CLAAS QUANTUM 3800 K QUANTUM 3800 P QUANTUM 3500 K QUANTUM 3500 P Operator's Manual- PDF DOWNLOAD

QUANTUM 3800 K QUANTUM 3800 P QUANTUM 3500 K QUANTUM 3500 P QUANTUM 3500 S

Operator’s manual

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EC Declaration of Conformity according to EC Directive 89/392/EEC

We

CLAAS Saulgau GmbH Zeppelinstrasse 2

D-88348 Bad Saulgau

declare under their sole responsibility that the product

self-loading forage wagon - model 611 »QUANTUM 3500 K« self-loading forage wagon - model 610 »QUANTUM 3500 P« self-loading forage wagon - model 699 »QUANTUM 3500 S self-loading forage wagon - model 613 »QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S« to which this declaration refers corresponds to the relevant basic safety and health requirements of EC Directive 89/392/EEC, and to the requirements of the other relevant Directives.

-/For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) and/or technical specification(s) has (have) been applied:

EN 1553 - 1999

Bad Saulgau, January 22, 2004 Technical Management (Geng)

Production Management (Fetscher)

Quality management (Switalski)

Machine overview

Machine overview

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Quantum3800K_01a

1 Machine overview QUANTUM 3800 K / 3500 K Item no.

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1.1

Designation Ring hitch Articulated drawbar Hydraulic cylinder articulated drawbar Self-loading forage wagon control Self-loading forage wagon central electrical system Front plate Hydraulic cylinder collapsible dry forage extension Protective cloth Hydraulically folding collapsible dry forage extension Hoop Rear safety guards Tailgate Floor conveyor gearbox Wheel chock Steering axle (optional equipment) Parking brake (for air brake system or hydraulically operated brake only) Cutter trough Rotor chain drive Gauge wheel Baffle plate (short crop plate) Prop stand

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Machine overview

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Quantum3800K_02a

Item no.

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Designation Hydraulic cylinder collapsible dry forage extension Rotor Identification plate Control panel Electrical connection Hydraulic connection Drive shaft Main gearbox Pick-up Conveyor channel Floor conveyor Wheel chock

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

1.2

Machine overview

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Quantum3500S_01a

QUANTUM 3500 S Item no.

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1.3

Designation Ring hitch Articulated drawbar Hydraulic cylinder articulated drawbar Self-loading forage wagon control Self-loading forage wagon central electrical system Front plate Folding side extension Protective cloth Hoop Rear protective cloth Tailgate Floor conveyor gearbox Wheel chock Steering axle (optional equipment) Inspection hatch Parking brake (for air brake system or hydraulically operated brake only) Knife frame Rotor chain drive Gauge wheel Baffle plate Prop stand

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Machine overview

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Quantum3500S_02a

Item no.

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Designation Shredder drum Rotor Identification plate Control panel Electrical connection Hydraulic connection Drive shaft Main gearbox Pick-up Conveyor channel Floor conveyor Wheel chock Shredder drum gearbox

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

1.4

Machine overview

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Quantum3500P_02a

QUANTUM 3800 P / 3500 P Item no.

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1.5

Designation Hoop Protective cloth Folding side extension Front plate Self-loading forage wagon control/central electrics Identification plate Hydraulic cylinder articulated drawbar Control unit Electrical connection Hydraulic connection Ring hitch Drive shaft Articulated drawbar Main gearbox Prop stand Baffle plate/pick-up Gauge wheel Conveyor channel Rotor/rotor chain drive Knife frame Parking brake (for air brake system or hydraulically operated brake only) Floor conveyor Steering axle (optional equipment) Wheel chock Floor conveyor gearbox (left) Tailgate

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Introduction

Introduction

2 Introduction INTRODUCTION This manual provides information on the use, adjustment and servicing of the CLAAS self-loading forage wagon.

Follow the advice on correct maintenance and servicing in order to ensure maximum performance and a long service life of your machine.

Also, have assembly of your machine and regular inspections carried out by your specialist workshop.

Failure to carry out maintenance work, or incorrect operation will result in poor machine efficiency and loss of valuable time.

By ensuring correct operation, and carrying out maintenance and service work with care, you will be able to make full use of the technical knowledge and the experience with which your self-loading forage wagon has been designed.

Your CLAAS Service Department

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

2.1

Contents

Contents

3 Contents 1. Machine overview ................................................... 1.1 QUANTUM 3800 K / 3500 K ..................................................... 1.1 QUANTUM 3500 S ................................................................... 1.3 QUANTUM 3800 P / 3500 P ..................................................... 1.5

2. Introduction Introduction ............................................................................... 2.1

3. Contents ....................................................................... 3.1 4. Preface Of special importance ............................................................... 4.1 Identification plate ..................................................................... 4.2 Road transport .......................................................................... 4.2 Operating permit ................................................................ 4.2 Operating on public roads ................................................... 4.3 Number plate ...................................................................... 4.3 Regular inspection as required by law ............................... 4.3

5. Safety Instructions Designated use ......................................................................... 5.1 Identification of warnings and dangers ..................................... 5.1 General Safety and Accident Prevention Instructions ............... 5.2 PTO Operation .......................................................................... 5.3 Brakes ....................................................................................... 5.3 Hydraulic system ....................................................................... 5.4 Wheels and tyres, threaded fastenings ..................................... 5.4 Maintenance ............................................................................. 5.4 Sound pressure level ................................................................ 5.4 Safety decals with warning symbols ......................................... 5.5

6. Specifications QUANTUM 3500 K QUANTUM 3500 P QUANTUM 3500 S QUANTUM 3800 K QUANTUM 3800 P

................................................................... 6.2 ................................................................... 6.2 ................................................................... 6.2 ................................................................... 6.3 ................................................................... 6.3

7. Assembly Assembly .................................................................................. 7.1 QUANTUM 3800 P / 3500 P ............................................... 7.1 QUANTUM 3800 K / 3500 K ............................................... 7.2 QUANTUM 3500 S ............................................................. 7.3

8. Before Operation Check and observe the following before putting into operation 8.1 Coupling to the tractor ............................................................... 8.3 Hydraulic articulated drawbar ............................................. 8.3 Ring hitches ........................................................................ 8.4 Height adjustment of the drawbar ....................................... 8.5 Filling the accumulator of the hydraulic articulated drawbar ............................................................................... 8.5 Drive shaft ........................................................................... 8.6 Adjusting the universal drive shaft ...................................... 8.6 Electrical connection ........................................................... 8.8 Control unit ......................................................................... 8.8

3.1

Tractor electrical power supply (accessory equipment) ..... 8.9 Hydraulic system .............................................................. 8.10 Adjusting hydraulic system (QUANTUM 3500 S only) ..... 8.10 Open hydraulic system (standard system) ....................... 8.10 Closed hydraulic system .................................................. 8.11 Hydraulic connection ........................................................ 8.11 Connection for stopping the steering wheels on the steering axle (optional equipment) ................................................. 8.11 Prop stand ........................................................................ 8.12 After attaching the self-loading forage wagon .................. 8.12 Parking the self-loading forage wagon ............................. 8.12 Air brake system ............................................................... 8.12 Two-line system ............................................................... 8.12 Towing with tractors without air brake system ............................................................... 8.13 Hydraulically operated brake system ............................... 8.13 Parking brake ................................................................... 8.14 Setting brake .................................................................... 8.14 Releasing brake ............................................................... 8.14 Overrun brake .................................................................. 8.14 Wheel chocks ................................................................... 8.14 Inspection hatch (QUANTUM 3500 S only) ...................... 8.15 Unhitching ............................................................................... 8.15 Self-loading forage wagon with air brake system ............. 8.17 Self-loading forage wagon with hydraulically operated brake ................................................................. 8.17 Self-loading forage wagon with automatic overrun brake 8.17 Prior to transportation ............................................................. 8.18 Driving on public roads ..................................................... 8.18

9. Operation General note of the control unit ................................................ 9.1 Short instructions ...................................................................... 9.2 Loading operation ............................................................... 9.2 Cutting mechanism ............................................................. 9.2 Unloading operation ........................................................... 9.2 Hydraulic articulated drawbar ............................................. 9.2 Loading operation ..................................................................... 9.3 Lifting and lowering the pick-up .......................................... 9.3 Dry crop top (QUANTUM 3800 K / 3500 K) ....................... 9.3 Preselecting the working height of the pick-up ................... 9.3 Baffle plate ......................................................................... 9.4 Floor conveyor .................................................................... 9.4 Setting floor conveyor speed .............................................. 9.4 Opening and closing knife frame ........................................ 9.5 "Wagon full" indicator ......................................................... 9.6 Unloading ................................................................................. 9.6 Silage operation/hydraulic articulated drawbar .................. 9.6 Unloading the load space ................................................... 9.7 Divided tailgate (QUANTUM 3500 S only) ......................... 9.8 Opening the lower and top tailgate ..................................... 9.8 Opening the lower part of the tailgate ................................ 9.8 Operation of self-loading forage wagon .................................... 9.9 Loading operation (general) ............................................. 9.10 Driving on public roads ..................................................... 9.10 After use ........................................................................... 9.10

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Contents Steering axle (optional equipment) ................................... 9.11 Drawbar extension for automatic pick-up hitch M01 0010 (optional equipment) ........................................ 9.11 Emergency control .................................................................. 9.12 Floor conveyor .................................................................. 9.12 Additional functions .......................................................... 9.12

10. Maintenance Important Maintenance Instructions ........................................ 10.1 Wheels / tyres ................................................................... 10.1 Brakes and axles .............................................................. 10.1 Air brake system ............................................................... 10.1 Hydraulic system .............................................................. 10.1 Chassis ............................................................................. 10.2 Chains .............................................................................. 10.2 Bolts .................................................................................. 10.2 Lubrication ........................................................................ 10.2 Guards .............................................................................. 10.2 Brakes and axles .................................................................... 10.3 Air brake system ............................................................... 10.3 Draining compressed air reservoir .................................... 10.3 Air pipe filter ...................................................................... 10.4 Cleaning the filter element ................................................ 10.4 Components of the air cleaner ......................................... 10.4 Adjusting the brake - checking the brake cylinder piston stroke ..................................................................... 10.4 Brake linings ..................................................................... 10.5 Servicing and adjustment instructions for self-loading forage wagon axles with System 2000 automatic reverse overrider .. 10.5 Function of the automatic reverse overrider ..................... 10.5 Operation and handling .................................................... 10.6 Adjusting the wheel brake S 3006-7 RAZG ...................... 10.7 Basic setting of the wheel brake ....................................... 10.8 Adjusting the wheel brake S 3008 RAZG ......................... 10.9 Basic setting of the wheel brake ..................................... 10.10 Maintenance ................................................................... 10.11 After 50 operating hours ................................................. 10.11 Every 200 operating hours ............................................. 10.11 Quarterly ......................................................................... 10.11 Fault finding chart ........................................................... 10.12 Readjusting the taper roller bearing ............................... 10.12 Tightening torques .......................................................... 10.12 Cutting mechanism ............................................................... 10.13 Changing the cutting knives ........................................... 10.13 Knife removal .................................................................. 10.13 Knife installation ............................................................. 10.14 Pressure spring of the knife frame .................................. 10.14 Adjusting the scraper unit ..................................................... 10.15 Drive systems ....................................................................... 10.15 Main gearbox .................................................................. 10.16 Floor conveyor gearbox .................................................. 10.16 Shredder drum drive (front right) (QUANTUM 3500 S) ....................................................... 10.16 Shredder drum drive (right rear) (QUANTUM 3500 S) ....................................................... 10.17 Chains ................................................................................... 10.17 Tensioning the drive chains ............................................ 10.17 Tensioning pick-up drive chain ....................................... 10.18 Drive chains for shredder drum (QUANTUM 3500 S) .... 10.18

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

Main drive chain .............................................................

Floor conveyor chains ....................................................

Automatic chain lubrication ............................................

Clutch ...................................................................................

Adjusting the clutch for the main drive (Quantum 3500 S only) ..................................................

Adjusting the clutch for the shredder drum drive (Quantum 3500 S only) ..................................................

Cam-type cut-out clutch .................................................

Drive shaft ............................................................................

Electrical system ..................................................................

Adjusting the reed switches ...........................................

Hydraulic system ..................................................................

Accumulator ...................................................................

Hydraulic hose connections ...........................................

Gas shock absorber .............................................................

Tyres: ...................................................................................

Tailgate .................................................................................

Adjusting the tailgate ......................................................

Adjusting the hydraulic cylinder (QUANTUM 3500 S only) ...............................................

Adjusting the support (QUANTUM 3500 S only) ............

Pressure spring of tailgate (QUANTUM 3800 K / 3500 K only) ................................

Maintenance and lubrication holes .......................................

Guards ..................................................................................

Fasteners .............................................................................

Screw connections ...............................................................

End of season storage .........................................................

Lubrication chart ..................................................................

