting blades to the counterblade

Dull cutting blades and too great a distance between the cutting blade and the counterblade will result in an unnecessarily high requirement of force, poor chop quality and high wear and tear on the cutting elements.

Sharpening does not do any good unless the counterblade is readjusted as well.

As the corn cutters sharpen themselves very effectively, there is no need to "sharpen them until they shine" at every grinding interval. In corn mode, we recommend that you only adjust the counterblade several times a day between the grinding processes without having sharpened it beforehand. In doing so, the sharpness of the blades must be monitored continuously.

In the case of grass cutters, short grinding intervals with a brief grinding duration combined with readjusting the counterblades work better than long grinding intervals with long grinding times.

Work steps: 1. To relieve the machine, lower the attachment by pressing the button (1) until it is completely on the ground.

2. Move the maintenance release switch to the "on" position.

The maintenance menu appears on the Info Center display.

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

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

1

Readjusting the counterblade When 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" button and the "Move counterblade left to blade drum" button alternately and very lightly.

6. If there is a noise when readjusting one side (right/left) (cutters striking the counterblade!), release the button immediately and very briefly press the appropriate button "Move counterblade away from blade drum".

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.

8. Lift the header.

Depending on the attachment, the counterblade may have to be readjusted.

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14. Hydraulics: Charge Pressure/Low-Pressure Circuit Bosch Overview of Charge Pressure Circuit

6

5 4 3 7

1

2

(1) Charge pressure pump integrated in travelling gear pump (2) Main coupling valve (3) Clamping cylinder main belt (4) Valve for clamping cylinder main belt (5) Valve for grinding flap (6) Clamping cylinder belt for corn conditioner (7) Auxiliary function lifting unit 179

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14. Hydraulics: Charge Pressure/Low-Pressure Circuit Poclain Overview of Charge Pressure Circuit

4 6

1

3

7 5

Changeover

2

WHB_5.1 charge pressure_EN

8

WHB_5.1 changeover_EN

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

180

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

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

11

4

3 8

1 9

3

2 10

11

8

9

2

1

10

5

7 6 6 3

3

4

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!

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(1)

Receiving disc for pivoting angle potentiometer

(2)

Pivoting angle potentiometer

(3)

High-pressure limiting valves

(4)

Charge pressure limiting valves

(5)

Cold start valves

(6)

Gear-type pumps charge pressure

(7)

Cover feed pump

(8)

Adjustment unit

(9)

Switching magnets safety valves Y69 or Y70

(10) Proportional magnets pump control Y1 to Y4 (11) Gasket sets adjustment unit and pump flange Nominal pump size

Tightening torque for highpressure pressure limiting valve

Tightening torque for charge pressure pressure-limiting valve

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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14. Hydraulics: High-Pressure Circuit Poclain Travelling Gear 2

Overview 3

Changeover

4 5

1

WHB_5.1 high pressure transmission_EN

System control and monitoring by Smart Drive:

2

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

3 Axial piston variable displacement pumps travelling gear (Tandem unit: 105/75 ccm (BiG X 500/650/700) or 135/75 ccm (BiG X 800/850/1000/1100)) Wheel motor at front (with integrated drum brake) 2-stage (BIG X 500/650/700) or 3-stage (BIG X 650 (opt.) /700 (opt.) /800/850/1000/1100) Wheel motor at rear constant (BiG X 500) or 2-stage (BiG X 650/700/800/850/1000/1100) Combination valve (flush valves) High-pressure sensor (on front axle pump, sometimes connected to short hose) 182

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Outputs

14. Hydraulics: High-Pressure Circuit Poclain "Front Axle" Flush valves (1), hydraulically actuated  Oil is conveyed out of the return line to the cooling system. > 400 bar

1 M System control and monitoring by Smart Drive: Changeover

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

Outputs: Y1/Y2, Y3/Y4, Y69/Y70, …(see STLP) 183

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

M

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

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14. Hydraulics: High-Pressure Circuit Diagnostics Poclain Travelling Gear 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 travelling gear can be checked on the measurement connections M1 to M4.

WHB_5.1 high pressure transmission_EN

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 are not possible!

Removal of the valve plugs from the switching valves Y14/Y68 and Y11 facilitates reaching the maximum pressure.

The wheel motors operate in the small intake volume and therefore reach a correspondingly lower torque.

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14. Hydraulics:

Overview of Components for Bosch Travelling Gear

Location of the Components in the Machine

4

14

6

8

10

11

7 3b 5

2

6

13 12 6

14

3a 4

1b 15

12 13

1a

15 2

6

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Components

9

1a

Drive motor at front left

1b

Drive motor at front right

2

Planetary gearbox at front

3a

Drive motor at rear left

3b

Drive motor at rear right

4

Planetary gearbox at rear

5

Variable displacement pump

6

Speed sensor

7

High-pressure sensor B101

8

High-pressure sensor B102

9

"Forwards" valve

10

"Backwards" valve

11

Pivoting angle sensor

12

Feed valves

13

Drive motor valve at front

14

Drive motor valve at rear

15

Storage for feed

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14. Hydraulics: Bosch Function Description Function Sequences of Acceleration in Road and Field Mode 1. Acceleration forwards 0 - Vmax in road mode As soon as the driver has given the drive command via the driving joystick, the drive pump starts to swivel out. When the driver accelerates continuously, the drive pump then swivels continuously up to the maximum intake volume. Shortly before the pump has reached the maximum intake volume (approx. 8-9 km/h), the wheel motors start to reduce the intake volume. This results in a continuous, smooth acceleration from standstill up to the maximum speed of 40 km/h. The maximum speed backwards is limited to approx. 14 km/h.

2. Acceleration 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 speed backwards here is also approx. 14 km/h (electronically limited).

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14. Hydraulics: Bosch Function Description Function Sequences of Traction Control and Anti-Lock Braking System 3. Function of traction control (TC) The traction control prevents individual wheels from rotating uncontrollably if the traction forces on one wheel can no longer be transmitted due to the ground. This ensures even rotation of all wheels. A theoretical speed is calculated for each wheel depending on the speed of the other wheels and the steering angle. If the speed of one wheel is higher, the intake volume of the hydraulic motor on the corresponding wheel is reduced. This will occur until the torque on the wheel is so low due to the reducing intake volume that it is no longer adequate to turn the wheel. At the same time the pivoting angle of the pump is reduced to adjust the volumetric flow required for the current speed.

