Claas QUANTUM 3500, QUANTUM 6800 Service Manual

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QUANTUM 6800

QUANTUM 3500 - 6800

Technical Systems

Page 2

Technical Systems QUANTUM TIC

10/04

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TIC QUANTUM Technical Systems

Chapters

1 Technical Data

3 Operation

10 Brakes

11 Hydraulic System

12 Electric System / Diagnosis

10/04

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Technical Systems QUANTUM TIC

10/04

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TIC QUANTUM Technical Data

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3500 P, 3800 K, 3800 P..............................................................2

1.1

QUANTUM 3500 K, 3500 P, 3500 S, 3800 K, 3800 P, 2500 K, 2500 P..............................................2

1.2 QUANTUM 5500 S-18, 5500 S-16, 5500 S, 4500 S, 6800 S ..............................................................5

1.3 QUANTUM 6800 P, 6500 P, 5500 P-18, 5500 GT, 5500 P, 4500 P ...................................................8

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Technical Data QUANTUM TIC

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3500 P, 3800 K, 3800 P

1.1 QUANTUM 3500 K, 3500 P, 3500 S, 3800 K, 3800 P, 2500 K, 2500 P

Length (L) mm 8,100 8,100 8,200 Width (B) mm 2,550 2,550 2,550 Height (H) – dry forage assembly folded up Height (S) – dry forage assembly folded down Track width mm 1,850 1,850 1,850 Pick-up width mm 1,800 1,800 1,800 Platform height mm 1,180 1,180 1,180 Loading capacity (acc. to DIN 11741) m3 26.6 28 25.6 Kerb weight kg 5,160 5,200 5,860 Permissible total weight (Rückmatic / compressed air) Number of cutting knives 33 33 33 Shortest theoretical length of cut mm 45 45 45 Number of pick-up tines per tine bar 26 26 26 Tine spacing mm 61 61 61 PTO speed min-1 1,000 1,000 1,000 Tyres - Rückmatic up to 40 km/h or

- compressed air up to 40 km/h

- compressed air up to 60 km/h Tyre pressure - with tyres 500/50-17 555/45-17

19.0/45-17 Tightening torque of wheel nuts - wagon wheels Sound pressure level dB(A) 70 70 70

QUANTUM

3500 K

QUANTUM

3500 P

QUANTUM

3500 S

mm 3,410 3,600 3,600

mm 2,600 3,050 3,050

8,000/11,000 8,000/11,000 8,000/11,000

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

bar bar bar

3.5

3.0

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

3.5

3.0

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

3.5

3.0

Nm 300 300 300

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TIC QUANTUM Technical Data

QUANTUM

2500 K

QUANTUM

2500 P

Length (L) mm 8,100 8,100 Width (B) mm 2,550 2,550 Height (H) – dry forage assembly folded up mm 3,410 3,600 Height (S) – dry forage assembly folded down mm 2,600 3,050 Track width mm 1,850 1,850 Pick-up width mm 1,800 1,800 Platform height mm 1,180 1,180 Loading capacity (acc. to DIN 11741) m3 26.6 28 Kerb weight kg 4,500 4,750 Permissible total weight

8,000/11,000 8,000/11,000 (Rückmatic / compressed air) Number of cutting knives 33 33 Shortest theoretical length of cut mm 40 40 Number of pick-up tines per tine bar 26 Tine spacing mm 61 61 PTO speed min-1 540 540 Tyres - Rückmatic up to 40 km/h

- compressed air up to 40 km/h

- compressed air up to 60 km/h Tyre pressure - with tyres 500/50-17 555/45-17

9.0/45-17

15.0/55-17 Tightening torque of wheel nuts - wagon wheels M18x1.5 M20x1.5 Sound pressure level dB(A) 70 70