10.18 10.19 10.19 10.20 10.20 10.20 10.21 10.21 10.22 10.22 10.22 10.22 10.23 10.24 10.25 10.26 10.26 10.26 10.26 10.26 10.27 10.27 10.27 10.27 10.28 10.28

11. Lubrication Chart Safety Instructions .................................................................. 11.1 Lubricants ............................................................................... 11.1 Lubrication .............................................................................. 11.1

3.2

Preface

Preface

4 Preface OF SPECIAL IMPORTANCE Note that the CLAAS self-loading forage wagon is also referred to simply as the machine in the following chapters.

The instructions set forth in this manual must be read carefully and followed by all persons concerned with the operation, maintenance, repair or inspection of this machine in order to prevent accidents.

Read especially sections “Safety” and “Before Putting into Operation”.

The use of spare parts, accessories and additional equipment which is not originally manufactured, and checked and released by CLAAS can have its negative effect on specific design features of the CLAAS machine or on its operability, thereby impair active and/or passive operating safety, as well as safety at work (accident prevention).

CLAAS will in no way be liable for damage or personal injury caused by the use of other than original CLAAS parts, accessories and additional equipment.

Technical specifications, dimensions and weights are understood with the usual tolerances.

Front, rear, right and left refer to the direction of forward travel.

4.1

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Preface IDENTIFICATION PLATE The machine number (VIN) (3), the model and the serial number are required with all orders for spare parts and technical inquiries.This is necessary in order to ensure correct delivery of spare parts.

1

The identification plate (1) with the machine number (VIN) (3) is attached to the front right of the machine frame.

Machine number

2 67644

1

The machine number (2) is also punched on the right side of the machine frame.

(Fig. 1)

1

ROAD TRANSPORT Observe the applicable regulations in your country.

613/xxx xxxx

In other countries observe the relevant national or state regulations.

xxxxx

xxxxx 61302241

Note!

3 2

The following sections are applicable for the Federal Republic of Germany only.

Trailers with a speed up to 25 km/h require an operating permit.

The machine operator must have a driver's licence and the copy of the general operating permit issued by the federal motor vehicles office.

Trailers with a speed over 25 km/h must be registered.

The vehicle operator must have a driver's licence, the registration certificate and the test booklet.

Operating permit to 25 km/h: over 25 km/h:

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

Operating permit that allows operation of the tow vehicle is sufficient.

CE operating permit is required.

4.2

Preface Operating on public roads Before operating on public roads the trailer must be correctly connected to the towing vehicle, the lights must be connected and function of the lighting equipment must be checked. If the trailer has an air brake system the brake lines and the breakaway rope (breakaway brake) must be connected if an automatic overrun brake is installed.

All requirements specified in the copy of the operating permit and vehicle registration must be observed.

If any parts of the self-loading forage wagon are modified that are of a specific composition or could endanger other road users, the operating permit becomes invalid and a new operating permit must be obtained.

The self-loading forage wagon should be taken to the appropriate vehicle testing centre to be issued with the required certificate.

If there is any doubt as to whether this is required, please contact us.

Number plate to 25 km/h:

over 25 km/h:

Trailers must be fitted with a number plate issued to the vehicle owner for one of his vehicles (unofficial number plate).

Trailers must be fitted with an official number plate with a valid inspection sticker.

Regular inspection as required by law to 25 km/h: over 25 km/h:

4.3

Not required.

Major inspection every 12 months, minor inspection every six months, special brake inspection every 12 months.

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions

Safety Instructions

5 Safety Instructions DESIGNATED USE

IDENTIFICATION OF WARNINGS AND DANGERS All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please supply all safety instructions to any other user.

The CLAAS self-loading forage wagon is designed for the usual applications in agriculture only (designated use).

Danger!

The self-loading forage wagon is suitable for and designed to pick up and transport forage lying on the ground.

Failure to observe the instructions identified by this symbol results in danger for life and limb of the user or other persons.

Use in any other way is considered as contrary to the intended use. The manufacturer does not accept any liability for such use; the user accepts all risk arising from such use.

– Measures for avoiding danger.

Designated use also includes observing the service, maintenance and repair conditions as prescribed by the manufacturer.

The machine may be operated, serviced and repaired only by persons who are familiar with the machine and which have been informed of the risks.

Observe the relevant accident prevention regulations and other generally acknowledged regulations regarding safety and occupational health, as well as the regulations and standards relevant to motor vehicles and traffic.

Modifications of the tedder without proper authority exclude the manufacturer's liability for damage resulting from any such modifications.

Caution!

Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine.

– Measures for avoiding danger to the machine.

Note!

This symbol identifies instructions that make it easier to use the machine effectively and economically.

If any parts of the machine are modified that are of a specific composition or could endanger other road users, the operating permit becomes invalid and a new operating permit must be obtained.

Failure to observe the instructions identified by this symbol results in damage to the environment.

The machine should be taken to the appropriate vehicle testing centre to be issued with the required certificate.

There is an environmental hazard involved in careless handling of environmentally hazardous substances (e.g. used oil) and/or their disposal.

Applicable in the Federal Republic of Germany only.

In other countries observe the relevant national or state regulations.

If there is any doubt as to whether this is required, please contact us.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

Environment!

The warning and instruction signs placed on the combine provide recommendations for safe operation. These instructions involve your safety – observe them at all times!

5.1

Safety Instructions GENERAL SAFETY AND ACCIDENT PREVENTION INSTRUCTIONS Basic Rule: Check that the machine is roadworthy and safe to operate every time it is put into operation!

1. Observe the current regulations regarding safety and accident prevention as well as the information in the operator's manual.

2. When using public roads observe all traffic regulations.

3. Make yourself familiar with all equipment and controls and their functions before starting work as it will be too late once you have set off.

4. Make sure that there is no one in close proximity to the machine before putting it into operation (especially children!).

Check that visibility is good, particularly when reversing (have someone direct you if necessary).

8. Make sure no one is between the tractor and the self-loading forage wagon unless the vehicle is secured to prevent it from rolling away with the parking brake and/or wheel chocks.

9. The ground speed must always be matched to the conditions. Avoid sudden curves when driving up or downhill or across a slope. Disengage the differential lock when turning. Never disengage the clutch and change gear when going downhill.

10. Observe the maximum permissible axle loads and total weights!

11. Operate the machine only when all guards are fitted and in the correct position!

12. The baffle plate is a safety device and should not be removed during operation.

5. Clothing worn by the operator must be close-fitting. Avoid wearing loose jackets, shirts or ties!

13. Ensure that all swivelling parts are secured during transport to prevent dangerous load shifting.

6. Keep the machine clean to prevent fire.

14. The independent brakes must not be used when towing the self-loading forage wagon (lock the pedals).

7. The machine must not be used to carry passengers.

8. If it is necessary to access the machine, the PTO shaft and the tractor engine must be switched off. The ignition key of the tractor must be removed.

9. The safety guards must be checked regularly for wear and replaced if necessary.

15. With single-axle machines make sure that they do not tip when coupling and uncoupling because of an unevenly distributed load. Sufficient support is required.

16. Loaded single-axle machines must not be transported on the support wheel.

1. Use only the recommended fastenings on the machine!

17. With single-axle machines make sure that the front axle of the tractor is not raised and the steering impaired by the drawbar load. Ensure that the tractor has the approved drawbar load.

2. Do not exceed the maximum support load on the trailor drawbar (the max. permissible hitched weight on the swinging drawbar).

18. The drawbar height for drawbars with drawbar support must be adjusted by a suitable specialist workshop.

3. Use extreme caution when coupling and uncoupling the machine from the tractor to avoid risk of injury.

19. Ensure that the machine is stable when parked.

General

4. Secure the machine against rolling away (parking brake, wheel chocks).

5. A risk of injury due to crushing or shearing exists in the vicinity of the 3-point linkage!

6. Couple the machine as specified by the instructions. Check the function of the trailer brake system. Observe the manufacturer's instructions.

5.2

7. Road performance, steering and braking are all influenced by the self-loading forage wagon and its load. Make sure that there is sufficient steering and braking capacity.

20. Risk of injury by crushing or shearing when operating support equipment.

21. All equipment must be placed in transport position before driving on the road. Lock the hydraulically operated articulated drawbar.

22. Do not stand on the floor conveyor unless the PTO shaft and tractor engine are switched off.

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions 23. Feed and pick-up devices, such as pick-up, conveyors, shredders and output drums, cannot be made completely safe because of their function; therefore it is imperative to remain a safe distance from these moving parts while the machine is operating. These instructions also apply for all other auxiliary equipment.

24. Do not stand near the discharge area.

25. There are dangerous implements under the safety devices that may continue to run after the drive has been switched off. Keep well clear of these devices until they have stopped.

26. Always switch off the drive and the engine before carrying out troubleshooting, and for repair, maintenance and cleaning work.

Remove the tractor ignition key.

27. When working under raised covers make sure that they are sufficiently supported.

28. When handling sharp-edged parts, such as cutting knives, wear appropriate protection (gloves, shoes etc.).

29. Wear safety goggles when sharpening knives.

30. Do not stand near hinged covers.

31. Leave safety guards in position and always place them in safe position.

PTO OPERATION

10. Before switching on the PTO shaft make sure that no one is near the self-loading forage wagon.

11. Before switching on the PTO shaft make sure that the selected PTO speed of the tractor matches the allowed speed of the machine.

12. When working with the PTO shaft no one may be near the rotating PTO shaft or universal drive shaft.

13. When using the removable PTO shaft note that the speed depends on the speed of travel and that the direction of rotation is reversed when moving backwards.

14. Maintain the permitted angling and distance of travel in curves.

15. Always switch off the PTO shaft when it is not required.

16. After switching off the PTO shaft the machine may run on because of its inertia. Do not approach it until it has stopped. Only work on the machine when it has come to a standstill.

17. To clean, lubricate or adjust the PTO driven machine or the universal drive shaft, the PTO shaft and engine must be switched off and the ignition key removed.

18. The universal drive shaft must be coupled or completely removed when transporting.

1. Use only the universal drive shafts recommended by the manufacturer.

19. Place the universal drive shaft on the bracket when the machine is uncoupled.

2. Connect and disconnect the universal drive shaft with the engine switched off and the ignition key removed.

20. When the universal drive shaft has been disconnected place the protective cover over the PTO stub.

3. Always ensure that the guards for the universal drive shaft and PTO stub shaft are installed and in a good condition!

21. Damage must be repaired immediately before continuing to work.

4. Overload or freewheel clutches must be installed on the machine. Installation on the tractor is permitted only if the clutch is covered by the safety guard on the tractor.

5. The universal drive shafts must have the recommended overlap.

6. Always ensure that the universal drive shaft is correctly installed and securely fastened!

7. Make sure that overrun brake systems have sufficient travel.

8. Secure the drive shaft guard to prevent it from rotating.

9. Never switch on the PTO shaft with the engine off.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

BRAKES 1. Check the brakes before every journey.

2. Check the brake system thoroughly at regular intervals.

3. The independent brakes must not be used when driving on the road (lock pedals).

4. If the brake system malfunctions, stop the tractor immediately. Repair faults immediately.

5. Any adjustments and repairs to the brake system must be carried out by specialist workshops or qualified brake specialists.

6. Change to a lower gear before going downhill.

7. Engage the parking brake before coupling or uncoupling the tractor.

5.3

Safety Instructions 8. The brakes must always be correctly adjusted.

No liability can be accepted for normal wear or unauthorised modifications.

HYDRAULIC SYSTEM

5. Make sure that the jack has sufficient load capacity.

6. Avoid an excessive inflation pressure. Danger of bursting!

1. The hydraulic system is under high pressure!

7. The specified tyre pressure (– see »Specifications« on page 6.1) must be maintained.

2. When connecting hydraulic cylinders and motors make sure that the hydraulic hoses are correctly connected.

8. Stand clear of the tyre when inflating.

9. Check the pressure regularly.

3. When connecting the hydraulic hoses to the tractor hydraulics, make sure that the hydraulic systems are unpressurised on the tractor side and on the machine side.

10. When working under the propped self-loading forage wagon no persons are permitted to be on it.

4. The female and male couplings between the tractor and the machine should be labelled to prevent incorrect connections. If connections are reversed (e.g. lifting/lowering), there is a risk of accident.

12. All mounting bolts and nuts must be tightened to the torque specified by the manufacturer.

5. Keep the hydraulic plugs clean.

6. Check hydraulic lines at regular intervals, and replace them if they are damaged or aged.

7. Replaced hydraulic lines must correspond to the technical requirements of the equipment manufacturer!

8. Use suitable material to prevent risk of injury when searching for leaks, such as cardboard or wood.

9. Fluid escaping under high pressure (hydraulic oil) can penetrate the skin and cause serious injuries. Seek medical attention in the event of injury of this type – risk of infection.

10. The tractor engine must be switched off and the system depressurised before starting work on the hydraulic system.

11. Repair work on the hydraulic system must be carried out by authorised specialised workshops only.

WHEELS AND TYRES, THREADED FASTENINGS 1. Repair work to the tyres must be carried out by qualified technicians using suitable tools.

2. When working on the wheels make sure that the self-loading forage wagon is secured and that wheel chocks are in place to prevent it from moving.

11. Regularly check nuts and screws for tight fit and tighten them, if necessary!

MAINTENANCE 1. Always switch off the drive and the tractor engine before carrying out any troubleshooting, and before all repair, maintenance and cleaning work. – Remove the ignition key!