Animation TC

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14. Hydraulics: Description of Function Bosch Drive Concept Function Sequences in Drive Mode: Data Recording Sequence: The machine was accelerated from standstill to 40 km/h and then decelerated to a standstill via the driving joystick.

5000 4500 4000 3500 3000

Hochdruck MA [bar]

2500

Schwenkwinkel [mV]

Hochdruck MB [bar] Strom Pumpe vorwärts [mA]

2000

Drehzahl Radmotor vorne rechts [Hz] Strom Radmotor vorne rechts [mA]

1500

Strom Radmotor hinten rechts [mA]

1000 500 0

189

0

5000

10000

15000

20000

25000 30000 Time [ms]

35000

40000

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50000

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14. Hydraulics:

Component Overview for Bosch Travelling Gear

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

4

2

1b

6

3b 9

12

6

10

B101

7

5 11

12

8 B102

3a

1a

6

6

Components 1a

Drive motor at front left

3b

Drive motor at rear right

7

High-pressure sensor B 101

11

Pivoting angle sensor

1b

Drive motor at front right

4

Planetary gearbox at rear

8

High-pressure sensor B 102

12

Feed valves

2

Planetary gearbox at front

5

Variable displacement pump

9

"Forwards" solenoid valve

13

Storage for feed

3a

Drive motor at rear left

6

Speed sensor

10

"Backwards" solenoid valve

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14. Hydraulics: Component Overview of Bosch Drive Pump Components of Drive Pump

12

10

9

Components

8

11

7

13 1 14 3

2

191

4

5

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1

Drive shaft

2

Housing cover

3

Leakage oil connection

4

Charge pressure limiting valve

5

High-pressure limiting valve

6

Suction connection

7

High-pressure limiting valve

8

Valves for pump adjustment

9

Measurement connection for setting pressure X2

10

Measurement connection for setting pressure X1

11

Mech. Zero position centering

12

Pivoting angle sensor

13

Valve for pressure cut-off

14

Charge pressure connection

6

© KRONE Training Team, Spelle, Germany

14. Hydraulics: Component Overview of Bosch Drive Pump Components of Drive Pump

5

4

Components

3

6

2 1

7

10

8

192

1

Pivoting angle sensor

2

Measurement connection for setting pressure X2

3

Measurement connection for setting pressure X1

4

Proportional magnet "forwards"

5

Setting valve block

6

Proportional magnet "backwards"

7

Working connection B

8

Working connection A

9

High-pressure sensor MA

10

High-pressure sensor MB

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14. Hydraulics: Component Overview/Design of Bosch Drive Motors Hydraulic Motor A6VE

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

Components

2

5

1

1

6

Components Power unit

2

1. Power Speed sensor unit

3

Proportional valve

4 5 6

2. Speed sensor 3. Proportional valve Non-return valve 4. Non-return valve 5. valve Flush valve Flush 6. Setting piston Setting piston

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

4

4 3

3

2 193

Flows = Vg,max

Vg,min approx. 400 mA approx. 1200 mA

Flush valve: Flush rate: approx. 10 l/min

Coil resistance

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approx. 5.5 ohm

14. Hydraulics: Intake / Header Drive, Overview (1) (2)

(3) (4)

(5)

(6)

Axial piston variable displacement pump intake 105 ccm (BiG X 500/650/600/700/850/1100), Axial piston variable displacement pump header 55 ccm (all BiG X 500/650/ BIG X 700/850/1100 until year of manufacture 2010) 75 ccm (BIG X 600/700/850/1100 from year of manufacture 2011) Gear-type pump charge pressure Fixed displacement motor intake 75 ccm (all BiG X) Fixed displacement motor header 55 ccm (all BiG X 500/650/700 BiG X 850/1100 until year of manufacture 2010) 75 ccm (BIG X 600/700 BiG X 850/1100 from year of manufacture 2011) Quick-stop valve

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4

6 5

4

1 6

Layout of Hydraulic Circuit

Overview

2

5

WHB_4.1 high pressure intake_EN

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3

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

Variable displacement pump

Speed sensor B 26

M

Hydraulic motor with Flush valve

Quick-stop valve M11 : p = 24 – 400 bar

Diagnostics on intake:

The intake high-pressure circuit can be checked on the measurement connections 9 and 11.

Observe supply line and return line arrangement!

WHB_4.1 high pressure intake_EN

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14. Hydraulics:

Intake / Header Drive, Quick-Stop Valve

Quick-stop function in the intake 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 swiveled back to the neutral position.

196

Stop valve

Pilot valve

(Main valve)

(Y 35, conducts to earth)

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14. Hydraulics: Fan Drive BIG X 600/700/850/1100 High-pressure measurement connections

6

Mode of operation: - Drive runs in the closed system - Pump is actuated in one direction only - > fan has only one direction of rotation - When the plug is removed, the pump swivels all the way out -> maximum fan speed (fail-safe function) - Fan speed is controlled depending on the temperature of charge air, 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)

Setting valve Y 82

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14. Hydraulics: Operating and Brake Hydraulics Pressure Supply Brake and Work Hydraulic Circuit (1) Triple pump (2) High-pressure filter

4

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

3 1 2

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14. Hydraulics: Operating and Brake Hydraulics Overview of Work Hydraulics Components

8

WHB_4.4 valve block working hydraulics_EN

5 9

4

7

(1)

Accumulator charging valve

(2)

Hydraulic accumulator parking and foot brake

(3) (4) (5)

Hydraulic accumulator lifting unit (vibration damping) Valve block work hydraulics (with oil circulation function) EHR (Electronic lifting unit adjustment)

(6)

2/2-way seat valves pendulum frame

(7)

Lifting unit storage connection block

(8)

Gearbox for rotating the discharge chute

(9)

Valve foot brake and measurement connection

(10)

Wheel gearbox with integrated brake

(11)

Cylinder for grinding device

(12)

Cylinder for pendulum frame

6

11

10 1 199

2

3

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14. Hydraulics: Bosch Brake System, Accumulator Charging Valve Function of Accumulator Charging Valve The accumulator charging valve is a priority valve which 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

Supply line from work pump Manometric switch brake tank pressure Valve block work hydraulics Storage service brake and brake valve Tank line Storage parking brake Connection manometric switch parking brake Manometric switch parking brake (B110) Connection parking brake in the drive motor Solenoid valve parking brake

R

P

B

N

F

X1

N

R4

R

X

B P

Y18 B110

X1

F Y18

B110

X1

X X P R4

200

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B

N

Y18

© KRONE Training Team, Spelle, Germany

R4

14. Hydraulics: Concept of Brake System on Bosch Travelling Gear Concept of 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 driving joystick - Intake volume on the drive motors is increased - Pump is supported on the diesel engine (support moment of the diesel engine is utilized)

2.