15.0/55-17

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

bar bar bar bar

Nm Nm

3.5

3.0

3.5

270 380

15.0/55-17

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

3.5

3.0

3.5

270 380

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Technical Data QUANTUM TIC

QUANTUM

3800 K

QUANTUM

3800 P

Length (L) mm 9,250 9,250 Width (B) mm 2,550 2,550 Height (H) – dry forage assembly folded up mm 3,410 3,600 Height (S) – dry forage assembly folded down mm 2,600 3,050 Track width mm 1,850 1,850 Pick-up width mm 1,800 1,800 Platform height mm 1,180 1,180 Loading capacity (acc. to DIN 11741) m3 31.8 33.2 Kerb weight kg 5,550 5,650 Permissible total weight (compressed air) 11,000 11,000 Number of cutting knives 33 33 Shortest theoretical length of cut mm 45 45 Number of pick-up tines per tine bar 26 26 Tine spacing mm 61 61 PTO speed min-1 1.000 1.000 Tyres

- compressed air up to 40 km/h

- compressed air up to 60 km/h Tyre pressure - with tyres 500/50-17 555/45-17

19.0/45-17 Tightening torque of wheel nuts - wagon wheels M18x1.5 M20x1.5 Sound pressure level dB(A) 70 70

500/50-17 10 PR

555/45-17 10 PR bar bar bar

3.5

3.0

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

270 300

3.5

3.0

270 300

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TIC QUANTUM Technical Data

1.2 QUANTUM 5500 S-18, 5500 S-16, 5500 S, 4500 S, 6800 S

QUANTUM

5500 S-18

QUANTUM

5500 S-16

QUANTUM

6800 S

Length (L) mm 9,250 9,250 10,500 Width (B)

- Standard

- with tyres 700/45-22.5

- with tyres 600/55-R26.5

- with tyres 700/50-R26.5

- with tyres 800/40-R26.5 Height (H) - dry forage assembly folded

2,550 2,720

mm mm

3,990

2,550

3,930

2,550 2,720 2,550 2,750 2,930 3,990 4,000

- with tyres 800/40-R26.5 Height (S) - dry forage assembly folded

mm mm

3,290

3,230

3,290 3,300

- with tyres 800/40-R26.5 Track width - with tyres 22.5

- with tyres 26.5

mm mm

1,950

2,000 Pick-up width mm 1,800 1,800 1,800 Platform area mm 2,160 x 5,700 2,160 x 5,700 2,160 x 5,700 Loading capacity (acc. to DIN 11741) m3 31 31 38 Kerb weight with tyres 800/40-R26.5 incl. forced steering

kg kg

8,340

7,600

8,810

9,350 Permissible total weight 18,000 16,000 20,000 Number of cutting knives 33 33 33 Shortest theoretical length of cut mm 45 45 45 Number of pick-up tines per tine bar 26 26 26 Tine spacing mm 61 61 61 PTO speed min-1 1,000 1,000 1,000

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Technical Data QUANTUM TIC

Tyres:

- up to 40 km/h without AGS

- up to 50 km/h without AGS

- up to 60 km/h without AGS

- up to 60 km/h air suspension

- Pick-up wheels Tyre pressure

- with tyres: 555/45-17 500/55-20 600/55-22.5 550/45-R22.5 650/50-R22.5 700/45-22.5 600/55-R26.5 700/50-R26.5 800/40-R26.5 Pick-up wheels Tightening torque of wheel nuts M18 x x1.5 M20 x 1.5 M22 x x1.5 Sound pressure level dB(A) 70 70 70

QUANTUM

5500 S-18

700/45-22.5 12PR

600/55-22.5 12PR

650/50-R22.5 12PR

16x6.5-8 4PR

bar

3.0

1.5

2.5

380 510

QUANTUM

5500 S-16

555/45-17 154F

550/45-R22.5

555/45-17 154F

500/55-20 12PR

16x6.5-8 4PR

3.0

4.5

3.0

2.5

270

QUANTUM

6800 S

700/45-22.5 12PR

700/50-R26.5 800/40-R26.5

650/50-R22.5 12PR

600/55-R26.5

16x6.5-8 4PR

3.0

1.5

3.0

1.5

2.5

510

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TIC QUANTUM Technical Data

QUANTUM

5500 S

QUANTUM

4500 S

Length (L) mm 9,250 8,160 Width (B) mm 2,550 2,550 Height (H) – dry forage assembly folded up – dry forage assembly folded down

mm mm

3,840 3,040

3,840

3,040 Track width mm 1,850 1,850 Pick-up width mm 1,800 1,800 Platform height mm 1,240 1,240 Platform area mm 2,160 x 5,700 2,160 x 4,700 Loading capacity (acc. to DIN 11741) m3 31 26,3 Kerb weight kg 6,920 6,500 Permissible total weight 13,000 11,000 Number of cutting knives 33 33 Shortest theoretical length of cut mm 45 45 Number of pick-up tines per tine bar 26 26 Tine spacing mm 61 61 PTO speed min-1 1,000 1,000 Tyres - up to 40 km/h without AGS

