Kemper Pickup C3003, Operator'S Manual

Page 1: ...Pickup C3003 OMKM128609 OPERATOR S MANUAL Pickup C3003 OMKM128609 ISSUE B0 ENGLISH Maschinenfabrik Kemper GmbH Co KG European Edition PRINTED IN U S A...

Page 2: ...ely record all the numbers to help in tracing the machine should it be stolen Your KEMPER dealer also needs these numbers when you order parts File the identification numbers in a secure place away fr...

Page 3: ...Introduction AG CC03745 280 19 09FEB00 1 1 Dealer s Record Owner s Name Date Sold Address Model Number City Serial Number State Zip 022520 PN 3...

Page 4: ...Introduction 022520 PN 4...

Page 5: ...d topped up if necessary 6 Chains are correctly tensioned and lubricated 7 All moving parts can move freely 8 Check tire pressure adjust if necessary The correct tire pressure is 450 kPa bar 4 5 bar 6...

Page 6: ...Introduction 022520 PN 6...

Page 7: ...oints 15 1 Securing Pickup for Haulage Lashing Points 15 2 Preparing the Pickup Unpacking and First Setup 20 1 Set Gauge Wheel Height 20 1 Check Adjustment of Automatic Auger Lifting 20 2 Attaching At...

Page 8: ...anism 55 6 Every 500 Hours Gear Case 55 6 Every 500 Hours Angle Drive 55 6 Troubleshooting Pickup Operation 60 1 Service Metric Bolt and Screw Torque Values 65 1 Adjusting the Drive Chains 65 2 Mounti...

Page 9: ...Identification View KM00321 00009EF 19 06FEB20 1 1 Identification View KM404026 UN 06FEB20 C3003 Pickup 00 1 022520 PN 9...

Page 10: ...thorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your KEMPER dealer TS20...

Page 11: ...tally and physically capable of accessing the operator station and or controls and operating the machine properly and safely Never allow a child or an untrained person to operate the machine Instruct...

Page 12: ...aring Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Operating equipment safely requires the full attention of the...

Page 13: ...or damaged items TS951 UN 12APR90 Operate Pickup Safely To avoid injury or death by being pulled into the machine DO NOT attempt to feed crop into the machine or unplug feed area WHILE PICKUP IS RUNN...

Page 14: ...ect wiring harnesses from tractor before servicing electrical system components or welding on machine Falling while cleaning or working at height can cause serious injury Use a ladder or platform to e...

Page 15: ...deform the wheel When inflating tires use a clip on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly Use a safety cage if available...

Page 16: ...or attachment be lifted provide secure support for them If left in a raised position hydraulically supported devices can settle or leak down Do not support the machine on cinder blocks hollow tiles o...

Page 17: ...contact ballast the harvester at the rear end as necessary Observe the maximum permissible axle loads and total weights KM239211 UN 18MAR15 Remove Paint Before Welding or Heating Avoid potentially to...

Page 18: ...or damaged safety decals Replacement safety decals are available from your KEMPER dealer CC1021545 CC1021545 UN 23APR02 Dispose of Waste Properly If waste disposal is carried out improperly this may...

Page 19: ...l state and local laws regulations or ordinances governing the handling or disposal of waste fluids example oil fuel coolant brake fluid TS1133 UN 15APR13 filters batteries and other substances or par...

Page 20: ...placement on the machine and a brief explanatory text are shown below TS231 19 07OCT88 Replace Safety Signs Replace missing or damaged safety signs Use this operator s manual for correct safety sign p...

Page 21: ...remove ignition key KM400155 UN 16JAN20 Windrow Pickup DANGER Stay clear of header Disengage header drive shut off engine and remove key before servicing or unclogging header Do not allow persons or c...

Page 22: ...ay Clear of Rotating Driveline Entanglement in rotating driveline can cause serious injury or death Keep driveline shields in place at all times KM402657 UN 16JAN20 Pickup Wheels To avoid crushing inj...

Page 23: ...nd gas under pressure KM404027 UN 06FEB20 Roller Compression Unit Tips of Rake DANGER Pay extreme attention when clearing blockages or working under a raised roller compression unit The tips of the ra...

Page 24: ...0321 0000268 19 07FEB14 1 1 Windrow Pickup Hanging Points Should the pickup be moved without attaching it to a self propelled forage harvester use the hanging points shown KM1002393 UN 17JAN14 15 1 02...

Page 25: ...404028 UN 06FEB20 Lashing Points Front KM404029 UN 06FEB20 Lashing Points Rear A Bracket During haulage on a truck or a trailer use the intended holes on the frame to secure the machine during haulage...

Page 26: ...ave been incurred during transport Complete pickup and assemble all options per instructions delivered with the pickup KM1000781 UN 30MAR12 Set Gauge Wheel Height Adjust the pickup so that the cylinde...

