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Kemper Pickup C3003 Operator's Manual

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Pickup C3003
OPERATOR'S MANUAL
Pickup C3003
OMKM128609 ISSUE B0
(ENGLISH)
Maschinenfabrik Kemper GmbH & Co. KG
European Edition
PRINTED IN U.S.A.

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Summary of Contents for Kemper Pickup C3003

  • Page 1 Pickup C3003 OPERATOR'S MANUAL Pickup C3003 OMKM128609 ISSUE B0 (ENGLISH) Maschinenfabrik Kemper GmbH & Co. KG European Edition PRINTED IN U.S.A.
  • Page 2 Accurately record all the numbers to help in arbitrary modifications carried out on this windrow pickup tracing the machine should it be stolen. Your KEMPER will relieve the manufacturer of all liability for any resulting dealer also needs these numbers when you order parts.
  • Page 3 Introduction Dealer's Record Owner's Name Date Sold Address Model Number City Serial Number State AG,CC03745,280 -19-09FEB00-1/1 022520 PN=3...
  • Page 4 Introduction 022520 PN=4...
  • Page 5 Introduction Predelivery Inspection The following checks, adjustments and service jobs 10. □ Test run of the machine has been carried out and were performed prior to delivery of the machine: is OK. 1. □ Pickup has been properly assembled. 11. □ Hydraulic hoses and connections are free from leaks. 2.
  • Page 6 Introduction 022520 PN=6...

  • Page 7: Table Of Contents

    Contents Page Page Identification View Identification View..........00-1 Haulage Windrow Pickup Hanging Points ......15-1 Safety Securing Pickup for Haulage (Lashing Points) ...15-2 Recognize Safety Information ......05-1 Follow Safety Instructions........05-1 Preparing the Pickup Understand Signal Words........05-1 Unpacking and First Setup .........20-1 Observe Road Traffic Regulations......05-2 Set Gauge Wheel Height........20-1 Operator Ability...........05-2 Check Adjustment of Automatic Auger Lifting ..20-2...
  • Page 8 Contents Page Lubrication and Maintenance Lubrication Intervals ...........55-1 Grease..............55-1 Transmission Oil..........55-2 Alternative and Synthetic Lubricants ....55-2 Lubricant Storage ..........55-2 Mixing Lubricants..........55-3 Every 10 Hours — Drive Chains......55-3 Every 10 Hours — Pickup Drive Shaft....55-3 Every 50 Hours — Pivoting Gauge Wheels..55-4 Every 50 Hours —...

  • Page 9: Identification View

    Identification View Identification View C3003 Pickup KM00321,00009EF -19-06FEB20-1/1 00-1 022520 PN=9...

  • Page 10: Safety

    Replacement safety signs are available from your KEMPER dealer. Before you start working with the machine, learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

  • Page 11: Observe Road Traffic Regulations

    Safety Observe Road Traffic Regulations Always observe local road traffic regulations when using public roads. FX,ROAD -19-01MAY91-1/1 Operator Ability and/or controls, and operating the machine properly and safely. • Machine owners must make sure that operators • Never allow a child or an untrained person to operate are responsible, trained, have read the operating the machine.

  • Page 12: Prepare For Emergencies

    Safety Prepare for Emergencies Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. DX,FIRE2 -19-03MAR93-1/1 Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

  • Page 13: Use Safety Lights And Devices

    Safety Use Safety Lights and Devices Prevent collisions with other road users. Slow moving tractors with implements or drawn equipment, as well as self-propelled machines are especially dangerous on public roads. Always pay attention to traffic approaching from behind, particularly when changing direction. Provide for safe traffic conditions by using turn signals.

  • Page 14: Practice Safe Maintenance

    Safety Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing away from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground.

  • Page 15: Service Tires Safely

    Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting KEMPER specifications. KM00321,00008FF -19-02APR19-1/1 05-6 022520 PN=15...

  • Page 16: Service Machines Safely

    Safety Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

  • Page 17: Transport With Harvesting Unit Installed

    Safety Transport with Harvesting Unit Installed Before driving forage harvester on public roads, raise harvesting unit and secure it in its fully raised position. It must not, however, obstruct operator's view of the road. In case of harvesting unit equipped with the crop deflector, always store the deflector in its transport position before driving on the road.