- up to 60 km/h without AGS

- up to 80 km/h with AGS

- up to 60 km/h air suspension

- Pick-up wheels Tyre pressure - with tyres 500/50-17 555/45-17 500/55-20 16x6.5-8 Tightening torque of wheel nuts – wagon

555/45-17 146F

555/45-17 146F 555/45-17 146F 555/45-17 146F

16x6.5-8 4PR bar bar bar

3.0

2.5

500/50-17 10PR

555/45-17 146F 555/45-17 146F

16x6.5-8 4PR

3.5

3.0

2.5

Nm 300 300 wheels Sound pressure level dB(A) 70 70

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Technical Data QUANTUM TIC

1.3 QUANTUM 6800 P, 6500 P, 5500 P-18, 5500 GT, 5500 P, 4500 P

QUANTUM

6800 P

QUANTUM

6500 P

QUANTUM

5500 P-18

Length (L) mm 10,180 10,019 9,250 Width (B) mm 2,550 2,550 2,550 Height (H) – dry forage assembly

mm 3,990 3,950 3,990 folded up Height (S) – dry forage assembly

mm 3,290 3,190 3,290 folded down Track width mm 1,950 1,950 1,950 Pick-up width mm 1,800 1,800 1,800 Platform height mm 1,240 1,240 1,490 Platform area mm 2,160 x 7,600 2,160 x 7,550 2,160 x 6,550 Loading capacity (acc. to DIN 11741) m3 40 45.7 34 Kerb weight kg 8,030 7,440 7,240 Permissible total weight kg 20,000 16,000 18,000 Number of cutting knives 33 33 33 Shortest theoretical length of cut mm 45 45 45 Number of pick-up tines per tine bar 26 26 26 Tine spacing mm 61 61 61 PTO speed min Tyres - up to 40 km/h without AGS

- up to 50 km/h without AGS

- up to 60 km/h without AGS

- up to 80 km/h with AGS

- up to 60 km/h air suspension

- Pick-up wheels Tyre pressure - with tyres 555/45-17 500/55-20 600/55-22.5 650/50-R22.5 700/45-22.5 600/55-R26.5 700/50-R26.5 800/40-R26.5 Pick-up wheels

-1

1,000 1,000 1,000

700/45-22.5 12PR

700/50-R26.5

650/50-22.5 12PR

16x6.5-8 4PR

bar

3.0

1.5

3.0

1.5

2.5

2x 500/50-17 14PR

4x 8.25 R70 14PR

16x6.5-8 4PR

4.5

2.5

600/55-22.5 12PR 650/55-22.5 12PR

16x6.5-8 4PR

3.0

1.5

2.5 Tightening torque of wheel nuts Nm 300 300 300 Sound pressure level dB(A) 70 70 70

1-8 10/04

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TIC QUANTUM Technical Data

QUANTUM

5500 GT

QUANTUM

5500 P

QUANTUM

4500 P

Length (L) mm 8,860 8,860 7,770 Width (B) mm 2,550 2,550 2,550 Height (H) – dry forage assembly folded up mm 3,800 3,800 3,800 Height (S) – dry forage assembly folded

mm 3,040 3,040 3,040 down Track width mm 1,900 1,850 1,850 Pick-up width mm 1,800 1,800 1,800 Platform height mm 1,240 1,240 1,240 Platform area mm 2,160 x 6,500 2,160 x 6,550 2,160 x 5,400 Loading capacity (acc. to DIN 11741) m3 34 34 29.3 Kerb weight kg 6,550 6,200 5,740 Permissible total weight kg 16,000 13,000 11,000 Number of cutting knives 33 33 33 Shortest theoretical length of cut mm 45 45 45 Number of pick-up tines per tine bar 26 26 26 Tine spacing mm 61 61 61 PTO speed min-1 1,000 1,000 1,000 Tyres - up to 40 km/h without AGS