-

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

Concept of Brake System (Parking Brake)

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

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14. Hydraulics: Parking Brake, Emergency Release Hydraulic Release for the Parking Brake

A hand pump is provided to release the parking brake manually (supplied with the machine). The unit consists of a hand pump (1), a hydraulic hose with coupling sleeve (3) and a connecting hose.

The hand pump (1) is located on the hydraulic tank. Close the hand pump drain valve. Take the hand pump joystick extension and the connecting hose out of the tool box and fit them. Operate the hand pump to vent the connecting hose until fluid emerges with no bubbling.

Close the shut-off valve (5) and connect the connecting hose to the measurement connection (4) (position may vary slightly between machines with Poclain and Bosch travelling gear). Pump to release the brake. While strongly increasing the force applied while pumping, move the machine to check whether the brake has released far enough. The hydraulic pressure can be relieved by opening the drain valve (2).

The position of the pump may vary depending on the year of manufacture and model.

The joystick extension and the connecting hose are in the tool box.

1

202

Connecting hose

3

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5 4

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14. Hydraulics: Valve Block Work Hydraulics Work hydraulics: Hydraulic block Bosch SB12 Raise external LS line for lifting unit*

BMK

01

EMR - Valve

Y32/Y33

02

Intermediate plate with pressure limiting valve and ext. LS*

03

Autopilot

Y39/Y40

04

Grinding device

Y31/Y30

05

Pendulum frame

Y37/Y38

06

EF: Guide wheels EC: Plant divider

Y28/Y29

07

EF: Holding-down device EC: Flaps

Y26/Y27

08

Y24/Y25

09

Raise/lower discharge chute Discharge chute flap

10

Rotate discharge chute

Y20/Y21

11

Intermediate plate with shuttle valve*

12

Inlet plate

02 06

02 03 04

03 07

05 06 07 08

04 08

09 10

05 09

11 12

10 11

Return line "T"

203

Designation

01 01

Intake "P"

Item

12

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Y22/Y23

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

Valve blocks from spare parts have the same status from 2014. © KRONE Training Team, Spelle, Germany

14. Hydraulics: Valve Block Work Hydraulics Valve Block Work Hydraulics

Individual pressure balances

Pressure limiting valve: 230 bar

WHB_4.4 valve block working hydraulics_EN

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

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

LS pressure limiting valve: 210 bar

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

m 2 >> m 1

The different loads are applied up to the respective directional 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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14. Hydraulics: Valve Block Work Hydraulics Connection Plate Valve Block for 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 1 206

2

Bosch_repair manual

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14. Hydraulics: Valve Block Work Hydraulics Intermediate Plate for External Feed of LS Signal

M

3 2 1

The additional intermediate plate (2) shown here is only fitted to machines from year of manufacture 2014. On all machines up to then, the connection plate (1) is connected directly to the first directional valve plate (3).

The LS signal pressure from the lifting unit can be measured at the measurement connection (M). Provided that the lifting unit is not activated, tank pressure should be present here.

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14. Hydraulics: Valve Block Work Hydraulics 5/3-Way Valve Plate for Valve Block for Work Hydraulics

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

1

2 3

(1)

Magnetic coil

(2)

Return spring

(3)

Valve slide

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

Emergency manual operation:

Each valve can be actuated manually.

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14. Hydraulics: Work Hydraulics Valve Block 5/3-Way Valve with Hydraulically Unlockable Non-Return Valve (Seat Valve) Valve Block Work Hydraulics

If problems occur, non-return valves can be replaced. They are available individually in the spare-parts list

Locking block (1):

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14. Hydraulics: Work Hydraulics Valve Block Valve Block Work Hydraulics: Intermediate Plate with Pressure Limiting Valve

Until year of manufacture 2013

From year of manufacture 2014 In addition to this pressure limiting valve, there is an additional pressure limiting valve directly on the gear-type 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.

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

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14. Hydraulics: Work Hydraulics – Throttle Non-Return Valves Throttle Valves for Setting the Speed Raise DC flap Lower DC flap

Raise/lower discharge chute

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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14. Hydraulics: Work Hydraulics - Lifting Unit (1)

Corn/maintenance Grass

EMR valve Y 32 - lifting valve

4

Y 33 - lowering valve (2) Storage connection block

3

(3)

Three-way valve grass/corn

(4)

Safety shut-off valve

(5)

Pressure sensor

4

1

5

2

5 212

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14. Hydraulics: Work Hydraulics Diagnostics Checking the maximum pressure in the works hydraulics: Initially the lifting unit/header must be placed completely on the ground. Close both shut-off valves on the lifting cylinders. Switch on field switch and leave diesel engine idling. Press joystick button "Raise lifting unit manually". On the following connections the pressure of p = 200/210 bar can now be measured.

Alternatively for all machines:

Pressure measurement on the plug-in couplings for the pendulum frame cylinder or for the header

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

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

213

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14. Hydraulics: Steering, Overview Steering Hydraulics Components (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 steering_EN

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14. Hydraulics: Additional Axle (Optional), Overview

Additional Axle (1)

3

(2)

Accumulator charging valve additional axle Valve block additional axle

(3)

Pressure limiting valve additional axle

2

1

(4)

Axle with lifting cylinders

(5)

Measurement connection

5 4

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14. Hydraulics: Additional Option Drive Molasses Pump 1

3

4

2

Hydraulic Connection for Molasses Pump - Additional gear-type pump (1) on the main gearbox - High-pressure filter (2) in the intake - Valve block (3) for single-acting function at the back of the machine - Couplings (4) for pressure line and depressurized return line 216

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14. Hydraulics:

Additional Option 1 x Double-Acting Control Unit

1

3

2 Double-Acting Control Unit - Additional gear-type pump (1) on the main gearbox - High-pressure filter (2) in the intake - Bosch valve plate 5/3-way valve SB 12 (3)

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14. Hydraulics:

Additional Option 2 x Double-Acting Control Unit 1

2

3 Two Double-Acting Control Units - Additional gear-type pump (1) on the main gearbox - High-pressure filter (2) - Valve block (3) from Hydac with two 4/3-way valves 218

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14. Hydraulics: Gearbox Oil Cooling BIG 700/850/1100 4

6

6a 1 2

7

from the radiator to the radiator

3

6

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

Measurements taken at measurement connection (7) should always be below 30 bar.