  • Page 18: Avoid Heating Near Pressurized Fluid Lines

    Dispose of Waste Properly If waste disposal is carried out improperly, this may damage the environment and ecological systems. Potentially harmful waste used with KEMPER equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 19: Decommissioning: Proper Recycling And Disposal Of Fluids And Components

    • Contact your local environmental or recycling center, or or ordinances governing the handling or disposal of your KEMPER dealer for information on the proper way waste fluids (example: oil, fuel, coolant, brake fluid); to recycle or dispose of waste.

  • Page 20: Safety Decals

    Safety Decals Pictorial Safety Signs At several important places of this machine safety signs are affixed intended to signify potential danger. The hazard is identified by a pictorial in a warning triangle. An adjacent pictorial provides information how to avoid personal injury.

  • Page 21: Repair And Maintenance

    Safety Decals Repair and Maintenance Before carrying out adjustment, repair and maintenance work, shut off forage harvester engine and remove ignition key. KM00321,00009CC -19-16JAN20-1/1 Windrow Pickup DANGER - Stay clear of header. Disengage header drive, shut off engine and remove key before servicing or unclogging header.

  • Page 22: Hydraulic Lines

    Safety Decals Hydraulic Lines Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. KM00321,00009CF -19-16JAN20-1/1 Stay Clear of Rotating Driveline Entanglement in rotating driveline can cause serious injury or death. Keep driveline shields in place at all times. KM00321,00009D0 -19-16JAN20-1/1 Pickup Wheels To avoid crushing injury between pickup and wheel,...

  • Page 23: Accumulator - Roller Compression Unit Float System

    Safety Decals Accumulator - Roller Compression Unit Float System Avoid bodily injuries from hydraulic oil and gas under pressure. KM00321,00009F0 -19-06FEB20-1/1 Roller Compression Unit - Tips of Rake DANGER - Pay extreme attention when clearing blockages or working under a raised roller compression unit.

  • Page 24: Haulage

    Haulage Windrow Pickup Hanging Points Should the pickup be moved without attaching it to a self propelled forage harvester, use the hanging points shown. KM00321,0000268 -19-07FEB14-1/1 15-1 022520 PN=24...

  • Page 25: Securing Pickup For Haulage (Lashing Points)

    Haulage Securing Pickup for Haulage (Lashing Points) Lashing Points (Front) Lashing Points (Rear) A—Bracket During haulage on a truck or a trailer, use the intended NOTE: Remove brackets (A) from pickup after haulage. holes on the frame to secure the machine during haulage (see illustration).

  • Page 26: Preparing The Pickup

    Preparing the Pickup Unpacking and First Setup As soon as packaging material is removed, check the pickup for any damage that might have been incurred during transport. Complete pickup and assemble all options per instructions delivered with the pickup. KM00321,000010E -19-03FEB09-1/1 Set Gauge Wheel Height Adjust the pickup so that the cylinder teeth are X = 50 mm (2 in.) above the ground.

  • Page 27: Check Adjustment Of Automatic Auger Lifting

    Preparing the Pickup Check Adjustment of Automatic 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 Pickup Section. A—Auger Lifting Device KM00321,0000A03 -19-11FEB20-1/1 20-2 022520...

  • Page 28: Attaching

    Attaching Attaching to a Type 498 Forage Harvester with Variable Header Drive Pickups for the Claas type 498 forage harvesters are technically partially prepared for the variable header drive. In addition, programming steps in the forage harvester software are required, which must be coordinated with Claas.

  • Page 29: Adjust Jackstand Height

    Attaching Adjust Jackstand Height When installing the pickup on a forage harvester for the first time, it is necessary to adjust the height of jackstands (A) in relation to the size of the tires on the harvester. To do this, it is necessary to take off the outer shields at left and right.

  • Page 30: Attaching The Pickup

    Attaching Attaching the Pickup IMPORTANT: Before attaching the pickup, refer to the Operator’s Manual of the forage harvester for the correct preparation or adaptation to the machine. NOTE: The pickup must be attached on level ground. Attach the pickup as follows: 1.
  • Page 31 Attaching 5. Raise the cutterhead assembly and lift the pickup. IMPORTANT: On both sides of the pickup, check that the lower latches (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.
  • Page 32 Attaching 7. Raise handle (A) and secure with spring-loaded pin (B). IMPORTANT: Check that both lower hooks (C) correctly lock the pins (D). Never attempt to operate the pickup with improper hook latch. In case that hooks (C) do not lock the pins (D) correctly: •...