2. Use suitable tools and wear safety gloves when replacing working parts!

3. Used oil should be disposed of correctly after an oil change.

4. Always disconnect the power supply before working on the electrical system!

5. Guards and protecting devices that are subjects to wear must be checked at regular intervals and replaced in good time!

6. Spare parts must at least comply with the technical standards required by the manufacturer of the implement! This is assured with original spare parts.

7. Always disconnect the connections at the alternator and battery before starting any electric welding work on the tractor and hitched machines.

SOUND PRESSURE LEVEL If the sound pressure level at the operator's ear exceeds 85 dB (A) (– see »Specifications« on page 6.1), ear protection must be used.

3. Tighten the wheel nuts after the first trip with a load.

4. After replacing the wheels retighten the wheel nuts or bolts after the first 10 operating hours, then check them every 50 hours.

5.4

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions

Safety Instructions SAFETY DECALS WITH WARNING SYMBOLS Safety decals with warning symbols are placed in all danger areas of the machine to help identify risks of injury. The warning symbols in these decals show how to avoid injury and accidents by appropriate behaviour.

The location of the decals on the machine and their wording is shown on the following pages.

The CLAAS spare part number of the decal is quoted before each description.

The figures in brackets refer to the location of the decals shown in the figures.

Immediately replace damaged or illegible safety decals with warning symbols.

When replacing parts with decals affixed to them, make sure you affix new decals again to the new parts.

1 2

3 65084

1

2 Warning symbol 514 945.1 (1) Read and follow the operator's manual and the safety instructions before putting the machine into operation!

(Fig. 1, 2)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

5.5

Safety Instructions

1

2

3 65084

3

4 Warning symbol 514 826.1 (2) Before carrying out repair and maintenance work, shut off engine and remove the key.

(Fig. 3, 4)

3

7 Warning symbol 514 869.1 (3)

65077

5

Never reach into the pick-up area while the drive engine is running.

(Fig. 5, 6, 7)

1 2

3 65084

5.6

6

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions

4

9 Warning symbol 514 842.1 (4) 64294

8

Keep well clear of crush/pinch area.

(Fig. 8, 9)

5

64317

10

5

12 Warning symbol 514 808.1 (5) Do not open or remove safety covers during operation.

Potential hazard caused by rotating machine parts.

6

(Fig. 10, 11, 12) 64316

11

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

5.7

Safety Instructions

5

6

64316

13

QUANTUM 3500 S

16

8 Warning symbol 514 744.1 (6) Do not touch machine components before they are completely stopped.

6

(Fig. 13, 14, 15, 16)

7 67942

14

QUANTUM 3500 S

8

6

7 67945

15

7

18 Warning symbol 514 884.1 (7) 64297

5.8

17

Always keep well clear of the path of the tailgate when the tractor engine is running.

(Fig. 17, 18)

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions QUANTUM 3500 S

8

6 23 Warning symbol 514 884.1 (7)

7 67945

19

QUANTUM 3500 S

Always keep well clear of the path of the tailgate when the tractor engine is running.

(Fig. 19, 20, 21, 22, 23)

8

6 7 67942

20

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8 9 7

65098

21

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8

9 7

65099

22

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

5.9

Safety Instructions QUANTUM 3500 S

8

6

7 67945

24

QUANTUM 3500 S

28 8

Warning symbol 514 802.1 (8)

6

Keep well clear of raised tailgate until the retainer is in place.

(Fig. 24, 25, 26, 27, 28)

7 67942

25

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8 9 7

65098

26

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8

9 7

65099

5.10

27

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Safety Instructions QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8 9 7

65098

29

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

8

31 Warning symbol 514 818.1 (9) 9

Do not enter the loading area with the drive on and the tractor engine running.

7

(Fig. 29, 30, 31)

65099

30

QUANTUM 3500 S

10

33 Warning symbol 514 885.1 (10) 64409

32

Do not enter the loading area with the drive on and the tractor engine running.

(Fig. 32, 33)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

5.11

Safety Instructions

11

6

68369

34

36

11 Warning symbol 514 814.1 (11) Keep hands away from hazardous crush or pinch areas as long as parts can still move.

(Fig. 34, 35, 36) 68392

35

12

64296

37

39 Warning symbol 514 843.1 (12) 12

Position wheel chock before disconnecting or parking the machine to prevent it from rolling away.

(Fig. 37, 38, 39)

64295

5.12

38

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Specifications

Specifications

6 Specifications Note!

Technical specifications, dimensions and weights are understood with the usual tolerances.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

6.1

H H

S S

Specifications

64323F

LL

B B

1

QUANTUM 3500 K

QUANTUM 3500 P

QUANTUM 3500 S

Length (L)

mm

8100

8100

8200

Width (B)

mm

2500

2500

2500

Height (H) - forage assembly folded up Height (S) - forage assembly folded down Platform height

mm mm mm

3410 2600 1180

3600 3050 1180

3600 3050 1180

Track width

mm

1850

1850

1850

Pick-up width

mm

1800

1800

1800

26.6 5040 8000 / 11000

28 5320 8000 / 11000

25.6 5660 8000 / 11000

33 45 26 61 1000

33 45 26 61 1000

33 45 26 61 1000

Loading capacity (DIN 11741) Unladen weight Approved total weight (autoreverse/air brake system) Number of cutting knives Shortest theoretical length of cut Number of pick-up tines per tine bar Tine clearance PTO speed Tyres

3

m kg kg

mm mm rpm

19.0/45-17 19.0/45-17 19.0/45-17 500/50-17 10PR 500/50-17 10PR 500/50-17 10PR 500/50-17 10PR 500/50-17 10PR 500/50-17 10PR 555/45-17 10PR 555/45-17 10PR 555/45-17 10PR

- Autoreverse up to 40 km/h or - Air brake up to 40 km/h - Air brake up to 60 km/h

Tyre pressure - with tyres

500/50-17 555/45-17 19.0/45-17

bar bar bar

3.5 3.0 3.0

3.5 3.0 3.0

3.5 3.0 3.0

Tightening torque for wheel nuts

M18X1.5 M20X1.5

Nm Nm

270 380

270 380

270 380

Sound pressure level Max. power consumption

dB (A)

70

70

70

A

15

15

15

(Fig. 1)

6.2

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

H

S

Specifications

B

L

66216F/01

66216F_01

2

QUANTUM 3800 K

QUANTUM 3800 P

Length (L)

mm

9250

9250

Width (B)

mm

2500

2500

Height (H) - forage assembly folded up Height (S) - folded assembly folded down Platform height

mm mm mm

3410 2600 1180

3600 3050 1180

Track width

mm

1850

1850

Pick-up width

mm

1800

1800

31.8 5560 11000

33.2 5650 11000

33 45 26 61 1000

33 45 26 61 1000

Loading capacity (DIN 11741) Unladen weight Approved total weight (air brake system) Number of cutting knives Shortest theoretical length of cut Number of pick-up tines per tine bar Tine clearance PTO speed

3

m kg kg

mm mm rpm

Tyres - Airbrake up to 40 km/h - Airbrake up to 60 km/h

500/50-17 10PR 500/50-17 10PR 555/45-17 10PR 555/45-17 10PR

Tyre pressure- with tyres

500/50-17 555/45-17 19.0/45-17

bar bar bar

3.5 3.0 3.0

3.5 3.0 3.0

Tightening torque for wheel nuts

M18X1.5 M20X1.5

Nm Nm

270 380

270 380

Sound pressure level

dB (A)

70

70

A

15

15

Max. power consumption (Fig. 2)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

6.3

Assembly

Assembly

74

3 6

2 5

41

41

64309F_01 64309F/01

1

7 Assembly Danger!

Always work on the machine with the engine switched off.

– Switch off engine.

– Remove the ignition key.

ASSEMBLY QUANTUM 3800 P / 3500 P Raise the hoop and foldable boards. Lock the boards with the journals (1).

Install the front protective cloth (2) on the hoop with a bar (3) and fasten it at the rear to the eyelets of the tensioning ropes. The rubber tensioner of the ropes must face forwards.

Use the bar (4) to secure the other end of the ropes to the rear hoop of the wagon top. Secure the bar against lateral movement with washers and split pins.

(Fig. 1)

7.1

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Assembly 15

62

3 7

64307F 64307F

2

QUANTUM 3800 K / 3500 K Wind the tension ropes around the rear hoop (Fig. 2) and install the roll pins (5) to prevent them from moving sideways. The rubber tensioner of the ropes must face forwards.

Pass the bar (6) through the front protective cloth and through the straps on the front hoop (7). Secure the bar on both sides with washers and split pins. Attach the tensioning ropes to the S-shaped hooks on the other side of the cloth.

88

Install the rear protective cloths (8) as shown in Fig. 3.

64308F

3

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

(Fig. 2, 3)

7.2

Assembly

912

19

912

11 3

11 3 10 2

67930F_01 64464F/01

4

QUANTUM 3500 S 14

13

Fold up hoop (9) and foldable boards (10). Lock the boards with the journals (11) (Fig. 4).

16

Pull the rear protective cloth (13) through the rear hoop (14) and fasten it to the tailgate frame profile with the rod (15). Attach the centre tensioning ropes (16) to the rod (17) in the front of the protective cloth. Attach the four outer tension ropes on both sides to the bolt on the rear hoop (14) and secure with the self-locking nut (12).

17 12 64485F_02

7.3

15

(Fig. 4, 5) 5

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation

Before Operation

8 Before Operation Danger!

Always work on the machine with the engine switched off.

– Switch off engine.

– Remove the ignition key.

CHECK AND OBSERVE THE FOLLOWING BEFORE PUTTING INTO OPERATION 1. The tractor must be equipped for operation with a single acting return and a double-acting control valve.

Hydraulic connections– see »Hydraulic system«, page 8.10 2. Brake system of the self-loading forage wagon: • The self-loading forage wagon can be fitted with one of the three following types of brake systems (depending on the traffic regulations and the approved total weight): – Air brake system »dual-circuit system«, connection – see »Air brake system«, page 8.12.

– Hydraulically actuated brakes, connection – see »Hydraulically operated brake system«, page 8.13.

– Automatic overrun brake – see »Overrun brake«, page 8.14.

• The tractor brake system must be the same as that of the self-loading forage wagon.

3. Check the brakes before every journey.

4. Check oil level in the gearboxes.

5. Check safety equipment (e.g. overload clutches, covers of drive components, ...) for function and correct position.

6. Thoroughly lubricate the self-loading forage wagon before operation.

7. Check that all bolts and screws are tight.

8. Hitching self-loading forage wagon – see »Coupling to the tractor«, page 8.3.

9. Fill accumulator for articulated drawbar with oil – see »Filling the accumulator of the hydraulic articulated drawbar«, page 8.5.

10. Connect universal drive shaft – see »Drive shaft«, page 8.6.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.1

Before Operation 11. Secure universal drive shaft gear against rotating by hanging in the chains.

12. Couple the tractor PTO shaft at idle speed only.

13. Observe maximum PTO speed – see »Specifications«, page 6.1!

14. Connect 2-pole plug for power supply of self-loading forage wagon to tractor – see »Electrical connection«, page 8.8.

Make sure that the tractor cables are sufficiently in size for the power supply.

The voltage must be 10.8 V for correct operation of the solenoid valves on the self-loading forage wagon (measured at the solenoids). If necessary, install the 6-quadrat cable (available from the spare parts department) – see »Tractor electrical power supply (accessory equipment)«, page 8.9.

15. Connect the 7-pole plug for the light system to the tractor socket.

16. Check the wheel nuts for tightness (tightening torques – see »Specifications«, page 6.1). Check tyres for correct inflation, if required correct according to »Specifications«, page 6.1.

17. After every wheel installation check the wheel nuts again for tightness after the first 10 hours of operation. Tightening torques – see »Specifications«, page 6.1.

Wheels must be installed using a jack with sufficient lifting capacity for the weight of the machine.

18. Check the tension and state of the drive chains.

19. After hitching the self-loading forage wagon and connecting the universal drive shaft check that the shaft can move freely by turning right and left carefully.

20. Never leave the self-loading forage wagon running unattended.

21. Make sure that there are no loose parts on the machine and tractor before moving off. Securely attach or cover parts which can fall off during travel.

22. Make sure no-one is in the area of danger; immediately switch off the self-loading forage wagon if any person approaches the area of danger.

8.2

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation COUPLING TO THE TRACTOR Danger!

Always work on the machine with the engine switched off.

– Switch off engine.

– Remove the ignition key.

Self-loading forage wagons must be towed by tractors that can support the specified drawbar load of the self-loading forage wagon.

– Observe drawbar load – see »Specifications«, page 6.1 or identification plate.

Before operating the self-loading forage wagon for the first time, adjust the hitch and universal drive shaft for the tractor.

Hydraulic articulated drawbar Attach the hitch to the tractor to ensure that there is sufficient clearance between the universal drive shaft and drawbar, particularly when operating the articulated drawbar.