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

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

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1

SI_150395886_valve circulation oil lubrication of the transmission EN © KRONE Training Team, Spelle, Germany

14. Hydraulics: High-Pressure Filter BIG X 500/650/800/1000 BIG X 500, 650 Work and steering hydraulics High-pressure filters are installed in the pressure lines after the work and steering pumps. They are located near the left rear wheel.

Charge pressure line In the charge pressure lines of the drive pumps and intake / header pumps high-pressure filters are in the pipelines between the charge pressure pumps and the main pumps.

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

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

Caution! Observe installation direction!

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14. Hydraulics: High-Pressure Filter BIG X 700/850/1100 High-pressure fine filter for work hydraulics and steering hydraulic pump - With contamination indicator - Replacement of the filters as required or when hydraulic oil is changed - Bypass function when filter contaminated

High-pressure filters are not fitted in the charge pressure circuits on all machines equipped with MAN engines!

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14. Hydraulics: Error Messages and Accessories Manometric switch suction return air filter When the permitted contamination is reached, the return line pressure before the filter increases to over 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 for Poclain travelling gear) 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 interval: 500h Tank capacities:

BiG X 500

90 liters

BiG X 650

90 liters

BIG X 600/700/850/1100

120 liters

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

Hydraulic oil change: During the 500 h hydraulic oil service the hydraulic oil should be drained out of the tank into a suitable container via the quick coupler with a hose. The hydraulic oil filters must also be replaced.

To drain the oil out of the complete system, disconnect the line from the housing (flushing and leakage oil) of the motors from intake and header to the radiator on the motors.

Before starting up the machine, vent the complete system (wheel motors and pumps)!

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14. Hydraulics: Start-Up Start-up 1.

Fill components that cannot be vented (e.g. variable displacement pumps) with the hydraulic oil recommended by KRONE (HLP 46, see operating instructions). Utmost cleanliness is essential! Information about the procedure and the position of the connections are contained on the following pages.

2. Fill the hydraulic oil tank up the middle of the inspection glass with the hydraulic oil recommended by KRONE (HLP 46, see operating instructions). Utmost cleanliness is essential!

3. Vent the system from bottom to top as required (for example, if the variable displacement pump header has been replaced, the wheel motors do not need to be vented). Always start with the components at the lowest point. Information about the procedure and the position of the connections are contained on the following pages.

4. Connect suitable pressure gauges to the charge pressure test connections to monitor the supply pressure at start-up. (Refer to the relevant system descriptions for the charge pressures) 5. Start the diesel engine. Use the inspection glass to check the charge pressure and fill level of the hydraulic tank.

6. Once the fill level of hydraulic oil is no longer visible in the inspection glass, stop the engine and top up with hydraulic oil. Repeat the process until the hydraulic oil level remains constant.

7. At the same time, check charge pressure. Within 30 seconds, the charge pressure of all pumps must have reached the respective charge pressure. If this is not the case, stop the procedure immediately and identify the source of the error! The system will be seriously damaged if it is operated for extended periods without charge pressure!

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

9. Drive the machine slowly forwards and backwards and check whether the charge pressure remains stable. On machines fitted with Poclain travelling gear, do not allow the wheel motors to turn for extended periods without load (machine jacked up)! The wheel motors will be damaged!

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

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14. Hydraulics: Start-Up Poclain Venting the Wheel Motors Wheel motors at front, hexagonal socket head screw on inside BiG X 650/700/800/850/1000/1100

Wheel motors at rear, hexagonal socket head screw at top

Wheel motors at front, hexagonal socket head screw at top

BiG X 500

Wheel motors at rear, hexagonal socket head screw on inside

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

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14. Hydraulics: Start-Up Venting the Pumps To vent the pumps, detach the hydraulic hoses on the top of the pumps until the air has escaped and the hydraulic oil flows out without bubbles.

Venting the Components of the Fan Drive (MAN)

Variable displacement pump fan drive The leakage oil lines must be connected and the pump housing must then be vented through the upper filler plug (X).

Fixed displacement motor fan drive The motor must be filled as far as possible via the leakage oil connection (T).

There is then no further need for venting.

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

T X The static pressure is sufficient to force the air out of the system.

It is not necessary to start the engine.

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14. Hydraulics: Start-Up Bosch Venting the Components of the Bosch Travelling Gear Variable displacement pump travelling gear To vent the pumps, detach the hydraulic hoses on the top of the pumps (-> leakage oil lines connection X) until the air has escaped and the hydraulic oil flows out without bubbles.

X

Variable adjusting motor travelling gear The motor must be filled as far as possible via the leakage oil connection (T). There is then no further need for venting.

T

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

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15. Electrical System/Electronics: Design Sensors

KMC 4

Actuators

A35

AutoScan 120Ω

A40

optional

A1

Sensors

Actuators

~150Ω

Buttons LED

120Ω

120Ω

CAN 2 A2

A6

Actuators

A10

A11

Smart Drive

Sensors Actuators Sensors

KMC 2

Actuators

120Ω

switched!

KMC 3

DIOM

A5

Sensors Actuators

EMR

A3 Autopilot

120Ω

CAN 1

CAN 3

A9

Joystick Control unit console

Switch

228

Actuators

120Ω

A15 Actuators

Sensors

A16

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

A14

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A7

CAN MAN

A8

© KRONE Training Team, Spelle, Germany

EDC (MAN) MR (MB)

15. Electrical System/Electronics:

Component Overview of Console

Console BIG X 500/650/800/1000

Console BiG X 700/850/1100

A16 A14

A16

A14 A33 A31

A22

A22

A6 A8

A3

A1 A3 A2

A5 A12 A7

A1

Component designations see circuit diagram!

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A7

A2

A17

A6

A5

© KRONE Training Team, Spelle, Germany

15. Electrical System/Electronics:

Component Overview of Console

Console BiG X 600_1/700_1/850_1/1100_1 A14

A16

A17

A5

A22 A3

A2

A2 A3

A6

A7

A1

A19

Component designations see circuit diagram!

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15. Electrical System/Electronics:

Console and Cab Circuit Board Installation position BX V8/V12/500/650/800/1000

Tasks

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 (see circuit diagram) Cab circuit board

A22 A4

G

Console circuit board

Installation position BX 700/850/1100

A22

Tasks

Cab circuit board

The cab circuit board (A4) protects e.g. the "VEHICLE" electronics (light, window washer, brake light etc.)