- up to 50 km/h without AGS

- up to 60 km/h without AGS

- up to 60 km/h air suspension

- Pick-up wheels Tyre pressure

- with tyres 500/50-17 550/45-R22.5 555/45-17 500/55-20 550/45-17 154F Pick-up wheels Tightening torque of wheel nuts M18 x 1.5 M20 x 1.5 Sound pressure level dB(A) 70 70 70

555/45-17 154F

550/45-R22.5

555/45-17 145F

500/55-20 12PR

16x6.5-8 4PR

bar

4.5

3.5

3.0

2.5

270 380

555/45-17 146F

16x6.5-8 4PR

3.0

2.5

270 380

500/50-17 10PR

555/45-17 146F

16x6.5-8 4PR

3.5

3.0

2.5

270 380

10/04 1-9

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Technical Data QUANTUM TIC

1-10 10/04

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TIC QUANTUM Operation

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3800 K, 3800 P, 3500 S ..........................................................2

1.1 Control box short instructions .....................................................................................................3

1.2 Operation ....................................................................................................................................4

2.0 QUANTUM 4500 S / 5500 S / S-16 / S-18 / 6800 S ............................................................................8

2.1 Control box short instructions .....................................................................................................9

2.2 Operation ..................................................................................................................................11

3.0 QUANTUM 4500 P / 5500 P / 5500 P-16 / 5500 P-18 / 5500 GT / 6800 P.......................................18

3.1 Control box short instructions ...................................................................................................19

3.2 Operation ..................................................................................................................................21

10/04 3-1

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Operation QUANTUM TIC

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3800 K, 3800 P, 3500 S

Caution! When draining oil over a more extended period than usual (tractor –

forage wagon – floor conveyor), the pump system of the tractor must be known (see “Prior to operation – Hydraulic system”).

The buttons on the control box are only used to pre-select the different functions of the forage wagon. Operating the single-acting control valve on the tractor will activate the desired function.

Between the different operations, the single-acting control valve of the tractor must be switched back to the neutral position. Only then a new function can be pre-selected on the control box.

The floor conveyor is controlled using the double-acting control valve on the tractor. On the S-wagon, the floor conveyor speed can be varied using the rotary knob. This knob has no function on the K and P wagons!

3-2 10/04

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TIC QUANTUM Operation

1.1 Control box short instructions

Loading operation

Knife frame

Control system ON

Control system OFF

Pick-up up/down

Dry crop top up/down (Quantum 3500 K only)

Wagon full indicator

Opens / closes the cutting trough

Opens the cutting trough totally

Unloading operation

Articulated drawbar

Opens / closes the tailgate

Drawbar up/down

10/04 3-3

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Operation QUANTUM TIC

1.2 Operation

Loading operation

Pick-up lowered/raised

Use this key of the control box to switch on the control unit. The red

indicator light lights up.

Use this key to pre-select the pick-up mode. The pick-up can now be

raised and lowered using the single-acting control valve. Switch on the pto for loading.

Attention The pick-up will only remain in floating position if the pick-up mode is pre-

selected on the control box and the single-acting control valve is set to floating position.

Quantum 3500 K / 3800 K /

To switch off the rotor and the pick-up the pto must be disengaged.

3500 P / 3800 P

Quantum 3500 S Raising the pick-up will automatically disengage the rotor and the pick-up.

Dry crop top

(QUANTUM 2500 K, 3500 K only)

Use this key to pre-select the dry crop top mode. To erect the dry

crop top, pressurize the single-acting control valve. To lower it, set the system to the float position.

3-4 10/04

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TIC QUANTUM Operation

Floor conveyor

Floor conveyor speed

Opening the knife frame

The floor conveyor is controlled using the double-acting control valve on

the tractor. To set the floor conveyor to forwards or reverse, set the double-acting control valve to the raise or lower position.

QUANTUM 3500 S:

The floor conveyor speed can be varied using the rotary knob provided the pick-up or the tailgate has been pre-selected.

QUANTUM 3500 K / P, 2500 K / P, 3800 K / P: If the tractor is fitted with a flow rate controller, this can be used to vary the floor conveyor speed.

The knob on the control unit has no function on the K and P wagons.