Adjust the drawbar of the self-loading forage wagon so the loading area of the self-loading forage wagon is horizontal to slightly inclined to the front (ca. 2°) when attached to the tractor.

(Fig. 1) 65075F

1

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.3

Before Operation Ring hitches Danger!

20°

20°

To ensure the required steering angle (as per DIN 74052) (Fig. 2, 3) the tractor hitch must be suitable for the specific self-loading forage wagon ring hitch (see also the tractor manufacturer's operator's manual). If this is not observed the hitch may be damaged and other road users endangered.

66237F

– Use the specified hitch or larger tractor with matching hitch.

2

70

°

– Observe maximum drawbar load – see »Specifications«, page 6.1.

QUANTUM with approved total weight of 8 tonnes and overrun brake = ring hitch as per DIN 11043 (3).

QUANTUM with approved total weight of 11 tonnes and air brake = ring hitch as per DIN 74054 (2).

70

°

(Fig. 2, 3, 4)

66238F

3

The type designation of the ring hitch (e.g. DIN 11043) is shown on the ring hitch identification plate (1) or on the ring hitch (2).

(Fig. 4)

2

3 1

68370

8.4

4

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation Height adjustment of the drawbar Caution!

6

4

The height of the drawbar must be adjusted by a specialist workshop only. Incorrect settings may damage the hydraulic articulated drawbar.

5

– Adjust the hydraulic cylinders to the same setting on both sides.

65097

5

Loosen lock nut (6) (SW 46).

The spindle (5) can now be screwed in or out by turning the hydraulic ram (4) with an open spanner (SW 41).

After the adjustment tighten the lock nut (6) again.

(Fig. 5)

Filling the accumulator of the hydraulic articulated drawbar 7

Before operating for the first time and after extended downtime the accumulator (7) for the hydraulic articulated drawbar must be filled. It is not necessary to hitch the vehicle for this.

Lower the hydraulic articulated drawbar completely with the tractor hydraulics – see page 9.6, »Silage operation/hydraulic articulated drawbar«.

Maintain down pressure for a short time.

6

If the tractor control valve is now switched to float position, the drawbar must be lifted to its top position.

(Fig. 6)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.5

Before Operation Drive shaft The drive shaft with the cam-type cut-out clutch must be located on the machine side.

Danger!

Risk of injury by universal drive shaft coming loose during operation.

– Check that all locks are securely engaged before starting work with the PTO drive shaft.

7 Adjusting the universal drive shaft Pull drive shaft sections apart and connect both sections to the PTO stub shafts. Hold the two sections of the universal drive shafts together in the shortest operating position and mark them.

(Fig. 7)

Observe the maximum permissible shaft length (LB).

Try to have the maximum possible overlap of the profile tubes.

8

During operation the universal drive shaft overlap (PU) must never be less than 50% of the overlap when the tubes are fully compressed (LZ).

The universal drive shaft halves must not bottom against each other at the shortest operating position. A minimum clearance of (a) = approx. 40 mm must still be available.

(Fig. 8)

Cut the male and the female guard tubes uniformly.

Cut the same length from the male and female profile tubes. File the cut area to remove any metal burrs, remove any metal filings. Grease the sliding surfaces of the profile tubes.

(Fig. 7)

8.6

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation

9 Danger!

Never use universal drive shafts without guards or with damaged guards (8) – risk of injury!

– Mount shaft guard and protective tube.

8

– Fasten them to prevent them rotating.

65111

– The universal drive shafts must only be operated when in good condition.

9

Caution!

Otherwise damage or increased wear of drives may occur.

– Always engage the PTO shaft slowly to save the drive mechanism.

– Observe the recommendations of the PTO shaft manufacturer.

Attach the safety chains (9) for the shaft guard to the hook on the drawbar and tractor.

(Fig. 9)

Note the maximum shaft angles!

Wide-angle synchronism joint:

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

For continuous operation

25°

For short-term operation

45°

For standstill

90°

8.7

Before Operation Electrical connection Control unit Fit bracket (10) for the in-cab control unit (11) on the tractor in a position within reach of the operator.

100%

To install the control unit first insert the cable (13) into the guide (12) and then press the control unit into the bracket.

10 4

4 6 2

11 5

8

(Fig. 10)

0 10

Contro l

Termin al

13 12 7 6

65063F

10 Connect control unit cable to the socket (14) on the self-loading forage wagon.

(Fig. 11)

14

64379

11 Connect the 2-pole plug (17) for the power supply of the self-loading forage wagon to the accessory socket on the tractor.

Maximum power consumption of the self-loading forage wagon – see »Specifications«, page 6.1.

15 16

Do not exceed the maximum load of the socket. Also observe the instructions in »Tractor electrical power supply (accessory equipment)«, page 8.9.

17

(Fig. 12) 64948

12

Lighting equipment: Connect the 7-pole plug (15) for the lighting equipment to the socket (16) on the tractor.

(Fig. 12)

8.8

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation Tractor electrical power supply (accessory equipment)

1

Danger!

Overloaded or inadequate wiring can cause electrical faults and may cause wiring fires.

011

– Observe maximum load of accessory socket.

8.0

70

67641

13

– Do not exceed maximum power consumption of self-loading forage wagon – see »Specifications«, page 6.1.

– If necessary, upgrade wiring.

Note!

18

If the voltage drop in the tractor power supply is too high, correct functioning of the electro-hydraulic operation cannot be assured.

64948

14

The voltage must be at least 10.8 V for correct operation of the solenoid valves on the self-loading forage wagon (measured at the solenoids).

If necessary install the 6-quadrat cable with 2-pole socket (18) (available from the spare parts department).

Order no.:

011 708.0

Connection Lay out cable (black) with 16 A in-line fuse from the 2-pole socket to the tractor battery (or to the starter if the battery is not possible) and connect it securely.

Connect earth cable (brown) to the tractor chassis.

(Fig. 13, 14)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.9

Before Operation Hydraulic system Adjusting hydraulic system (QUANTUM 3500 S only) 19 Caution!

Because different tractors have different hydraulic systems, the tractor operator's manual must be followed in all cases. This is the only way to prevent damage to the tractor hydraulic system.

– Follow tractor operator's manual.

64961

Look out for pinch and crush points when connecting the hydraulic lines.

15

– Lay out hydraulic lines so they cannot be pinched or crushed during operation.

Do not allow the tractor hydraulics to overheat.

Observe any warning signals installed on the tractor.

The hydraulics of the self-loading forage wagon must be adjusted to the tractor hydraulics. The adjustment is made at the stop valve (19).

(Fig. 15)

Danger!

The hydraulic system must be depressurised before making any adjustments.

– Switch off engine.

– Remove the ignition key.

– Depressurise hydraulic system.

The factory setting on the self-loading forage wagon is for a tractor with an open hydraulic system (standard system).

Open hydraulic system (standard system) Tractor with constant flow - pump or load sensing - pump without control line:

19

Turn stop valve (19) anticlockwise to the left to the limit stop (factory setting) = free circulation of oil.

(Fig. 16) Normal Betrieb Sachnr:

LS-o.JD-Betrieb

65064F

8.10

P max: Typ: Dat:

bar

16

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation Closed hydraulic system 19

Caution!

If one of the following systems is installed, the pressure relief valve of the self-loading forage wagon must be set to a higher value than the pressure relief valve of the tractor.

Normal Betrieb Sachnr:

LS-o.JD-Betrieb

P max: Typ: Dat:

bar

Tractor with constant pressure pump (e.g. John Deere, Case Maxxum, Case Magnum, Ford Series 40):

20 65076F

17

Turn stop valve (19) clockwise to the right to the limit stop = oil circulation blocked.

To do this loosen the bolts (20), turn stop valve (19) to the right, tighten bolts again.

(Fig. 17)

Hydraulic connection Caution!

Dirty quick release couplings can cause increased wear in the hydraulic pumps and can cause failure of the hydraulic system.

Incorrectly connected hydraulic hoses will also damage the hydraulic system!

21

– Always clean the male couplings of the hydraulic hoses and the hydraulic coupling sockets on the tractor before connecting them.

22 64948

18

Look out for pinch and crush points when connecting the hydraulic lines.

– Lay out hydraulic lines so they cannot be pinched or crushed during operation.

Connect the two hydraulic hoses (22) of the floor conveyor drive to a double-acting control valve on the tractor.

Connect the single hydraulic hose (21) to a single-acting control valve on the tractor.

(Fig. 18)

Connection for stopping the steering wheels on the steering axle (optional equipment) Connect the hydraulic hose for the hydraulic cylinder for locking the steering wheels on the steering axle to a single-acting control valve on the tractor.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.11

Before Operation Prop stand After attaching the self-loading forage wagon

• Raise the self-loading forage wagon slightly by

23

actuating the hydraulic articulated drawbar.

• Remove the pin (23) from the stand (24).

• Slide stand up and secure with the pin.

• Secure the pin with the spring clip.

24

(Fig. 19) 68368

19

Parking the self-loading forage wagon Danger!

A risk of injury due to crushing or shearing exists when parking the self-loading forage wagon.

– Caution when setting the stand.

– Never step or reach under the stand.

• Lift the self-loading forage wagon with the hydraulic articulated drawbar.

• Remove the pin (23) from the stand (24).

• Slide stand right down and secure with the pin.

Secure the pin with the spring clip.

• Lower self-loading forage wagon.

(Fig. 19)

Air brake system Two-line system Danger!

25 65110

If hoses come loose suddenly, the brake system of the self-loading forage wagon will fail. The coupling heads must be securely clicked into place. The hoses must be in good condition.

26 20

– Check all connections for correct seating after attaching the quick release couplings.

– Check the hose layout to ensure that no hoses can be crushed.

Connect the pressure hoses (25, 26) to the quick release couplings on the tractor.

8.12

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation First connect the yellow then the red coupling head.

Uncouple in reverse order.

(Fig. 20)

Towing with tractors without air brake system If compressed air is available in the reservoir at a pressure of approximately 4 bar, the brake on the self-loading forage wagon can be operated with pressure hoses uncoupled. If the pressure is below 4 bar, the brake cannot be operated with the push button (27). In this case the system must be refilled. Proceed as follows to release the brake:

27

• Before releasing the brake make sure that the 64937

21

self-loading forage wagon cannot move. Attach self-loading forage wagon to the tractor.

• Release brake by pressing the push button (27) on the reversing valve (release valve).

After manoeuvring actuate brake again as follows:

• Pull out push button (27) to the stop.

When the pressure hoses are connected to the tractor again the push button is automatically pushed out again.

(Fig. 21)

Hydraulically operated brake system Caution!

Look out for pinch and crush points when connecting the hydraulic line.

– Lay out the hydraulic line so it cannot be pinched or crushed during operation.

28 67913

22

Connect the hydraulic hose (28) for the hydraulically operated brake to the matching quick release coupling on the tractor.

(Fig. 22)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.13

Before Operation Parking brake Danger!

B

When the self-loading forage wagon is uncoupled, it may roll away. Before uncoupling the self-loading forage wagon secure it to prevent it from rolling away.

A 29

– Set parking brake.

– Place wheel chocks under the wheels.

65096

23

Setting brake Turn crank (29) in direction of rotation (A).

Releasing brake Turn crank (29) in direction of rotation (B).

After operating the parking brake swing the crank (29) in.

(Fig. 23)

Overrun brake On self-loading forage wagons with overrun brake attach the breakaway rope (31) to the handbrake lever (30) and the tractor.

30

For more information see »Servicing and adjustment instructions for self-loading forage wagon axles with System 2000 automatic reverse overrider«, page 10.5 and following pages.

31

(Fig. 24) 67647

24

Wheel chocks The wheel chocks (32) are located in the right and left wings of the self-loading forage wagon.

The wheel chocks must always be carried.

Secure the self-loading forage wagon against rolling away with the wheel chocks.

(Fig. 25) 32

65106

8.14

25

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation Inspection hatch (QUANTUM 3500 S only) Danger!

Danger from the drive starting suddenly or the self-loading forage wagon rolling away.

Do not enter the load space unless the tractor engine is stopped and the parking brake is set.

33

– Switch off engine.

– Remove the ignition key.

65091

26

– Set parking brake.

– Place wheel chocks under the wheels.

The loading space of the self-loading forage wagon can be accessed through the side inspection hatch (33).

(Fig. 26)

UNHITCHING Danger!

When the self-loading forage wagon is unhitched, it may roll away. Before unhitching the self-loading forage wagon secure it to prevent it from rolling away.

– Park the self-loading forage wagon on hard level ground only.

– Set tractor parking brake.

– Place wheel chocks under the wheels of the self-loading forage wagon.

– Set parking brake of self-loading forage wagon.

To unhitch the self-loading forage wagon proceed as follows:

• Drive the self-loading forage wagon to a hard level site.

• Switch off drive.

• Lift the self-loading forage wagon at the front with the hydraulic articulated drawbar.

• Switch off hydraulics.

• Switch off the engine and remove the ignition key.

• Set the tractor parking brake.

• Do not leave the tractor until the engine is stopped and the parking brake has been set.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.15

Before Operation • Pull out stand and secure – see »Prop stand«, page 8.12.