  • Page 33: Adjust The Automatic Driveline Coupler (Only For Initial Use)

    Attaching 9. Connect hydraulic hoses (A) and wiring harness (B) to the relevant outlets of the forage harvester. A—Hydraulic Hoses B—Wiring Harness KM00321,00009F2 -19-07FEB20-6/6 Adjust the Automatic Driveline Coupler (Only for Initial Use) Make sure that clutch claw (A) on the pickup and clutch claw (B) on the forage harvester are in alignment.

  • Page 34: Adjust The Scrapers

    Attaching IMPORTANT: Make sure that groove (B) on clutch claw of the forage harvester turns freely and does not touch housing (A). CAUTION: Risk of fire - Incorrect setting may result in airborne sparks! A—Housing B—Groove KM00321,00009F3 -19-13FEB20-2/2 Adjust the Scrapers When installing the pickup on a forage harvester for the first time, the clearance between auger flights and scrapers must be adjusted.

  • Page 35: Detaching

    Detaching Detaching the Pickup IMPORTANT: Before detaching the pickup, make sure that pickup hydraulic functions are all released. Proceed as follows: 1. Disconnect hydraulic hoses (A) and wiring harness (B). 2. Lower pickup (C) to the ground. IMPORTANT: Leave the pickup standing at a height that allows the unit to be reattached to the forage harvester at a later time.
  • Page 36 Detaching 5. Pull spring-loaded pin (A), then lower handle (B) so that latching hooks (C) are fully 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.

  • Page 37: Transporting

    Transporting Observe Road Traffic Regulations machine of any potential danger and give him indications to maneuver and travel safely, especially when leaving the farm or the fields, CAUTION: Before transporting the machine and on roads at junctions. on public roads, make sure that the machine conforms to the regulations on the use of agricultural vehicles on the road.
  • Page 38 Transporting 3. When transporting the pickup on public roads, always fold the gauge wheels (A) inwards to the transport position. IMPORTANT: It is necessary to raise roller compression unit (B) completely before folding gauge wheels (A) inwards. Failure to do so can result in machine damage.

  • Page 39: Operating The Pickup

    Operating the Pickup Follow Safe Operating Procedures 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 underneath to prevent pickup from lowering.

  • Page 40: Working Under A Raised Roller Compression Unit

    Operating the Pickup Working Under a Raised Roller Compression Unit CAUTION: Pay extreme attention when clearing blockages or working under a raised roller compression unit. The tips of rake (A) can cause serious injury. Before working under a raised roller compression unit, proceed as follows: 1.
  • Page 41 Operating the Pickup 3. Raise roller compression unit (A) completely: Actuate switch (B) in direction of arrow until the roller 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.

  • Page 42: Setting Roller Compression Unit In Operating Position

    Operating the Pickup Setting Roller Compression Unit in Operating Position 1. Fully extend cylinders (B) to raise roller compression unit (A). To do this, actuate switch (C) in direction of arrow. A—Roller Compression Unit C—Switch B—Cylinder KM00321,00009F7 -19-10FEB20-1/3 2. Move the gauge wheels outwards to their operating position: •...

  • Page 43: Operating The Roller Compression Unit

    Operating the Pickup 3. Slowly lower the roller compression unit (A). NOTE: Gauge wheels are automatically unlocked and can turn freely when they are lowered onto the ground. Lower the pickup onto the ground and drive the forage harvester forward until gauge wheels are swiveled into driving position.

  • Page 44: Adjusting Roller Of Roller Compression Unit

    Operating the Pickup Adjusting Working Height of Roller Compression Unit Add or remove shims (A) at rubber stop until 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.) KM00321,00009F9 -19-10FEB20-2/2 Adjusting Roller of Roller Compression Unit 1.

  • Page 45: Roller Compression Unit Float Adjustment

    Operating the Pickup Roller Compression Unit Float Adjustment When the roller compression unit is in operating position, adjust float mode as follows: 1. First adjust downstop (A) in the slot holes so that the stop (B) floats approximately 5 mm above the tube (C). 2.