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

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15. Electrical System/Electronics: A17

Potential Distributor Circuit Board

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 500/650/800/1000

A17

17X1

17X11

17X12 17X8

17X3

17X5

17X13

17X9

17X14 17X10

17X6

17X1 7

17X15 17X16

17X18

17X19

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17X21

17X4

17X20

17X7 17X2

15. Electrical System/Electronics: Fundamentals of CAN Bus 12 V GND

A1

A2

A3

A4 CAN high

R1

R2 CAN low

CAN Bus The CAN bus is a network by means of which different controls (here: S1-S4) can exchange data.

To do this, all controls are connected to two lines which transmit the data in digital form.

A voltage signal, which contains the data, is transmitted in the opposite direction on both lines.

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

Each control can only be an active user on the CAN bus when the power supply is intact.

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

CAN 3 (A 33)

(on BiG X 500/650 only)

A33

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

The CAN 2 is fed directly from the KMC 2 to the rear panel of the console!

The models with a new console (BiG X 600/700/850/1100) are not equipped with a CAN BUS distributor circuit board. The wiring is basically the same, although the wire connections are in the cable harness. The terminating resistors are designed as external resistors and are situated in the cable harness in the console.

A31

CAN 1 (A 31)

A33 A31

Blue wire: CAN HIGH Green wire: CAN LOW

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15. 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 shown with color-coded connection lines.

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

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

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

120Ω

A2 KMC 2 A1 SD

A31

A6

120Ω

DIOM

A5 AP

A15

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

CAN high CAN low

A14

Control unit console

A16

Diagnostics

KMC 3

A3

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

120Ω

Always measure without voltage!

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

120 Ω ║120 Ω WD_CAN 1_EN

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 60 Ω total resistance © KRONE Training Team, Spelle, Germany

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

A33

120Ω

R

A9 ADM 2

A8

120Ω ADM 1

A7

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

CAN high CAN low

Diagnostics

KMC 3

A14

A3

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

120Ω

Always measure without voltage!

Terminating Resistors The two CAN BUS lines (CAN high/CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors 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

WD_CAN 3_EN

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 60 Ω total resistance © KRONE Training Team, Spelle, Germany

15. 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 A14

120Ω

Control unit console

A16

KMC 3

A3

Resistance measurement between CAN high and CAN low.

The individual terminating resistors or the cable connections can be tested by removing a resistor and then measuring the resistance in the open plug connection.

Always measure without voltage!

Terminating Resistors The two CAN BUS lines (CAN high/CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for the CAN 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)).

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Diagnostics

 120 Ω terminating resistor

120 Ω ║120 Ω WD_CAN 1_MAN_EN

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 60 Ω total resistance © KRONE Training Team, Spelle, Germany

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

A9

120Ω

2

1

MFR

120Ω MFR

R

A7

CAN high

120Ω

CAN low

KMC 3

A14

A3

Diagnostics Resistance measurement between CAN high and CAN low.

The individual terminating resistors or the cable connections can be tested by removing a resistor and then measuring the resistance in the open plug connection.

Always measure without voltage!

Terminating Resistors

 120 Ω terminating resistor

The two CAN BUS lines (CAN high/CAN low) are terminated with a 120 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors for the CAN 3 are located as external resistors in the cable harness (in the front part of the console (1) and next to the EMR (2)).

120 Ω ║120 Ω WD_CAN 3_MAN_EN

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 60 Ω total resistance © KRONE Training Team, Spelle, Germany

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

AutoScan

120Ω

A40

A55

A35

Rock Protect (Option)

~150Ω

120Ω

Crop Control (Option)

optional

KMC 4

CAN high

NIR humidity sensor (Option)

CAN low

A11

A10 ~150Ω

Terminating Resistors The two CAN BUS lines (CAN high/CAN low) are terminated with a 120 - 150 Ω resistor. This prevents the transmitted data from being reflected as an "echo". The terminating resistors of 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 has been attached or not.

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CAN 2

120Ω

A2 KMC 2 120Ω

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Resistor connected in the KMC 2 Without AutoScan: Resistor connected in the KMC 2 With AutoScan: Resistor disconnected in the KMC 2

120 Ω ║~150 Ω  ~ 66 Ω total resistance © KRONE Training Team, Spelle, Germany

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

A55

AutoScan

Resistance measurement in the CAN 2 As the CAN 2 is fed 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 2 in an easily accessible location and measure the terminating resistors individually. e.g. on the intake plug 25X12.

Resistor connected in the KMC 2 WD_KMC 2_EN

120Ω

A40

Rock Protect (Option) Crop Control (Option)

optional

A35

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

AutoScan not attached: Terminating resistor of 120 Ω in the KMC 2cannot be measured on the 25X12 plug, as the resistor is connected in an energized state only. It is therefore necessary to set a bridge to "simulate" the connection (see circuit diagram).

A11

KMC 4

A10

NIR humidity 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, Germany

15. Electrical System/Electronics: CAN 2 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)

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15. Electrical System/Electronics: ISOBUS ISOBUS – Layout and Diagnostics ISOBUS In-cab Socket 30X6

120Ω

ISOBUS

120Ω

A2 KMC 2 A1 SD/DRC

A6 DIOM

A5

ISOBUS Diagnostics socket 30X9

AP

CAN ISO

CAN 1

CAN high CAN low

A15 120Ω A14

120Ω Control unit console

A16

KMC 3

A3

Layout of the ISOBUS System From year of manufacture 2013, ISOBUS preparation is available as an option and can be retrofitted with a color terminal for all BiG X machines. The ISOBUS preparation only contains another Autopilot computer and the corresponding cables with the two sockets for diagnostics and for connecting additional ISOBUS devices (e.g. KRONE-CCI-200 terminal, ISOBUS autopilot systems, etc.).

The Autopilot computer forms the interface between the CAN1 Bus and the ISOBUS. 243

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15. Electrical System/Electronics: Layout of Wiring Diagram BiG X 500/650/800/1000, from year of manufacture 2006 BiG X 600/700/850/1100 Wiring Diagram - Table of Contents

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

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

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15. Electrical System/Electronics: Layout of Wiring Diagram Layout of Wiring Diagram The wiring diagram is presented on several pages. Each page is named and numbered according to its functions.

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

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

245

D6

D7

D8

E6

E7

E8

F6

F7

F8

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15. Electrical System/Electronics: Layout of Wiring Diagram 1 Colored Field

To better clarify the assignment of the individual switching parts of the machine, different colors have been used.