• Start tractor engine again and switch on hydraulics for the self-loading forage wagon.

• Position self-loading forage wagon on the stand with the hydraulic articulated drawbar and release the load from the hitch (drawbar coupling).

• Switch off hydraulics.

Caution!

Pressurised hydraulic lines cannot be coupled again.

– Before unhitching the self-loading forage wagon always depressurise the hydraulic system.

• Switch off engine again and depressurise hydraulic system.

• Set parking brake of self-loading forage wagon– see »Parking brake«, page 8.14.

• Place wheel chocks under the wheels of the self-loading forage wagon.

Caution!

Dirty quick release couplings can cause increased wear in the hydraulic pumps and failure of the hydraulic system.

– Lay out the hydraulic and compressed air hoses so the quick release couplings are not contaminated.

• Disconnect all hydraulic and compressed air hoses and insert quick release couplings into the holders on the drawbar.

Caution!

Moisture in the control unit will cause the electro-hydraulic control of the self-loading forage wagon to malfunction.

– Protect control unit against moisture.

– Place it in the bracket provided.

• Remove control unit from the tractor and store it away from moisture; cover it if necessary.

• Disconnect plugs for self-loading forage wagon power supply and lighting equipment from the tractor.

8.16

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Before Operation • Uncouple universal drive shaft and install guard on PTO drive.

• Attach the wide-angle universal drive shaft to the drawbar with the chain (1).

• Release drawbar from the tractor.

(Fig. 27)

1 65115

27 Self-loading forage wagon with air brake system

• First disconnect the red then the yellow coupling.

Connect the air hoses to the blind couplers (2) on the drawbar.

(Fig. 28) 2 Self-loading forage wagon with hydraulically operated brake

67646

28

Danger!

A dirty quick release coupling may cause the brake system to fail.

– Lay out the hydraulic hose so the quick release coupling is not contaminated.

– Place the quick release coupling in the bracket provided and cover it with a protective cap.

• Remove the hydraulic hose for the hydraulically operated brake from the quick release coupling on the tractor.

• Protect quick release coupling and coupler socket from dirt with protective caps.

Self-loading forage wagon with automatic overrun brake

• Set handbrake lever.

• Remove breakaway rope from tractor and lay on drawbar.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

8.17

Before Operation PRIOR TO TRANSPORTATION 1. Hitch self-loading forage wagon, secure hitch pins.

2. Couple universal drive shaft and hydraulic hoses.

3. Connect compressed air hoses or hydraulic hose in the case of a hydraulically operated brake system.

4. On self-loading forage wagons with automatic overrun brake attach the breakaway rope to the tractor.

5. Connect electrical cable.

6. Lift pick-up to highest position.

7. Close and lock tailgate and lateral inspection hatch.

8. Stow wheel chocks in the brackets.

9. Raise and lock stand.

10. Lower hydraulic articulated drawbar.

11. Release parking brake.

12. Check that the self-loading forage wagon is safe to drive and operate.

During road transport avoid operating the control levers of the hydraulics inadvertently.

Driving on public roads When operating on public roads place hydraulic control lever in neutral position and secure to prevent accidental operation.

The applicable laws and regulations must be observed when travelling on public roads!

Observe the applicable regulations in your country.

Observe the corresponding regulations in other countries.

The ground speed must conform to the traffic and road conditions. Observe the applicable speed limits!

Reduce speed as appropriate when going around curves.

Prepare self-loading forage wagon for transport.

Additionally for steering axle (optional equipment): Before reversing set steering axle straight ahead and lock – see »Steering axle (optional equipment)«, page 9.11!

8.18

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation

Operation

9 Operation GENERAL NOTE OF THE CONTROL UNIT 100% The keys on the control unit are used to preselect the different functions of the self-loading forage wagon.

Operation of the single-acting control valve of the tractor will then actuate the desired function.

The single-acting control valve must always be switched to neutral position between different operations. Only then can a new function be selected on the control unit.

1

4

The floor conveyor is switched on with the double-acting control valve of the tractor. On the S-trailer the speed of the floor conveyor can be varied with the rotary knob (1); on the K and P-trailers this knob has no function (Fig. 1).

6 8

2 0

10 Note!

If the self-loading forage wagon control system is not operated for a period of 20 minutes, the control unit is automatically switched off to prevent the tractor battery from being discharged.

(Fig. 1) Control Terminal

1

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.1

Operation SHORT INSTRUCTIONS 100% Control system ON

Control system OFF

Loading operation Pick-up up/down

4

6 8

2 0

Dry crop top up/down (QUANTUM 3800 K / 3500 K only)

10 Wagon full indicator

Cutting mechanism Knife frame open/closed (to clear a blockage)

Control Terminal

Knife frame fully open

2

Unloading operation Tailgate open/closed

Hydraulic articulated drawbar drawbar up/down

(Fig. 2)

9.2

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation LOADING OPERATION 100% To switch on the control box switch the hydraulics to pressure. The display shows self-loading forage wagon.

Lifting and lowering the pick-up Use this key to preselect the pick-up. The pick-up can now be lifted and lowered with the single-acting control valve. For loading switch on the PTO.

4

6 Note!

8

2 0

The pick-up will only remain in floating position if the pick-up mode is preselected on the control unit and the single-acting control valve of the tractor is set to floating position.

10

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P To switch off the pick-up and rotor disengage the PTO. QUANTUM 3500 S Rotor and pick-up are automatically disengaged when the pick-up is raised.

Control Terminal

3

(Fig. 3)

Dry crop top (QUANTUM 3800 K / 3500 K) Use this button to preselect the dry crop top.

To raise the dry crop top switch the single-acting control valve to pressure. To lower it select floating position.

(Fig. 3)

Preselecting the working height of the pick-up Danger!

1

The pick-up can be switched on from the tractor. Beware of rotating spring tines.

2

Before working on the pick-up: – Switch off engine.

– Remove the ignition key.

65109

4

To preset remove the plug (1) and attach the relevant hole of the perforated strip (2) to the pin. Set right and left gauge wheels to the same height.

Tines should be 10 - 20 mm off the ground depending on the crop, stubble height and ground contours.

(Fig. 4)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.3

Operation Baffle plate Danger!

Beware of rotating spring tines.

4

– The baffle plate (3) must not be removed when the machine is running.

The pick-up can be switched on from the tractor. Before working on the pick-up:

3

– Switch off engine.

64302

5

– Remove the ignition key.

Lower the baffle plate with light crops, raise it for heavy crops (such as wilted swaths). Adjust the chain (4) appropriately to raise and lower the baffle plate.

(Fig. 5)

Floor conveyor 100%

The floor conveyor is operated with the double-acting control valve of the tractor. To switch the floor conveyor to forward or reverse just set the double-acting control valve to lifting or lowering.

Setting floor conveyor speed QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

5

The turn switch on the control unit has no function with K and P-wagons.

4

6

On tractors with an adjustable throughput regulator this switch can be used to vary the floor conveyor speed.

8

2 0

10 QUANTUM 3500 S The floor conveyor speed can be varied with the turn switch (5) if the pick-up or the tailgate is preselected.

(Fig. 6)

Control Terminal

9.4

6

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation Opening and closing knife frame 100% Danger!

The knife frame can be lifted from the tractor – pinch point!

Before working on the knife frame: – Switch off engine.

– Remove the ignition key.

4

When working on or in the knife frame there is an increased risk of injury by sharp-edged machine parts.

6 8

2

– Wear gloves.

0

10 If a blockage occurs in the conveyor channel (drive shaft cut-out clutch is triggered), switch off the PTO shaft.

Use this key to preselect the knife frame on the control unit. Then set the lever of the single-acting control valve to floating position; this opens the knife frame.

Control Terminal

7

Engage the PTO shaft to clear the blockage. Once the conveyor channel is free, set the lever of the single-acting control valve to pressure; this closes the knife frame.

If the knife frame has to be fully lowered (e.g. for repairs or to replace knives), press this key first. Then set the single-acting control valve to floating position.

Then press these two keys simultaneously.

Caution!

If the knife frame is fully open, make sure that the cutting knives do not bottom against the rotor tines.

– Close the knife frame carefully and slowly.

Set the control valve to pressure to close the knife frame.

(Fig. 7)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.5

Operation "Wagon full" indicator 100%

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P The wagon is fully loaded when the indicator light (6) (Fig. 8) in the display flashes. Switch off the floor conveyor, set the double-acting valve to neutral position, lift the pick-up and switch off the universal drive shaft.

6

(Fig. 8)

QUANTUM 3500 S

4

6

The wagon is fully loaded when the indicator light (6) (Fig. 8) in the display flashes. The floor conveyor is switched off automatically. Lift the pick-up and switch off the universal drive shaft.

8

2 0

10

(Fig. 8)

Control Terminal

8

UNLOADING 100% Danger!

The floor conveyor can be switched on from the tractor. If it is necessary to enter the load space: – Switch off engine.

– Remove the ignition key.

4

– Do not enter the load space while unloading.

6 8

2 0

To switch on the control press this key on the control unit. The indicator light comes on.

10

Silage operation/hydraulic articulated drawbar During silage operation lift the front of the self-loading forage wagon with the hydraulic articulated drawbar. Press this key to preselect the hydraulic articulated drawbar and then switch the single-acting control valve to pressure.

Control Terminal

9.6

9

After unloading lower the wagon again. Set control valve to floating position.

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation

Note!

If the wagon cannot be fully lifted with the hydraulic articulated drawbar, this means that there is an oil leak in the hydraulic cylinders. To drain the oil retract the hydraulic cylinder to the limit stop.

(Fig. 9)

Unloading the load space 100% Danger!

The tailgate can be opened and closed from the tractor and is automatically opened for unloading – pinch point!

– Direct all persons away from the swivel range when opening and closing the tailgate.

1

4

– Keep a sufficient safety distance.

6 8

2 0

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P Open the tailgate for unloading. Press this key to preselect the tailgate and then switch the single-acting control valve to pressure.

10

Switch on the floor conveyor with the double-acting control valve.

To close the tailgate, set the single-acting control valve to floating position until the tailgate latches are correctly locked.

QUANTUM 3500 S Control Terminal

10

Open the tailgate for unloading. Press this key to preselect the tailgate and then switch the single-acting control valve to pressure.

Activate the shredder drums with the PTO shaft. The tailgate must be open for this. Then switch on the floor conveyor with the double-acting control valve. The floor conveyor speed can be controlled with the turn switch (1).

To close the tailgate, set the single-acting control valve to floating position until the tailgate is closed.

To reverse the floor conveyor move the double-acting control valve lever in the opposite direction.

On tractors with an adjustable throughput regulator this switch can be used to vary the floor conveyor speed.

(Fig. 10)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.7

Operation Divided tailgate (QUANTUM 3500 S only) This self-loading forage wagon is fitted with a divided tailgate.

2

Danger!

A

B

The drive and the engine must always be switched off when working on the self-loading forage wagon.

3

64520

– Switch off engine.

– Remove the ignition key.

11

Opening the lower and top tailgate (short flat silo and thick forage mat)

• Turn the bars (2) on the right and left side from position B to position A.

• Secure the bars (2) against rotation with the spring clip (3).

Opening the lower part of the tailgate (long flat silo and thin forage mat)

• Turn the bars (2) on the right and left side from position A to position B.

• Secure the bars (2) against rotation with the spring clip (3).

(Fig. 11)

Note!

The top section of the tailgate can also be locked. Insert latch (4) on the left side into the centre hole.

4 (Fig. 12)

64956

9.8

12

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation

Note!

The complete tailgate can be opened when latch (4) is secured in the top hole.

(Fig. 13) 4 64957

13

OPERATION OF SELF-LOADING FORAGE WAGON

• • • •

Check that the tailgate and knife frame are closed.

Lower pick-up.

Engage PTO shaft at slow idle speed.

Observe maximum PTO speed – see »Specifications«, page 6.1!

• Then increase speed and ground speed in accordance with the fodder and ground conditions.

• Disengage PTO shaft and lift pick-up when negotiating tight curves.

• The indicator light of the "Wagon full" indicator on the control unit flashes when the self-loading forage wagon is fully loaded. Switch off floor conveyor and disengage PTO shaft.

• Lift pick-up.

• Always open the tailgate before unloading.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.9

Operation Loading operation (general) Danger!

The drive and the engine must always be switched off when clearing blockages.

– Disengage PTO drive.

– Switch off tractor engine.

– Remove the ignition key.

Note!

The knife frame and tailgate must be fully closed for loading.

The pick-up and feed components are protected against overload by the cam-type cut-out clutch on the universal drive shaft.

Reduce the PTO speed and ground speed before negotiating curves.

Pick up mower swath from the head.

Work only with sharp cutting knives.

The swaths should as uniform as possible to ensure a continuous feed of crop into the wagon. This will also make operation smoother and improve cutting quality.

When loading silage do not exceed the permissible total weight.

Driving on public roads The road traffic regulations must be observed when driving on public roads – see »Driving on public roads«, page 8.18.

When operating on public roads place tractor control valves in neutral position and secure to prevent accidental operation.