  • Page 46: Adjusting Gauge Wheel Height

    Operating the Pickup Adjusting Gauge Wheel Height Adjust the pickup so that the cylinder teeth are 50 mm (2 in.) above the ground. To increase the clearance of the teeth from the ground, take out locking pin (A) and set gauge wheel (B) lower along the row of holes.

  • Page 47: Adjusting Feed Auger Height

    Operating the Pickup Adjusting Feed Auger Height Adjust feed auger springs. (See Adjusting Feed Auger Springs in this section.) When feed auger arm (E) rests on the rubber stop (D), the distance (G) between feed auger flight (A) and bottom sheet (F) should be within specification.

  • Page 48: Adjusting The Scrapers

    Operating the Pickup Adjusting the Scrapers 1. Slacken off nuts (A). 2. Move scrapers (B) forward to obtain specified clearance between flight (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 installed with screw head facing down.

  • Page 49: Adjusting Automatic Auger Lifting (Option)

    Operating the Pickup Adjusting Automatic Auger Lifting (Option) When cylinders (A) are fully extended and the roller compression unit is completely raised, feed auger arm (B) must not touch the lower stop support (G). Adjust a minimum distance (X) of 1—3 mm (0.04—0.12 in.). If the distance is not correct, proceed as follows: 1.

  • Page 50: Opening The Side Guard

    Operating the Pickup Opening the Side Guard 1. Fold the gauge wheels inwards. 2. Open folding side guard (A) with a suitable tool, width across flats 13 mm. 3. Swing side guard (A) outwards. A—Side Guard KM00321,00009DD -19-22JAN20-1/1 Adjusting Feed Auger Paddles (Short Crops) The paddles (B) improve feeding in light and short crops.

  • Page 51: Removing Feed Auger Paddles (High Crops)

    Operating the Pickup Removing Feed Auger Paddles (High Crops) 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 procedure for each paddle.

  • Page 52: Lubrication And Maintenance

    Lubrication and Maintenance Lubrication Intervals Using self propelled forage harvester hour meter as a guide, perform services at the hourly intervals indicated on following pages. IMPORTANT: The recommended lubrication intervals are based on normal conditions. Severe or unusual conditions may require more frequent lubrication or oil changes.

  • Page 53: Transmission Oil

    Some lubricants may not be available in your location. Re-refined base stock products may be used if the finished lubricant meets the performance requirements. Consult your KEMPER dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

  • Page 54: Mixing Lubricants

    Lubrication and Maintenance Mixing Lubricants In general, avoid mixing different brands or types of oil. Consult your KEMPER dealer to obtain information and Oil manufacturers blend additives in their oils to meet recommendations. certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

  • Page 55: Every 50 Hours - Pivoting Gauge Wheels

    Lubrication and Maintenance Every 50 Hours — Pivoting Gauge Wheels Lubricate with grease. KM00321,00009FB -19-11FEB20-1/1 Every 50 Hours — Lift Arms of Roller Compression Unit Lubricate with grease. KM00321,0000918 -19-11APR19-1/1 55-4 022520 PN=55...

  • Page 56: Every 50 Hours - Cylinder Of Roller Compression Unit

    Lubrication and Maintenance Every 50 Hours — Cylinder of Roller Compression Unit Lubricate with grease. KM00321,0000919 -19-11APR19-1/1 Every 50 Hours — Feeding Auger Pivot Points Lubricate grease. KM00321,000091A -19-11APR19-1/1 Every 50 Hours — Jackstands Lubricate with grease. KM00321,000091B -19-11APR19-1/1 55-5 022520 PN=56...

  • Page 57: Every 50 Hours - Handle Of Locking Mechanism

    Lubrication and Maintenance Every 50 Hours — Handle of Locking Mechanism Lubricate with grease. KM00321,00009FC -19-11FEB20-1/1 Every 500 Hours — Gear Case Change the oil after every 500 hours of operation or at the end of each harvesting season. Raise pickup slightly so that it is horizontal, and check oil level in gear case (A).