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

3

2

1

4 246

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15. Electrical System/Electronics: Layout of Wiring Diagram

Change

The areas marked with a letter indicate that something there has been changed. Changes with the same letter have been incorporated 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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15. Electrical System/Electronics: Layout of Wiring Diagram Termination arrow (1)

This arrow indicates that the electric potential is carried 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) on which the potential is taken up. Example: Page 109, circuit path 1

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 standardized 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: Upper beam, upper beam control 56b: Lower beam 58: Background lighting 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 labeled with its designation. The designation (3) can also be found on the circuit diagram. Example: Yellow lead with black label PLD1 15

Wire colors BX 500/650/800/1000: Power supply Signal line/switch circuit Earth (white) 248

CAN high CAN low

2

3

3

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

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15. Electrical System/Electronics: Layout of Wiring Diagram 11 - Plug Number

X...

Diagram Layout

Plug

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

Plug

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

a – Pin contact b – Socket contact

11X... Manual operation (A 11) 14X... Terminal (A14) 15X... Joystick (A 15) 16X... CU (A 16)

One plug is identified with X. The number before the x describes the affiliation with the module, the number after – the affiliation with a component or the number of the plug. The small letter "a" indicates pin contacts and "b" indicates socket 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 labeled according to the "old" system.

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

B49 - Component

19X... EasyControl (A 19) 20X... Console (A 20) 22X... Console relay circuit board (A 22) 249

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15. Electrical System/Electronics: Layout of Wiring Diagram Input – Output Job Computer

1

1. The function of the input or the output.

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

2 3 4 5

5 4 3

CAN H CAN L

2

- CAN High - CAN Low

4. Connection contact (e.g. plug X3 pin 12) 5. Module designation

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15. Electrical System/Electronics: Layout of Wiring Diagram Job Computer - Complete Overview The complete overview describes all input and all outputs according to function. The representations (X1) and (X2) indicate the pin assignment of the plugs on the job computer.

2

1

X2

Supply voltages, Power Supply of Electronics: The marked area (1) of the complete overview represents the 4 supply voltages of the computer or the power supply of the electronics. It can be seen from the designation which supply voltage is responsible 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

The 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. electromagnetic valves or electric motors.

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

22F78 Voltage V3 KMC3

Quick-stop switch 22K32 Release switch maintenance

22LD34

IN9

IN7

IN13

GAL logic -IC1

-A22

OUT 6

F12

KMC 3

LD40

PWM_LA8

Relay circuit board Console

LD31

Valve grinding stone on left

-A3

Y31

0 Volt Both job computers (KMC2 + KMC3) have a separate load and electronic power supply. The load supply supplies only the output circuit of the job computers. This load supply comes from the relay circuit board and is switched there depending on the different inputs (release switch, etc.) via a GAL logic.

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15. Electrical System/Electronics:

Overview of Job Computer

(1) ● LD 27 – LD 29

LEDs supply voltages

(2) ● F2, F6, F12, F13

internal fuse load voltages V1 – V4

(3) ● LD 37 – LD 41

LEDs load voltages V1 – V4

(4) ● LD 1 – LD 12 and LD 30 – LD 36

LEDs outputs

(5) ● LD 13 – LD 26

LEDs inputs

(6) ● LD 38

Life LED (status of the job computer)

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WD_KMC 2_EN

© KRONE Training Team, Spelle, Germany

15. Electrical System/Electronics: GAL - Logic 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

A22 LD xxx

GAL

Console relay circuit board 254

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15. Electrical system/Electronics: GAL - Logic GAL Logic Module Tasks If the GAL logic module has the required input signals, it switches the relay with the output signal via MOS-FET. The conditions for the respective output signals are described in the table (T).

GAL

T

The switched relays then conduct the supply voltages V1V4 for KMC2 and KMC3 as well as the plus supply for Smart Drive, autopilot and DIOM. The respective supply voltage is protected by a fuse and can be checked by a light-emitting diode LD. Designation in the table (T) "0" – 0V "1" – 12V "0/1" – 0V or 12V

Statement if LED is lit: - Input conditions satisfied - Relay has switched - Fuse in working order  Supply voltage is applied to the output of the relay circuit board MOS-FET

Console relay circuit board 255

LD

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15. Electrical system/Electronics:

Diagnostics via LED on the KMC

V1 V2

Statement if LED is lit:

- Relay circuit board including GAL logic and fuse are in working order - Cable and plug connections up to KMC are in working order

V3 V4

Relay circuit board Console

V4 V3 Inputs: e.g. sensors and switches

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V1 V2

Outputs: e.g. valves

15. Electrical System/Electronics:

Diagnostics via LED on the KMC Overview of LEDs on the circuit diagram and on the computer Inputs: green/orange Outputs: red

- Connection upper signals: Input - Computer: KMC 2 - Function: DC position lower - LED in the computer: LD 25

Statement if LD 25 is lit or goes out as soon as sensor or switch changes its status: - Sensor or switch in working order - Cable and plug connections up to KMC in working order Statement if LD 1 is lit as soon as function is actuated - Supply voltage for this function is applied - Conditions for implementing this function have been satisfied - Job computer in working order 257

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4 x 4 = 16 outputs - Connection lower signals: Output - Computer: KMC 2 - Function: Raise discharge chute - Supply voltage for this function: V 4 - LED in the computer: LD 1 © KRONE Training Team, Spelle, Germany

16. Software: KRONE Download Center

2

3 A

1 4

5

Download Center

The Download Center is needed to perform a software update on the various computers in KRONE machines. A laptop with a USB connection is used for this. The connection to the computer for the software update is established via a CAN diagnostics socket (A) in the console.

The complete download package for all KRONE machines (including installation CD, all required cable connections and programmed PCAN dongle) can be ordered from your spare parts supplier (part 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" and "Phases" software (Poclain) 2. PCAN-USB dongle 3. Data cable 4. Data cable extension with adapters 5. Smart Drive diagnostics cable (Y-piece) 258

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SI_150369998 components softwareupdate_EN

WHB_7.10.1.KRONE Download Center_EN

© KRONE Training Team, Spelle, Germany

16. Software: Replacing Job Computer/Configuration Parameters and settings to be checked after replacing a job computer When certain controls (job computers) have been replaced in the BiG X, various settings or configurations are required depending on the control unit. On the one hand these are parameter settings which require the input of release codes/passwords. On the other hand calibrations may be required. 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 control unit, 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 license!

The hard copy list is in the appendix to the training document.