After use At the end of each work day release the pressure from self-loading forage wagon hydraulic system. Switch off the tractor engine and actuate the tractor hydraulic valve several times.

9.10

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Operation Steering axle (optional equipment) The tractor must be fitted with an additional single-acting control valve to control the steering axle.

Caution!

With the steering axle the rear wheels of the self-loading forage wagon are steered by the friction between the wheel and the ground.

The steering axle must be locked to prevent the wheels steering unexpectedly when driving over the silo, when reversing or when driving on slopes.

– Locking steering axle.

The steering wheels on the steering axle must be locked to prevent them steering when reversing, driving over the silo or when driving on slopes.

The wheels on the steering axle can be locked and released as follows:

• Drive straight ahead until the wheels on the steering axle are straight ahead.

• Apply pressure to the hydraulic cylinder on the steering axle to lock the wheels.

• Release the pressure on the hydraulic cylinder to release the wheels. This greatly reduces tyre wear caused by driving around curves.

Drawbar extension for automatic pick-up hitch M01 0010 (optional equipment) Depending on the tractor type, it may be necessary to install an extension (3) for the automatic pick-up hitch between the reversible ring hitch (1) and the drawbar (2).

2

1

Drawbar extension: Order no.: 3

66222F

66222F

971 929.0

(Fig. 14) 14

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

9.11

Operation EMERGENCY CONTROL Danger!

Beware of crush and pinch zones and rotating machine parts. Emergency control must be carried out with the tractor engine running. A second operator is required to sit on the tractor and to switch off and stop the hydraulic system and engine immediately in case of emergency. When operating the valves manually:

1 3 2 64961

15

– Disengage the PTO shaft.

QUANTUM 3500 P / 3500 S

– Maintain sufficient clearance from movable parts (pick-up, hydraulic articulated drawbar ...).

2

– In case of emergency switch off hydraulic system immediately.

– Switch off engine and remove ignition key.

A B

C

If there is a fault in the electrical system the self-loading forage wagon can be operated with the flow control valve (1) and the control block (2).

D

65073

16

Floor conveyor

QUANTUM 3800 K / 3500 K

Screw in bolt (3) on control valve (1) until it no longer protrudes. Set double-acting control valve on tractor for the floor conveyor to pressure.

2

Additional functions

A

B

Set single-acting control valve on tractor to pressure and lock it. Use an appropriate tool (screwdriver or similar) to press into the hole on the control block (2) that corresponds to the valve required.

C

D E

65073

17

Valve A:

pick-up

Valve B:

knife frame

Valve C:

tailgate

Valve D:

hydraulic articulated drawbar

(Fig. 15, 16, 17)

QUANTUM 3800 K / 3500 K only Valve E:

dry crop top

(Fig. 15, 17) Note!

All valves can be operated independently of one another to activate the desired function.

9.12

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance

Maintenance

10 Maintenance IMPORTANT MAINTENANCE INSTRUCTIONS

After replacing the wheels retighten the wheel nuts or bolts after the first 10 operating hours, then check every 50 hours. For tightening torques see »Specifications«, page 6.1.

Brakes and axles Danger!

Always switch off the drive and the tractor engine before carrying out any troubleshooting, and before all repair, maintenance and cleaning work.

– Remove ignition key and uncouple universal drive shaft.

– Secure the self-loading forage wagon against rolling away (parking brake, wheel chocks).

When carrying out repair, maintenance and cleaning work and troubleshooting under or on the raised self-loading forage wagon, make sure that it is securely supported.

– Use appropriate supports.

Assembly work on pretensioned energy storage devices (springs, accumulators, gas shock absorbers etc.) requires sufficient knowledge and appropriate tools and must only be carried out in specialist workshops.

Energy storage equipment (springs, accumulators etc.) must be released as specified before working on it.

Wheels / tyres Note!

Repair work on tyres must be carried out by qualified technicians using suitable equipment.

Danger!

Incorrect repairs on the brake system may cause the brake system to fail.

– Have all work on the brake system carried out by a specialist workshop.

– Follow the manufacturer's recommended maintenance schedule.

– Have brake systems thoroughly inspected regularly.

Air brake system Check brake hoses for proper condition. Damaged brake hoses must be replaced. No welding or soldering may be performed on fittings, tubes and air reservoir. Damaged parts must be replaced.

If a visual inspection, function check or efficiency test of the air brake system reveals any faults, have the complete system checked by an approved service station.

Hydraulic system Danger!

Fluid escaping under high pressure (hydraulic oil etc.) can penetrate the skin and cause serious injuries. Immediately consult a doctor in case of injury, otherwise serious infections can set in.

Danger!

– Before working on the hydraulic system, self-loading forage wagon or hydraulically actuated components, release pressure or drain the system.

Excessive pressure may cause tyres to burst.

– Always depressurise the hydraulic system.

– Stand clear of the tyre when inflating.

– Check hydraulic lines at regular intervals, and replace them if they are damaged or aged.

– Check the pressure regularly.

– Maintain the specified tyre pressure – see »Specifications«, page 6.1.

The wheel mounting bolts must be tightened to the torque specified by the manufacturer.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

Only technicians with special knowledge and experience with the hydraulic system of the self-loading forage wagon may work on the hydraulic equipment.

Assembly work on the hydraulic system must be carried out by authorised specialised workshops only.

10.1

Maintenance Check hydraulic hoses at regular intervals, and replace them in the case of damage or ageing!

Replacement hydraulic hoses must meet the technical requirements of the equipment manufacturer. This is guaranteed when using original equipment hoses.

Environment!

The lubrication intervals stated apply to normal service conditions only. Lubricate more frequently if the machine is used in severe conditions.

Use only brand name lithium grease with a dropping point of 190 degrees Celsius to lubricate the wheel hub bearings. The wheel hub bearings must be repacked with new grease at least every six months or every 1000 hours of operation.

Dispose of oil and grease according to regulations!

Note!

Chassis Check suspension and axles fastenings with threaded fasteners daily. If technical changes to the leaf springs and excessive play at the bearing pins are noted, this must be corrected immediately.

Check that the mounting bolts of the ring hitch are firmly seated after the first 10 hours of operation and then every 50 hours thereafter.

Excessive lubricant can cause deposits of hardened grease and damage the bearings.

Guards Mount the all guards again after all maintenance and repair work.

Chains After harvest remove all steel roller chains, clean then, immerse them in warm chain grease or lubricated them thoroughly with chain oil and replace them.

When installing the chains make sure that the closed side of the chain link straps point in the direction of motion.

Bolts Check that all bolts are firmly seated after the first 10 hours of operation and then at regular intervals.

Tighten them if required. Tighten to specified torques.

Check that all split pins and roll pins are in place.

Lubrication Danger!

Take care when draining hot oil – danger of burning!

– Wear protective clothing (e.g. overalls, gloves etc.).

Environment!

Dispose of oil and grease according to regulations!

Observe the oil change intervals and the oil type in the gearbox specified by the manufacturer. Use good brand name lubricating grease or brand name lubricating oil to lubricate the machine. Clean the grease nipples before applying the grease gun. Lubricate regularly following the lubrication chart.

10.2

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance

Maintenance BRAKES AND AXLES Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

Only work under the self-loading forage wagon when it is securely supported.

– Secure self-loading forage wagon with suitable supports.

Incorrect repairs on the brake system may cause the brake system to fail.

– All repairs and adjustments must be carried out by a specialist workshop only.

– Follow the manufacturer's recommended maintenance schedule.

– Have brake systems thoroughly inspected regularly.

Service the air brake system and axles as specified by the manufacturer. See separate manufacturers manual.

Language

order no.:

German

299 686.0

English

299 687.0

French

299 688.0

Italian

299 689.0

Dutch

299 690.0

Spanish

299 691.0

Air brake system Draining compressed air reservoir The compressed air reservoir (1) must be drained of water regularly. It is drained by pulling the ring on the drain valve (2) to the side. Proceed as follows to drain the reservoir:

1

• Pull ring on drain valve (2) to the side until no more water comes out.

• After draining the reservoir make sure that the drain valve (2) is air tight again.

2

(Fig. 1) 1

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.3

Maintenance Air pipe filter Both air cleaner housings (5) are fitted with filter elements (7). If the filter elements are obstructed the air passes the air cleaner without being filtered.

5

To prevent damage to other brake components it is very important to clean the filter elements regularly.

(Fig. 2, 3) 3

4

Cleaning the filter element 2

64937

Proceed as follows to clean the filter elements:

• Release pressure from the air pipes before opening the air cleaner housings.

• Press in cover (3) and remove locking hook (4).

• Remove cover (3), o-ring (10), spring (6, 9), valve

5 6

seat (8) and filter element (7).

7 8

• Clean filter element.

9

Damaged filter elements (7) and seals (10) must be replaced.

10 3 4

Reassemble in reverse order, taking care not to damage the o-ring (10).

3

(Fig. 2, 3)

Components of the air cleaner 3 = cover 4 = hook retainer 5 = filter housing 6 = pressure spring 7 = filter element 8 = valve seat 9 = pressure spring 10 = o-ring (Fig. 3)

Adjusting the brake - checking the brake cylinder piston stroke All new self-loading forage wagons are equipped with a fully operational brake system.

During the first few miles of driving the brake linings are adapted to the drums and play gradually increases. For this reason the brake must be readjusted after the first 20 operating hours. The brakes must also be readjusted every 80 hours to compensate for natural wear of the brake linings.

Only two thirds of the stroke of the brake cylinder may be used. If this range is exceeded the brake system must be readjusted or repaired by a specialist brake workshop.

10.4

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance Brake linings Replace brake linings when required. Use only original brake linings approved by the manufacturer.

Otherwise the operating approval will be cancelled.

SERVICING AND ADJUSTMENT INSTRUCTIONS FOR SELF-LOADING FORAGE WAGON AXLES WITH SYSTEM 2000 AUTOMATIC REVERSE OVERRIDER General Information The following operating, handling, setting and maintenance instructions refer to BPW brakes, transmission, overrun and towing devices. They are an integral part of the warranty terms. The relevant operating instructions supplied by the vehicle manufacturer or the manufacturers of the other components must be observed.

Maintenance work must be carried out at the specified intervals to maintain the operational and road safety of the vehicle. If the vehicle owner does not have the required technical knowledge and technical facilities available, a specialist workshop should be used to repair defects or replace worn parts.

Operators are strongly recommended to use only genuine original BPW parts when installing spare parts.

Parts approved by BPW are subject to regular testing.

BPW accepts product responsibility for these parts.

The use of spare parts other than original BPW parts will invalidate our warranty.

Function of the automatic reverse overrider

1

A special brake shoe support arrangement in the wheel brake cancels the braking effect while reversing and thereby ensures that the vehicle can be reversed at any time, even uphill. This makes a reverse locking lever unnecessary for a mechanical locking operation.

Normal brake function is resumed immediately when driving forwards.

2 4 3 4

The associated overrun device has a gas pressure-assisted hydraulic shock absorber. This ensures smooth driving and braking. All individual components, such as wheel brake, transmission and overrun mechanism, are designed as a system for effective performance.

1 = secondary shoe 2 = expander unit 3 = primary shoe 4 = autoreverse lever (Fig. 4)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.5

Maintenance

A 5

6 7

11 10

8 9

5

Operation and handling A = adjustment facility 5 = handbrake lever 6 = Bowden or flexball cable 7 = axle lever 8 = choice ofrope or clevis 9 = wheel brake 10 = turnbuckle 11 = brake rods (Fig. 5)

The brake system operates fully automatically and requires no specific handling procedures. Please note the following information when operating the parking brake lever: Pull the parking brake lever firmly past the dead centre point (min. 3 teeth). The parking brake lever is automatically retensioned by the gas spring if the trailer tends to roll backwards.

Compressing the drawbar with the towing vehicle makes operation of the parking brake lever easier. In this case, the wheel brake is normally pushed into the automatic reverse overrider and the parking brake lever can be pulled to the end position (approx. 12 teeth).

10.6

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance The towing vehicle must be connected to the parking brake lever by a breakaway cable. If the trailer breaks away from the towing vehicle, the trailer will be stopped by the parking brake lever with the breakaway cable.

Adjusting the wheel brake S 3006-7 RAZG - constant monitoring necessary -

12

Secure the trailer to prevent it from moving and jack it up. Release the towing linkage to the overrun device and the parking brake lever. Lock the swivel cam of the wheel brake with the tool (12) (4 mm pin) from the outside by inserting the pin through the locking hole (insert to at least 50 mm).

13 13 68383

14

6

Tighten the adjusting nuts (14) on the wheel brakes with a spanner on the adjusting pin (13) until the wheel can no longer rotate in the direction of travel.

Back off the adjusting pin until the braking effect can no longer be felt when the wheel is rotated forwards.

Caution!

The wheel brake must only be adjusted at the adjusting pin.

Reconnect the towing linkage to the overrun device and adjust it so it is free of play. The drawbar of the overrun device must be completely extended and the reversing lever must rest on the drawbar. As a test lightly apply the parking brake and check that the braking torque (in the direction of travel) is the same on the left and right at the wheels.

Caution!

Remove the locking pin (4 mm pin) from the swivel cam.