  • Page 58: Troubleshooting

    Troubleshooting Pickup Operation before making any adjustments or performing any service operations. CAUTION: When lifting the pickup, place blocks underneath. Shut off the engine Symptom Problem Solution The pickup does not drop to the Reduce tire pressure Front tires over-inflated ground Float pressure too high Reset float pressure correctly...
  • Page 59 Troubleshooting Symptom Problem Solution Inside of scrapers is worn Spiral teeth on pickup collide with Find location of collisions, and rectify bent scrapers Increase pickup float Crop not conveyed, clogging at High-volume windrows and/or Reduce volume of windrows or slow feed opening excessive ground speed down...

  • Page 60: Service

    Service Metric Bolt and Screw Torque Values TS1742 —UN—31MAY18 10.9 12.9 12.9 10.9 Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Bolt or Screw Hex Head Flange Hex Head Flange Hex Head Flange Hex Head Flange Size Head Head Head Head...

  • Page 61: Adjusting The Drive Chains

    Service Adjusting the Drive Chains Use idler sprocket (A) to tighten chain (B) which drives the feed auger. Adjust idler sprocket (A) to get a slack of 3 to 10 mm (0.12 to 0.4 in.) on the strand opposite the drive chain idler. Use idler sprocket (C) to tighten chain (D) which drives the pickup cylinder.

  • Page 62: Trash Net

    Service Trash Net Keep trash net (A) tensioned. If necessary, tighten screws (B) for proper tension. A—Trash Net B—Screws KM00321,000028F -19-31JAN14-1/1 Oil Reservoir of Central Chain Lubrication Fill oil reservoir of central chain lubrication with biodegradable oil (e.g. FUCHS PLANTOLUBE KS 46 N). IMPORTANT: Never use an oil that is not biodegradable.

  • Page 63: Adjusting Oil Flow Of Central Chain Lubrication (Option)

    Service Adjusting Oil Flow of Central Chain Lubrication (Option) Adjust oil flow at each chain as follows: 1. Remove cover (A). 2. Identify the screw allowing to adjust the oil flow of the relevant brush. 3. Turn the screw clockwise to increase oil flow and counterclockwise to decrease oil flow.

  • Page 64: Storage

    Storage Storing the Pickup Thoroughly clean pickup. Chaff and dirt will draw moisture Remove chains and wash them in solvent. Then dry them and cause rust. and coat them with heavy oil. Store pickup in a sheltered location, standing on its Touch up any worn or damaged paintwork.

  • Page 65: Specifications

    All missing or damaged safety-related components, including safety Periodically inspect and review the machine in conjunction signs, should be repaired or replaced before operating. with your KEMPER dealer. The review may result KM00321,000092C -19-13APR19-1/1 C3003 Pickup ....................

  • Page 66: Ec Declaration Of Conformity

    Specifications EC Declaration of Conformity Kemper GmbH & Co.KG Am Breul D-48703 Stadtlohn, Germany The person named below declares that the product Machine type: Pickup Model: C3003 Fulfills all relevant provisions and essential requirements of the following directives: DIRECTIVE NUMBER...

  • Page 67: Serial Number

    4. When parking outdoors, store in a well-lighted and fenced area. 5. Make note of suspicious activity and report any thefts immediately to law enforcement agencies. 6. Notify your KEMPER dealer of any losses. KM00321,0000928 -19-12APR19-1/1 80-1 022520 PN=67...
  • Page 68 Serial Number 80-2 022520 PN=68...
  • Page 69 Index Page Page Adjusting Automatic Auger Lifting (Option)......45-11 Lashing Points ............15-2 Automatic Driveline Coupler ........30-6 Lubricant Storage Feed auger height........... 45-9 Storage, Lubricant........... 55-2 Feed Auger Paddles ..........45-12 Lubricants Feed Auger Springs ..........45-9 Mixing..............55-3 Gauge Wheel Height..........45-8 Lubrication Rake of Roller Compression Unit......
  • Page 70 Index Page Page Roller Compression Unit, Operating Position ..... 45-4 Torque charts Metric ..............65-1 Safety Transmission oil............55-2 Operator ability............05-2 Transport Protect against noise ..........05-10 Road Traffic Regulations......... 40-1 Safe maintenance, practice ........05-5 Roller Compression Unit, Transport Position ..40-1 Serial number Trash Net..............
  • Page 71 Index Index-3 022520 PN=3...
  • Page 72 Index Index-4 022520 PN=4...

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