Parameter check Machine configuration_EN

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16. Software: Electronics Packages Control of optional electronic systems Option not released Option released

Output of machine data for documentation

Interface for ISOBUS autopilot system

Load limit control

Autopilot using row tracers

Electronic power adjustment

Output of machine data for documentation

Fuel consumption measurement

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16. Software: Parameter Settings

Parameter_Service BiG X 700_1100_EN

Parameters must be set if: - A control is replaced (e.g. KMC)

- Software is updated (as specified in customer service info) - Settings have to be changed 261

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17. Maintenance Servicing and maintenance represent the most important factors to ensure smooth running for the machine.

The following pages (Chapter 14) provide some information on this topic.

The most important document for maintenance is always the operation instructions.

There are operating instructions for the basic machine as well as for the various headers.

The appropriate operating instructions can be identified by matching the machine number.

The document number is used for reordering. Also, each manual can be downloaded from the KRONE media center (www.krone.de).

(machine number)

(document number)

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17. Maintenance: Periodic Maintenance Maintenance

Periodic maintenance refers to the maintenance procedures which are to be carried out after a certain number of hours in operation.

This page details the procedures to be carried out after 10 operating hours (daily).

Check:

- Coolant - Hydraulic oil - Engine oil - Water separator - Air filter cartridges - Tire pressures - Lighting functions - Indicator lamps

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17. Maintenance: Central Lubrication System, General Central Lubrication System

The BiG X forage harvester is equipped as standard with a central lubrication system. The system is manufactured by Vogel, or on machines manufactured in 2009 and later by BEKA-MAX. The system comprises the pump (1) with integrated 300 ± 20 bar pressure limiting valve, the main distributor (2) with cycle switch (3) and the distributors for the intake, foraging unit, drives and discharge, rear axle and corn conditioner.

2

1 Fault Detection

2

264

3

The system functionality is signaled by the flashing of the LED in the cycle switch. If the piston in the distributor plate moves, the LED flashes. If the LED is not flashing, there may be a blockage in the hose or tanks may be empty. In this case check the hardness of the filler and the hoses to the subdistributors. Manual lubrication is possible, apart from the intake and cutting drum distributors (hardened hose indicates blockage).

In the event of a blockage, the system attempts to run 3 more cycles (lubrication/pause) before the error is indicated on the display.

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17. Maintenance: Central Lubrication System, VOGEL Lubricant Filling

The lubricant is injected through the hydraulic-type lubricating nipple (1) DIN 71412-AM10x1 by means of a commercially available grease gun.

Alternatively, a fill coupling can be installed.

The fill coupling (3) is enclosed ex works to provide quicker filling. The coupling on the port (2) is fitted as standard.

Fill Coupling (3) - Remove the lubricating nipple (1) and replace it with the filler neck 995-000-705 (3) - The coupling box 995-001-500 (5) must be fitted to the filling pump (4).

Filling Cylinder (6) - Remove the M20x1.5 locking screw (7) and replace it with filling connection 169-000-170 (8).

Filling through the cover is not permitted, as this may allow dirt and air bubbles to enter the reservoir and cause malfunctions.

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7

5 8 3 265

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4

6 © KRONE Training Team, Spelle, Germany

17. Maintenance: Central Lubrication System, VOGEL Programming

The central lubrication system can be "activated" manually as required by opening menu 3-7, "Maintenance/Calibration – intake and header" and switching on the "Road/Field" and „Header" switches. Troubleshooting can then be carried out on the system, or intermediate lubrication can be activated, by pressing the DK button directly on the central lubrication system.

Press the SET button to activate or deactivate programming mode. Krone factory default setting: Pause time: 0.5 h Pump running time: 14 min

Pushbutton

Function - Pressing during pause activates an intermediate lubrication - Error messages are reset and cleared

- Activate display in display mode - Select the next parameter in programming mode - Increase displayed value by 1 - Activate display in display mode - Select the next parameter in programming mode - Decrease displayed value by 1 - Toggle between programming and display mode - Confirm entered values 266

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17. Maintenance: Lubrication Chart, VOGEL

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17. Maintenance: Central Lubrication System, BEKA - MAX

1 2

Lubricant Filling The lubricant is injected through the hydraulic-type lubricating nipple (1) DIN 71412-AM10x1 by means of a commercially available grease gun.

A hydraulic breakaway coupling is fitted ex works to provide quicker filling. The counterpart of the coupling is enclosed in the accessories pack of the machine.

Fill Coupling (3) - Remove the lubricating nipple (1) and replace it with the filler neck 27 001 594 0 (3) - The coupling box 27 001 595 0 (5) must be fitted to the filling pump (4).

Filling cylinder 940 393 0 (6): - Remove the M20x1.5 locking screw (7) and replace it with filling connection 940 392 0 (8).

Filling through the cover is not permitted, as this may allow dirt and air bubbles to enter the reservoir and cause malfunctions.

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17. Maintenance: Central Lubrication System, BEKA - MAX Programming

G

А

R

The central lubrication system can be "activated" manually as required by opening menu 3-7, "Maintenance/Calibration – intake and header" and switching on the "Road/Field" and „Header" switches. Troubleshooting can then be carried out on the system, or intermediate lubrication can be activated, by pressing the button (A) directly on the central lubrication system. The cycle time and the number of cycles can be set using grid switches (Z) and (T) in the controller view window.

Krone factory default setting: BiG X 500/650/800/1000: Cycle time: Lubrication duration: BiG X 700/850/1100:

Cycle time: Lubrication duration:

10 min 37 cycles 8 min 34 cycles

Number of cycles

Т

Z

Grid switch (Z) : Set cycle time in min Grid switch (T) : Set lubrication duration in cycles

- One cycle more or less corresponds to 0.5 % lubricant - 2 min. cycle time more corresponds to 20 % less lubricant - 2 min. cycle time less corresponds to 20 % more lubricant

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17. Maintenance: Central Lubrication System, BEKA - MAX Diagnostics

The central lubrication system can be "activated" manually as required by opening menu 3-7, "Maintenance/Calibration – intake and header" and switching on the "Road/Field" and „Header" switches.

Control unit (F)

LED (G) : green LED (R) : red

F R G

The red LED (R) always indicates a fault The flash code indicates the type of fault:

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17. Maintenance: Lubrication Chart, BEKA-MAX

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17. Maintenance: Manual Lubrication Points Lubrication points

Although the central lubrication system supplies almost all lubrication points, there are a few which have to be greased manually.

BA_9.17 Lubrication chart_500_1000_EN

BA_9.17 Lubrication chart_700_1100_DE

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17. Maintenance: Engine Oil Engine maintenance

Each BiG X includes operating instructions and a maintenance booklet from the respective engine manufacturer.