(Fig. 6)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.7

Maintenance Basic setting of the wheel brake The basic setting is made at the factory before delivery.

12

The basic setting only requires adjustment after replacement of drawbars or parts of the support assembly.

Proceed as follows:

13

Release the towing linkage to the overrun device and the parking brake lever.

13 14

68383

7

Remove pins (17) (Fig. 8) by releasing the retaining clips.

Lock the swivel cam of the wheel brake with the tool (12) (Fig. 7; 4 mm pin) from the outside by inserting the pin through the locking hole (insert at least 50 mm).

Tighten the adjusting nuts (14) (Fig. 7)on the wheel brakes with a spanner on the adjusting pin (13) (Fig. 7) until the wheel can no longer rotate in the direction of travel.

16 15

17

For the basic setting note that the towing linkage must be mounted with approx. 2-3 mm pretension against the spring load of the reversing lever.

15 8

Note also that the holes in the yoke ends (15) (Fig. 8) line up exactly with the holes of the reversing lever taking the pretension into account (set towing linkage 2-3 mm shorter).

Now reinstall the pins (17) (Fig. 8) and secure with clips.

Back off the adjusting pin until the braking effect can no longer be felt when the wheel is rotated forwards.

Caution!

9

The wheel brake must only be adjusted at the adjusting pin.

Reconnect the towing linkage to the overrun device and adjust it so it is free of play. The drawbar of the overrun device must be completely extended and the reversing lever must rest on the drawbar.

With the parking brake lightly applied in the forward direction check the position of the brake lever of the support assembly (angle position approx. 40°, Fig. 9).

Readjust the brake setting if necessary.

Check that the brakes of one axle or one unit respond uniformly with the parking brake lightly applied. Readjust brake setting if necessary.

10

10.8

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance

Caution!

Remove the locking pin (4 mm pin) from the swivel cam.

With the parking brake lightly applied in the reverse direction check the position of the brake lever in relation to the support assembly (brake lever parallel to the axle body, Fig. 10). Readjust brake setting if necessary.

(Fig. 7, 8, 9, 10)

Adjusting the wheel brake S 3008 RAZG - constant monitoring necessary Secure the trailer to prevent it from moving and jack it up. Release the towing linkage to the overrun device and the parking brake lever.

18

Retighten the adjusting screws on the wheel brakes with a screwdriver in the direction of the arrow until the wheel can no longer rotate in the direction of travel.

68382

11

Back off the adjusting screw until the braking effect can no longer be felt when the wheel is rotated forwards.

Caution!

The wheel brake must only be adjusted at the adjusting screw.

Reconnect the towing linkage to the overrun device and adjust it so it is free of play. The drawbar of the overrun device must be completely extended and the reversing lever must rest on the drawbar.

As a test lightly apply the parking brake and check that the braking torque (in the direction of travel) is the same on the left and right at the wheels.

18 = inspection hole (Fig. 11)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.9

Maintenance Basic setting of the wheel brake The basic setting is made at the factory before delivery.

The basic setting only requires adjustment after replacement of drawbars or parts of the support assembly.

20 19

Proceed as follows: 21

Release the towing linkage to the overrun device and the parking brake lever.

19 12

Remove pins (21) by releasing the retaining clips.

Retighten the adjusting screws on the wheel brakes with a screwdriver in the direction of the arrow until the wheel can no longer rotate in the direction of travel.

For the basic setting note that the towing linkage must be mounted with approx. 2-3 mm pretension against the spring load of the reversing lever.

Note also that the holes in the yoke ends (19) line up exactly with the holes of the reversing lever taking the pretension into account (set towing linkage 2-3 mm shorter).

Now reinstall the pins (21) and secure with clips.

Back off the adjusting screw until the braking effect can no longer be felt when the wheel is rotated forwards.

Caution!

The wheel brake must only be adjusted at the adjusting screw.

(Fig. 12)

Reconnect the towing linkage to the overrun device and adjust it so it is free of play. Here the drawbar of the overrun device must be completely extended and the reversing lever must rest on the drawbar. With the parking brake lightly applied in the forwards direction check the position of the brake lever of the support assembly (angle position approx. 40°, Fig. 13). Readjust brake setting if necessary.

Check that the brakes of one axle or one unit respond uniformly with the parking brake lightly applied. Readjust brake setting if necessary.

13

10.10

(Fig. 13)

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance With the parking brake lightly applied in the reverse direction check the position of the brake lever in relation to the support assembly (brake lever parallel to the axle body, Fig. 14). Readjust brake setting if necessary.

(Fig. 14)

14

Maintenance After 50 operating hours After the initial period of operation the brake linings will have adapted to the brake drum and the components of the transmission will have settled. The resulting play must be taken up by adjustment.

Proceed as follows: 1. Adjust the wheel brake as described – see »Adjusting the wheel brake S 3006-7 RAZG«, page 10.7 or »Adjusting the wheel brake S 3008 RAZG«, page 10.9.

2. Then check the amount of overrun travel used when braking the vehicle to a stop. It should not exceed 50 - 60% of the maximum overrun range.

If it does, readjust the wheel brake.

3. Now check whether the tractor can easily push the trailer back. If the trailer brakes too much, the setting at the wheel brake should be slightly released.

4. On completion of the adjustment check that all lock nuts are tight.

Every 200 operating hours Check the function of the brake system. Adjust the wheel brakes as described. Now proceed from point 2 as described under – After 50 operating hours.

Check the thickness of the brake lining. Remove the plastic plug from the inspection hole of the brake plate and carry out a visual inspection. New brake shoes must be installed if the brake lining is damaged or is less than 2 mm thick. Replace any damaged parts (springs, brake shoe expanders etc. ) at the same time.

Quarterly Lubricate all bearing points at least every three months. Lubricate Bowden cables with grease gun oils, not with grease.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.11

Maintenance Fault finding chart Problem

Possible cause

Remedy

Insufficient braking effect

Brake linings not adapted to the drums

Problem disappears after some braking actions

Connecting rod completely retracted

Readjust

Excessive friction losses

Check transmission elements and lubricate if necessary

Difficult reverse movement

Brake system tension set too high

Readjust

Unsatisfactory driving characteristics

Defective shock absorber

Replace shock absorber

Brake system incorrectly adjusted

Adjust brake system

Brake linings not adapted to the drums

Problem disappears after some braking actions

Excessive friction losses

Check transmission elements and lubricate if necessary

Incorrect adjustment

Readjust

Parking brake effect insufficient

Readjusting the taper roller bearing 1. Remove the hub cap and split pin.

2. Tighten axle nut until the wheel hub or brake drum brakes slightly.

3. Turn back (release) axle nut to the next split pin hole.

4. Check the bearing play.

5. Lock the axle nut with the split pin, replace hub cap.

Caution!

An excessively stiff setting can damage the bearing.

Tightening torques Wheel studs, Wheel nuts

10.12

max. tightening torque

Size

M 18 x 1.5

24

270 Nm

M 20 x 1.5

27

380 Nm

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance CUTTING MECHANISM Changing the cutting knives Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

– Wear gloves when working on the cutting mechanism – risk of serious injury!

Only work under the self-loading forage wagon when it is securely supported.

– Secure self-loading forage wagon with suitable supports.

Blunt knives require unnecessarily high power, run roughly, yield poor cutting quality and increase wear of the knives.

Knife removal

• Raise the front of the self-loading forage wagon 2

with the hydraulic articulated drawbar– see page 9.6, »Silage operation/hydraulic articulated drawbar«.

3

• Open the knife frame to the stop (– see page 9.5, »Opening and closing knife frame«).

• Remove the safety pin (1) from the unlocking

1

lever. Fold the unlocking lever (2) completely down to unlock the knives.

15

64304

• Pull the ejection lever (3) to the top limit stop.

• The knives remain loose in the knife frame and can be removed.

Note!

The knife frame must be cleaned regularly to allow the cutting knives to be changed without difficulty.

3 2

64313

1

(Fig. 15, 16) 16

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.13

Maintenance Knife installation 2

Caution!

When closing the knife frame make sure that the cutting knives do not collide with the rotor tines.

1

– Close the knife frame carefully and slowly.

3

17

64305

• Press ejection lever (3) down to its initial position.

• Attach the knives to their brackets in the knife frame one by one.

Caution!

If the knives are not correctly secured the rotor and pick-up may be damaged.

– The locking pin (1) must be properly engaged.

• Pull the unlocking lever (2) to the top to lock the knives.

• Check that the safety pin (1) is properly engaged.

• Close the knife frame slowly.

• Lower the self-loading forage wagon with the hydraulic articulated drawbar.

(Fig. 17)

Pressure spring of the knife frame The pressure spring (4) that unlocks the knives must be tensioned in its basic position so dimension »X« = 180 mm.

(Fig. 18) X 4

67645

10.14

18

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance ADJUSTING THE SCRAPER UNIT Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

Only work under the self-loading forage wagon when it is securely supported.

19

68364

– Secure self-loading forage wagon with suitable supports.

2

Adjust the scraper unit so the tips of the scrapers are about 15 mm from the rotor housing.

(Fig. 19)

To do this loosen the securing nuts (1) and screws (2), move the unit in the slotted holes as required and retighten the nuts and screws.

1

20

(Fig. 20)

DRIVE SYSTEMS Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

Only work under the self-loading forage wagon when it is securely supported.

– Secure self-loading forage wagon with suitable supports.

For lubrication of the main gearbox use only SAE 90 hypoid transmission oil conforming to (MIL-L-2105 B) API-GL-5-90.

Oil change: After first being put into service or after a gearbox overhaul the first oil change is at 30 working hours and then every 500 working hours.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.15

Maintenance Main gearbox (1000 rpm gearbox) 1

Filling capacity: 2.5 litres 1 = oil level check plugs (Fig. 21) 2 = oil drain plug 3 = oil filler and breather (Fig. 21, 22)

21

65090

3

2 22

65066

Floor conveyor gearbox Filling capacity: 1.65 litres.

4 = oil filler and oil level check plug (Fig. 23)

4

23

64303

Shredder drum drive (front right) (QUANTUM 3500 S) Use only SAE 90 hypoid transmission oil conforming to API-GL-4 for lubrication of the shredder drum gearbox.

Filling capacity: 2.0 litres

5

5 = oil filler and oil level check plug (Fig. 24)

65069

10.16

24

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance Shredder drum drive (right rear) (QUANTUM 3500 S) Use only SAE 90 hypoid transmission oil conforming to API-GL-4 for lubrication of the shredder drum gearbox.

Filling capacity: 1.0 litres 6 = oil filler and oil level check plug

6

(Fig. 25)

64979

25

CHAINS Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

61278

Only work under the self-loading forage wagon when it is securely supported.

26

– Secure self-loading forage wagon with suitable supports.

Tensioning the drive chains Check all chains for correct tension after the first 10 operating hours.

Check the tension regularly while the self-loading forage wagon is in use.

Steel roller chains are correctly tensioned when the slack side, with the tight side slightly under load, can be pulled down with the thumb by about 2% of the centre distance between the sprockets.

Example:

Axle distance 500 mm 2 % = 10 mm.

(Fig. 26)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.17

Maintenance Tensioning pick-up drive chain Loosen bolt (1). Adjust chain tension with adjusting screw (2). Retighten the bolt (1) after adjustment.

1 2

(Fig. 27)

27

65182

Drive chains for shredder drum (QUANTUM 3500 S) 5

Drive chain right Unscrew the chain guard to tension the chain. Release lock nut (3) and use screw (4) to adjust chain tensioner (5).

3

Dimension »X« = approx. 3 cm Retighten lock nut after tensioning the chain and reinstall the guard.

4

X 28

67960

(Fig. 28)

Drive chain left Y

Unscrew the chain guard to tension the chain. Release lock nut (6) and adjust with screw (7).

Dimension »Y« = approx. 4 cm 6

Retighten lock nut after tensioning the chain and reinstall the guard.

7

(Fig. 29)

29

64962

Main drive chain 8

The chain is correctly tensioned if distance »Z« of guide (8) is 30 mm.

9

Distance »Z« = 30 mm Check this distance regularly and adjust if necessary.

For adjustment loosen lock nut (9). Turn spring guide (10) until the distance is 30 mm. After the adjustment tighten the lock nut again.

10 Z

(Fig. 30) 66221

10.18

30

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance Floor conveyor chains

11

12

13

Note!

If there is no more adjustment range left, chain links must be removed from the floor conveyor chains (always an even number – 2, 4, 6, ...).

QUANTUM 3800 K / 3800 P

31

65188

The floor conveyor chains are automatically tensioned by the tension springs (13). The tension of the tension springs can be corrected with the adjusting screw (11).

Loosen the lock nut (12) for this.

(Fig. 31)

QUANTUM 3500 K / 3500 P / 3500 S The floor conveyor chains are tensioned by the threaded rods (14) on both sides of the wagon. To adjust the tension turn the nut to the right with a spanner (SW 30).

(Fig. 32) 14

32

64326

Automatic chain lubrication The lubrication pump (15) is operated every time the pick-up is lowered.

16

Check the oil level in the reservoir (16) regularly and top up as required.