Page 27: ...atic Auger Lifting After all options have been properly assembled check adjustment of auger lifting device A on either side For proper adjustment see Adjusting Automatic Auger Lifting in Operating the...

Page 28: ...d for it Otherwise the pickup can only be used with constant speed NOTE From factory the A130FAM module is empty The A130FAM module must be programmed via the forage harvester To do this proceed as fo...

Page 29: ...outer shields at left and right There are several positions for screw B Screw B is installed in the third borehole when it leaves the factory When the forage harvester is equipped with 42 inch tires i...

Page 30: ...OTE The pickup must be attached on level ground Attach the pickup as follows 1 Lower the handle A so that latching hooks B are fully retracted A Handle B Latching Hook KM402933 UN 06FEB20 2 Lower cutt...

Page 31: ...ches A are correctly aligned and in contact with the pins B 6 Check position of latches A Only for Initial Use The position of latches A is pre adjusted by the factory In case if maladjustment proceed...

Page 32: ...e pickup Insert a shaft F with a diameter of 35 mm 1 38 in into the lower hook C Raise handle A Loosen nuts E Adjust the length of threaded rod F so that lower hook C locks the shaft F completely Reti...

Page 33: ...e Make sure that clutch claw A on the pickup and clutch claw B on the forage harvester are in alignment If necessary adjust the clutch claw A on the pickup Loosen screws C Adjust clutch claw A Apply L...

Page 34: ...ester for the first time the clearance between auger flights and scrapers must be adjusted Proceed as follows 1 Slacken off nuts A 2 Move scrapers B forward to obtain specified clearance between fligh...

Page 35: ...g at a height that allows the unit to be reattached to the forage harvester at a later time Never select a height that is too low 3 Shut off the engine remove the key from key switch and apply park br...

Page 36: ...retracted from pin D 6 Start the engine Lower the cutterhead assembly until engaging lugs E are slightly below the pickup crossbar openings F and drive out of the pickup frame A Spring Loaded Pin B H...

Page 37: ...leaving the farm or the fields and on roads at junctions CAUTION Check all road and warning lights to be sure that they are functioning Setting Roller Compression Unit in Transport Position 1 Drive f...

Page 38: ...eels A inwards Failure to do so can result in machine damage Actuate switch C and fold gauge wheels A inwards A Gauge Wheels B Roller Compression Unit C Switch KM404032 UN 10FEB20 KM404033 UN 10FEB20...

Page 39: ...rocedures CAUTION Before carrying out any adjustment always disengage all drives shut off engine and wait until all moving parts have stopped CAUTION Before working on a raised pickup place blocks und...

Page 40: ...oller compression unit The tips of rake A can cause serious injury Before working under a raised roller compression unit proceed as follows 1 Raise the pickup completely Press and hold bottom of switc...

Page 41: ...ller compression A unit is raised to its maximum height CAUTION Do not perform any work under a raised roller compression unit as long as the operator is in the cab A Roller Compression Unit B Switch...

Page 42: ...to raise roller compression unit A To do this actuate switch C in direction of arrow A Roller Compression Unit B Cylinder C Switch KM404037 UN 11FEB20 KM404031 UN 10FEB20 2 Move the gauge wheels outw...

Page 43: ...may only be detached or put into operation by hydraulically trained engineers or technicians Do not perform any welding soldering or other mechanical work on the accumulator Raise roller compression u...

Page 44: ...l there is a distance X of 3 5 mm 0 12 0 19 in between rake and feed auger wings A Shims X 3 5 mm 0 12 0 19 in KM204376 UN 05FEB14 KM1001013 UN 05OCT09 Adjusting Roller of Roller Compression Unit 1 Lo...

Page 45: ...ve the tube C 2 If the slot holes of downstop A are not sufficient for adjustment the valve D on the back can be adjusted via a row of holes E Set valve D higher to decrease space between stop B and t...

Page 46: ...teeth from the ground take out locking pin A and set gauge wheel B higher along the row of holes Reinstall locking pin A and secure with spring cotter C IMPORTANT Make sure that the value on scale D i...

Page 47: ...stop D and support C to obtain the desired distance NOTE The needed shims can be removed from the lower rubber stop 4 Adjust feed auger springs B See Adjusting Feed Auger Springs in this section KM10...

Page 48: ...ight C and the scrapers B Specification Flight to Scraper Clearance 0 2 mm 0 0 08 in 3 Retighten nuts A 4 Turn the auger by hand to make sure it can rotate freely IMPORTANT The scrapers must be instal...

Page 49: ...se to decrease distance X CAUTION Make sure that threaded rod D is always fully screwed in plastic ring of lock nut C 3 Raise roller compression unit completely to check distance X Repeat procedure as...