These documents are fundamental for the maintenance of diesel engines.

Additional useful information, e.g. lists of consumables, can be found on the Internet.

These lists provide information on which types of oil have been released by which manufacturer for the particular engines. This list is always up-to-date! We therefore recommend using the link below.

Mercedes engines

MAN engines

http://bevo.mercedes-benz.com/

https://mmrepro.mn.man.de/bstwebapp/BSTServlet

Mercedes-Benz regulations for consumables

Specification M3277 High-performance diesel engine oil

228.5 Multi-grade engine oils

Oil change intervals:

Oil change intervals:

- OM 502 LA - OM 460 LA

250 operating hours

- OM 926 LA

500 operating hours

(engine oil according to consumable regulation 228.5)

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- D 2862 LE 121 - D 2868 LE 121

500 operating hours

(engine oil according to specification M3277)

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17. Maintenance: Gearbox Oils Oil Change Intervals and Types of Oil Power take-off gear and transfer gearbox are filled with PG - synthetic oil (PGLP DIN 51502/viscosity 220) or PAO gearbox oil (Mobil SHC 630). Gearboxes which already include PAO oil are identified by a yellow sticker.

If PGLP oil has to be switched to PAO oil in machines with gearbox oil cooling due to the replacement of the power take-off gear, please always comply with the attached service information!!

Never mix PG oils and PAO oils!

The intake and discharge chute gearboxes are filled with gearbox oil (API GL 5 SAE 85W90).

Discharge chute tower gearbox: Oil change every 1000 h, or at least once a year In machines from year of manufacture 2014 Use only Mobil Glygoyle gearbox oil 460 (27 013 243 0).

SI_150397969_ Oil change when replacing the power take-off gear

Power take-off gear: 1. Oil change: Dependent on gearbox manufacturer!

Please always follow instructions on the next page or in the operating instructions for the machine!

Then every 1000 h or at least once a year

Feed drive gear: Bottom roller drive Angular gearbox Top roller drive Oil change every 1000 h, or at least once a year

Transfer gearbox: Oil change every 1000 h, or at least once a year 274

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17. Maintenance: Power Take-Off Gear Oil Change Intervals Motor Power Take-Off Gear Depending on the gearbox manufacturer, the oil change intervals are as follows: Gearbox manufacturer

First oil change interval

Walterscheid

200 h

Bass

200 h

Rögelberg

50 h

Main oil change interval 1000 h or at least 1 x annually 1000 h or at least 1 x annually 1000 h or at least 1 x annually

Before starting work, always ascertain the type of oil in the gearbox! Never mix PGLP and PAO oil!

If PGLP oil has to be switched to PAO oil, always comply with the attached service information, especially for machines with gearbox oil cooling!

SI_150397969_ Oil change when replacing the power take-off gear

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17. Maintenance: Bosch Wheel Gearbox Maintenance Planetary Gearbox

Perform all work while the gearboxes are warm! Caution: Gearboxes are then under slight pressure!!

Only "SHELL SPIRAX S4 CX 50" may be used here as gearbox oil!

First oil change interval after 100h operating hours! Thereafter, every 1000h or 1 x annually!

Wheel gearbox at front Oil level check • Oil level must reach inspection screw (1) in the illustrated position

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Oil change • Unscrew oil filler plug (2) to release pressure from the gearbox.

• Unscrew the oil drain plug (3).

• Screw in the oil drain plug (3) again.

• Fill with oil. The oil level must reach up to the control hole (1).

• Screw in the oil filler plug (2).

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Wheel gearbox at rear Oil level check • Oil level must be 40 mm below opening (1) in the illustrated position

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Oil change • Unscrew inspection screw (1) to release pressure from the gearbox • Move oil drain plug (2) into lowest position and unscrew.

• Screw in the oil drain plug (2) again.

• Turn the wheel upwards by approx. 30°.

• Unscrew the oil filler plug (1).

• Fill with oil. The oil level must be about 40 mm below the wheel hub.

• Screw in the oil filler plug (1).

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17. Maintenance: Checkpoints Feed Drive

- Bars on the two intake rollers - Inner wear plates, left/right - Smooth roller scraper (check gap)

- Rollers - Wear plate, cone - Wear plate, grass chute

Blade Drum

Discharge Accelerator

- Counterblade - Blade - Drum base - Grinding stone

- Discharge scoop - Scrapers - Wear plates, left/ right side

Transfer Chute

Discharge Chute

- Wear plates, individually interchangeable

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- Back wear plate - Wear plates, left/ right side

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17. Maintenance: Grass-Corn Conversion Grass-Corn Conversion

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2.

3.

4.

L

5.

After working in grass mode, and prior to the silo corn harvest, the forage harvester must be converted for corn working. This requires the following actions: Turn bar (L) from smooth to toothed.

Replace the tension spring (Z) by a double-action cylinder and fit it in the plug-in connections (S).

Fit grain capture plates (В) under the pre-compression rollers.

Open the shut-off valve (H) for the corn conditioner drive tensioning roller.

Set the three-way valve (W) on the left lifting unit cylinder to "Corn".

H

Z W

B

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17. Maintenance: Grass-Corn Conversion Grass-Corn Conversion

Replace the grass cutter with the corn cutter (M).

Replace the standard counterblade with the special counterblade (G).

Mount the blades and counterblade only on cleaned skid surface areas!

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M

G

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17. Maintenance: Grass-Corn Conversion Grass-Corn Conversion

Install the corn conditioner (С) in the machine. When installing pay attention to the cable routing and belt layout.

9. Open the left and right air baffles (D) to prevent a vacuum being created between the corn conditioner and the discharge accelerator.

10. Adjust the rear wall (R) to a distance of 3 mm between the discharge scoop and the wall panel.

11. When operating the forage harvester with an EasyCollect and at working widths from 7.5 m, a discharge chute extension (V) is fitted. When fitting, pay attention to the positioning of the wear plates, so that no crest lines are created.

On the EasyCollect 1053, a hydraulically folding discharge chute extension (K) is fitted as standard.

8.

С

D

D

BA_7.5.5. Converting the grass channel grain conditioner_EN

R K

V

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17. Maintenance: Grass-Corn Conversion Grass-Corn Conversion

12. To ensure safe and reliable operation of the forage harvester with the corn header attached, especially in road mode, additional weights (Y) must be attached to the rear part of the frame.

The additional weights are always supplied with the EasyCollect.

The operating instructions include a table indicating how many weights are fitted where.

Y

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