Use biodegradable chain oil to lubricate the chains.

Specifications – see »Lubrication chart«, page 10.28.

15

The reservoir capacity is 2.5 litres.

(Fig. 33) 65078

33

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.19

Maintenance CLUTCH Danger!

The drive and the engine must always be switched off when working on the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

Only work under the self-loading forage wagon when it is securely supported.

– Secure self-loading forage wagon with suitable supports.

Adjusting the clutch for the main drive (Quantum 3500 S only)

2

3

Adjust the clutch so distance »X« is 5 mm with the clutch disengaged.

1

Loosen lock nut (1) and turn connecting rod (2) in or out at clevis (3).

5

4

Retighten the lock nut after adjustment. Adjust the spring (4) with the set collar (5) until the spring is 92 mm long when the clutch is disengaged (distance »Y«).

Y

X

34

64951

Adjustment dimension: Distance »X« = 5 mm Distance »Y« = 92 mm (Fig. 34)

Adjusting the clutch for the shredder drum drive (Quantum 3500 S only) 6

Adjust the clutch so distance »Z« is 5 mm with the clutch disengaged.

8

7

To do this unhitch the tension spring (9), release lock nut (6) and turn connecting rod (7) in or out at the clevis (8).

9

Retighten the lock nut after adjustment.

Attach tension spring (9) again.

Z 64952

35

Adjustment dimension: Distance »Z« = 5 mm (Fig. 35)

10.20

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance Cam-type cut-out clutch Caution!

The adjustment distance of the cam-type cut-out clutch must not be changed, otherwise the universal drive shaft, transmission etc. may be seriously damaged.

– Adjust clutch to the maximum permissible adjustment distance.

10 67051

36

Torque of cam-type cut-out clutch (10) = 900 Nm (Fig. 36)

DRIVE SHAFT Danger!

Only work on the universal drive shafts with the drive and engine switched off.

– Switch off engine.

– Remove the ignition key.

Never run drive shafts without their guards, or if the guards are damaged.

– Mount shaft guard and protective tube.

– Fasten them to prevent them rotating.

– The universal drive shafts must only be operated when in good condition.

Service the PTO drive shaft in accordance with the instructions of the PTO drive shaft manufacturer (see operation manual of the manufacturer).

Observe the safety instructions of the manufacturer!

Replace immediately damaged or missing protective tubes, universal drive shaft guards and securing chains.

Protect the PTO drive shaft against the influence of the weather.

Protective tubes must be greased to prevent freezing during winter.

After long periods of disuse lubricate the PTO drive shaft again and check its function.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.21

Maintenance ELECTRICAL SYSTEM Caution!

Danger of short-circuit when working on the electrical system.

– Always disconnect the power supply before working on the electrical system!

Adjusting the reed switches The reed switches will only function correctly if every switch is correctly positioned in relation to the relevant solenoid. Proceed as follows to adjust the switches:

• Move the reed switch or solenoid to the position in which the switching action takes place.

• Set the distance between reed switch and solenoid to 1 - 3 mm.

• The solenoid must be offset 10 - 15 mm to the 37

64521

centre of the reed switch, because the centre of a reed switch is always located in a dead range.

(Fig. 37)

HYDRAULIC SYSTEM Only technicians with special knowledge and experience with the hydraulic system of the self-loading forage wagon may work on the hydraulic equipment.

Assembly work on the hydraulic system must be carried out by authorised workshops, if possible your CLAAS partner.

Accumulator 1 Danger!

Accumulators are under pressure – danger of bursting.

– Accumulators (1) must not be welded or brazed.

– Do not heat accumulators.

38

– Do not mechanically machine accumulators.

– Do not open by force.

– Only specialist workshops are permitted to work on the accumulator.

The accumulator (1) is charged with nitrogen. The prestress pressure in 40 bar.

10.22

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance Accumulators lose pressure by about 2 - 3% a year.

For this reason, we recommend checking the accumulator pressure every five years and have it corrected if necessary.

Otherwise accumulators are maintenance-free.

(Fig. 38)

Hydraulic hose connections Danger!

Fluid escaping under high pressure (hydraulic oil etc.) can penetrate the skin and cause serious injuries. Seek medical attention in the event of injury of this type – risk of infection. Before working on the hydraulic system: – Switch off engine.

– Remove the ignition key.

39

– Always depressurise the hydraulic system.

– Check hydraulic hoses for damage and ageing regularly.

– Exchange hydraulic hoses when damaged or aged.

Check hydraulic hoses before putting the machine into operation for the first time and afterwards at least once a year.

Note!

Hydraulic hoses may be used for a maximum period of 6 years after production.

The production date (month and year) is shown on the hydraulic hose.

Example: "2 Q-02“ indicates that the date of manufacture is the 2nd quarter of 2002.

(Fig. 39)

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.23

Maintenance GAS SHOCK ABSORBER Danger!

Gas shock absorbers are under pressure – danger of bursting.

– Gas shock absorbers must not be welded or brazed.

1

– Do not heat gas shock absorbers.

40

– Do not mechanically machine gas shock absorbers.

– Do not open by force.

– Only qualified technicians may repair and install gas shock absorbers.

Gas shock absorbers are prestressed when installed.

– Relieve tension before removing the gas struts.

The front cover is held in its end position with a gas shock absorber (1).

2 41

The wheels of the standard steering axle are steered back with a gas shock absorber (2).

The gas shock absorbers are charged with nitrogen.

Gas shock absorbers lose their pressure over time.

For this reason the gas shock absorbers should be checked for pressure at regular intervals and recharged if necessary.

Otherwise gas shock absorbers are maintenance-free.

(Fig. 40, 41)

10.24

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance TYRES: Danger!

Damaged tyres may lose pressure suddenly during operation and cause the machine to lose control. This also endangers stability, particularly when driving on slopes!

– Check tyres for damage and pressure loss regularly.

– Tyres must be repaired by qualified technicians with suitable equipment only.

Avoid excessive inflation pressure. Danger of bursting!

– Stand clear of the tyre when inflating.

– Use only compressed air to inflate tyres.

– Do not exceed maximum permissible air pressure.

Check the tyre pressure regularly.

Do not exceed the specified air pressure.

Approved air pressure – see »Specifications«, page 6.1.

After replacing the wheels retighten the wheel nuts or bolts after the first 10 operating hours, then check every 50 hours.

Tightening torques – see »Specifications«, page 6.1.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.25

Maintenance TAILGATE 3

Adjusting the tailgate

2

The following adjustments are required to ensure that the tailgate closes properly.

4 X

Adjusting the hydraulic cylinder (QUANTUM 3500 S only)

1

Adjust the hydraulic cylinder (1) as follows:

42

• Loosen lock nut (2).

• Move threaded spindle (3) by turning the hydraulic piston (4) in or out.

• Retighten lock nut (2).

Dimension »X«: 508 mm (centre of eye bolt to centre of location hole of hydraulic cylinder) (Fig. 42)

Adjusting the support (QUANTUM 3500 S only) Adjust the support (5) as follows:

• Turn nut (6) until the support (5) is set to adjustment dimension »Y«.

5

Dimension »Y«: 642 mm

Y

(Centre of screw to location hole of clevis) Note!

6

Carry out adjustments on both sides.

43 (Fig. 43)

Pressure spring of tailgate (QUANTUM 3800 K / 3500 K only) 7

The pressure spring (7) of the tailgate in its basic position must be tensioned so dimension »Z« is 320 mm.

Dimension »Z«: 320 mm (Fig. 44)

Z

67942

10.26

44

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Maintenance MAINTENANCE AND LUBRICATION HOLES 2 Danger!

Danger from rotating machine parts.

– After maintenance work replace the cover.

1

For maintenance and lubrication work remove plastic cover (1) as follows: 45

• Unscrew mushroom head screw (2) (M6x35) with a screwdriver just enough to allow the plastic cover (1) to be removed manually.

• After maintenance work replace the plastic cover (1) and retighten the mushroom head screw (2) (M6x35).

(Fig. 45)

GUARDS Danger!

The guards protect against rotating machine parts – risk of injury.

Before opening the guards: – Switch off engine.

– Remove the ignition key.

FASTENERS Check all safety-relevant fasteners such as pins, screw, bolts etc. regularly for wear and deformation.

Replace fasteners with new as required.

SCREW CONNECTIONS Check all screws and nuts of the entire self-loading forage wagon again after 10 working hours and retighten if necessary.

Thereafter check the screws regularly for tightness.

Check that the mounting bolts of the ring hitch are firmly seated after the first 10 hours of operation and then every 50 hours thereafter.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

10.27

Maintenance END OF SEASON STORAGE 1. Clean all grass and dirt from the self-loading forage wagon. Clean off grease and dust from the exterior of all bearings.

2. Lubricate all lubrication points thoroughly until the grease comes out of the bearings – see »Lubrication Chart«, page 11.2.

Run the self-loading forage wagon for a short time.

3. Check self-loading forage wagon for wear and damage and have it repaired.

4. Clean rust off and repair paint damage.

5. Paint tyres with a protective paint to prevent the rubber from deteriorating.

6. Store self-loading forage wagon in a dry weatherproof space away from synthetic fertiliser.

7. Remove the control unit from the self-loading forage wagon and store it in weather-proof place at room temperature (approx. 18° C).

LUBRICATION CHART Unit/ application Main transmission, floor conveyor gearbox Shredder drum drive Chain lubrication, other lubrication points Grease nipple

10.28

Specifications/ SAE class

Lubricant

Season/ Temperature

MIL-L-2105B/C/D, API-GL-5

Transmission oil

SAE 90

All-year

Hypoid transmission oil

MIL-L-2105, API-GL-4 (Hypoid)

CLAAS roller chain oil BIO HEES 46

Biodegradable lubricating oil CEC-L-33-A-93 > 80%

All-year

Multipurpose grease

DIN 51825 - K2K

All-year

SAE 90

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Lubrication Chart

Lubrication Chart

11 Lubrication Chart This lubrication chart is valid for all self-loading forage wagons QUANTUM 3500 K from serial no. 611 0 1001 QUANTUM 3500 P from serial no. 610 0 1001 QUANTUM 3500 S from serial no. 699 0 1001 QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S from serial no. 613 0 2001

SAFETY INSTRUCTIONS Danger!

Always switch off the tractor engine before lubricating the self-loading forage wagon.

– Switch off engine.

– Remove the ignition key.

LUBRICANTS Good quality lubricating grease, e.g.: FINA

“Marson EPL 2”

ARAL

“Aralub HLP 2”

FUCHS “Rendit TEP 2” SHELL

“Retinax EP 2” or “Alvania G3”

DEA

“Glisando EP”

FAG

“Arcanol L 135 V”

SKF

“LGEP2”

Biodegradable lubricating oil Specifications – see »Lubrication chart«, page 10.28.

LUBRICATION

Lubricate these grease points every 8 working hours.

Lubricate these grease points every 20 working hours.

Lubricate these grease points every 100 working hours.

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

11.1

Lubrication Chart

Lubrication Chart

11.2

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Lubrication Chart

3

2, 6

1

5

4 7

66218F 66218F

67643

1 64954

2

4x

65100 QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

65088

3 65086

4 64960

5

QUANTUM 3500 S

6 65070

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

7

11.3

Lubrication Chart

13, 14

11

8

12

9, 10 66217F 66217F

4x

65083

8 64949

9

65068

10 65087

11 64959

QUANTUM 3800 K / 3800 P / 3500 K / 3500 P

65093

11.4

12

QUANTUM 3500 S

13 65071

14

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Lubrication Chart

17

18

16

15 19

66218F 66218F QUANTUM 3500 S

64415 QUANTUM 3500 S

65092

QUANTUM 3500 S

15 64416 QUANTUM 3500 S

17 65089

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

16 QUANTUM 3500 S

18 65085

19

11.5

Lubrication Chart

21

20

22

66217F 66217F

64953 QUANTUM 3500 S

65092

11.6

20 QUANTUM 3500 S

21 67942

22

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Lubrication Chart

27 25

29 28

23

26

24

29

66218F 66218F

64955

23 64944

24

63647

25 64939

26 63646

64943

28 65193

29

299 617.6 - BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S

27

11.7

Lubrication Chart

30

36

37

33 36

66217F 66217F

34 35

32

33

31

64945

30 63650

31

64940

32 65185

33 63658

34

64942

35 64941

36 65094

37

11.8

BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S - 299 617.6

Following the policy of CLAAS KGaA mbH of continuous product improvement to keep abreast of technical development, we reserve the right to make modifications which must not necessarily correspond to the text and illustrations contained in this operator's manual, and this without assuming the obligation to modify any machines previously delivered.

Technical specifications, dimensions and weights are understood with the usual tolerances.

Reproduction or translation, in whole or part, only with written authorization by CLAAS KGaA mbH. All rights under the provision of the Copyright act are reserved.

CLAAS KGaA mbH 33426 Harsewinkel Germany

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel - Germany Tel. +49 (0) 5247 12-0 www.class.com

299 617.6 BA QUANTUM 3800 K / 3800 P / 3500 K / 3500 P / 3500 S EN- 01.04 Printed in Germany