Page 50: ...Feed Auger Paddles Short Crops The paddles B improve feeding in light and short crops NOTE Move paddle B further outward in short crop and further inward in higher crop 1 Loosen bolts A 2 Move paddle...

Page 51: ...rops When harvesting high crops or winter forage crops remove paddles A and paddle brackets B bolted on auger for smoother feeding 1 Loosen bolts C 2 Remove paddle A and paddle bracket B Repeat proced...

Page 52: ...ings immediately If a new fitting fails to take grease replace it or check whether the grease passage is blocked CAUTION Do not attempt to clean lubricate or adjust the pickup while the harvester engi...

Page 53: ...nthetic lubricants may be used if they meet the performance requirements as shown in this manual The temperature limits and service intervals shown in this manual apply to both conventional and synthe...

Page 54: ...d performance requirements Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance Consult your KEMPER dealer to obtain information and rec...

Page 55: ...FB 19 11FEB20 1 1 KM00321 0000918 19 11APR19 1 1 Every 50 Hours Pivoting Gauge Wheels Lubricate with grease KM1002434 UN 30JAN14 Every 50 Hours Lift Arms of Roller Compression Unit Lubricate with grea...

Page 56: ...091B 19 11APR19 1 1 Every 50 Hours Cylinder of Roller Compression Unit Lubricate with grease KM1002437 UN 31JAN14 KM1002438 UN 31JAN14 Every 50 Hours Feeding Auger Pivot Points Lubricate grease KM1002...

Page 57: ...is horizontal and check oil level in gear case A Oil level is correct when it reaches the bottom edge of oil level plug B IMPORTANT Do not overfill gear case A as this will result in overheating and o...

Page 58: ...djust scrapers properly Feed auger paddles are set too far outward Move feed auger paddles further inward Slip clutch worn Replace worn parts Only part of crop is picked up Pickup teeth turn too slowl...

Page 59: ...and or excessive ground speed Reduce volume of windrows or slow down Loss of pickup teeth Replace lost teeth Rake of roller compression unit option collides with feed auger Working height of roller c...

Page 60: ...840 1263 932 M30 932 687 1029 759 1327 979 1466 1081 1553 1145 1715 1265 M33 1258 928 1398 1031 1788 1319 1986 1465 2092 1543 2324 1714 M36 1617 1193 1789 1319 2303 1699 2548 1879 2695 1988 2982 2199...

Page 61: ...cket C to tighten chain D which drives the pickup cylinder Adjust idler sprocket C to get a slack of 10 to 15 mm 0 4 to 0 6 in on the strand opposite the drive chain idler A Idler Sprocket B Feed Auge...

Page 62: ...NT Never use an oil that is not biodegradable Specification Oil reservoir Capacity 4 L 1 US gal IMPORTANT Depending on the pump flow adjustment refill reservoir as required KM404045 UN 11FEB20 Bleedin...

Page 63: ...just the oil flow of the relevant brush 3 Turn the screw clockwise to increase oil flow and counterclockwise to decrease oil flow NOTE The pump is very precise Turn screw 1 4 turn by 1 4 turn to adjus...

Page 64: ...hains and wash them in solvent Then dry them and coat them with heavy oil Touch up any worn or damaged paintwork List replacement parts that will be needed for the next season and order them early Tak...

Page 65: ...ration See separate decommissioning section of this manual for information on disposal and recycling of machine components No machine should be operated if safety related components are missing or in...

Page 66: ...ricultural Machinery Safety Part 7 DIN EN ISO 4254 7 Self certification Safety of machinery DIN EN ISO 12100 Self certification Universal jointed shafts and their protection devices DIN EN 12965 Self...

Page 67: ...ght E Year of Manufacture F Model Year KM1001134 UN 24FEB10 Record Serial Number The serial number plate is located on the right hand side of the pickup KM371491 UN 12APR19 Keep Machines Secure 1 Inst...

Page 68: ...Serial Number 80 2 022520 PN 68...

Page 69: ...Lubricant Storage Storage Lubricant 55 2 Lubricants Mixing 55 3 Lubrication Angle Drive 55 6 Drive Chains 55 3 Feeding Auger Pivot Points 55 5 Gauge Wheels 55 4 Gear Case 55 6 Jackstands 55 5 Locking...

Page 70: ...nd 05 1 Sound Level 75 1 Specifications C3003 Pickup 75 1 Sound Level 75 1 Storage At end of season 70 1 Beginning of season 70 1 Synthetic lubricants 55 2 Page T Torque charts Metric 65 1 Transmissio...

Page 71: ...Index Index 3 022520 PN 3...

Page 72: ...Index Index 4 022520 PN 4...