If a blockage occurs in the conveyor channel (cut-out clutch of the

universal drive shaft is activated), switch off the pto.

Use this key to select the cutting mechanism mode. Set the lever

on the single-acting control valve to the float position in order to open the knife frame.

Engage the pto to clear the blockage. Once the channel is free, close the

knife frame again by moving the lever on the single-acting control valve to the pressure setting.

If the knife frame has to be totally lowered (e.g. for repair work or for

the replacement of knives), first set the single-acting valve to the float position and then press these two buttons simultaneously.

Attention If the knife frame is totally open, it must be closed very carefully and

“Wagon full” indicator

To close the knife frame, set the control unit to the pressure setting.

slowly. When folding up the frame, ensure that the cutting knives will not collide with the rotor tines.

The load space is filled when the “wagon full” indicator of the display

flashes (see figure). Switch off the floor conveyor, raise the pick-up and switch off the universal drive shaft.

QUANTUM 3500 S QUANTUM 3500 P / K 2500 P / K 3800 P / K

10/04 3-5

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Operation QUANTUM TIC

Unloading operation

Silo operation

Discharging the load

QUANTUM 3500 S

Attention If the swash plates are folded down, opening the tailgate is not allowed.

Discharging the load

QUANTUM 2500 K / P 3500 K / P 3800 K / P

Use this key of the control box to switch on the control unit. The

indicator light lights up.

For silo operation raise the wagon at the front with the articulated

drawbar. Use this key for pre-selecting the articulated drawbar and set the single-acting control valve to the pressure setting. When unloading is complete, lower the wagon again. Set the control unit to the float position.

Open the tailgate before unloading. Use this key for pre-selecting

the tailgate and set the single-acting control valve to the pressure setting.

Open the tailgate to enable activation of the shredder drums via the pto.

Then initiate the floor conveyor using the double-acting control valve. The floor conveyor speed can be varied using the rotary knob. To close the tailgate, the set the single-acting control valve to the float position until the tailgate has closed completely.

Open the tailgate before unloading. Use this key for pre-selecting

the tailgate and set the single-acting control valve to the pressure setting.

Initiate the floor conveyor using the double-acting control valve. To close the tailgate, the set the single-acting control valve to the float position until the lock has engaged. To reverse the floor conveyor, move the lever of the double-acting control valve to the opposite direction. If the tractor is fitted with a flow rate controller, this can be used to vary the floor conveyor speed.

3-6 10/04

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TIC QUANTUM Operation

10/04 3-7

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Operation QUANTUM TIC

2.0 QUANTUM 4500 S / 5500 S / S-16 / S-18 / 6800 S

Control light (rear wheel) flashes when steering axle is locked (reverse travel)

Caution: 1. Electric System

Connect the 2-pole plug with the tractor = on-board voltage to the distributor box.

2. To switch on the control box, the hydraulic system must be pressurized = (2 bar switch) on-board voltage from the distributor box to the control box.

The pump system of the tractor must be known (see chapter “Before

operating the hydraulic system”).

12 V On-board voltage display (10.8 V min., 15.5 V max.)

4 Display of floor conveyor speed

3. Flashing wheel The axle’s straight position is blocked by means of the cross conveyor key and a 3/2 way valve = flashing wheel.

QUANTUM with a separate hydraulic connection (single-acting) do not

have this equipment.

3-8 10/04

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TIC QUANTUM Operation

2.1 Control box short instructions

Loading operation/ manual

Pick-up up/down

The pick-up disengages when raised.

Setting filling mode/

automatic filling ON/OFF

Raise the pick-up.

The pick-up does not disengage when raised, benefit: this is easier on the dog clutch.

Pick-up down

Floor conveyor ON/

save floor conveyor speed

Floor conveyor speed

Speed down

Speed up

(Option S = quick unloading via 2-speed motor)

Reverse conveyor floor

Cutting mechanism

Open knife frame 1

position

Close knife frame 1

position

Open knife frame 2

position

Close knife frame 2

position

10/04 3-9

Page 24

Operation QUANTUM TIC

Unloading operation

Articulated drawbar

Unloading operation start/stop

Turning direction of cross conveyor belt and locking/unlocking of

steering axle.

Articulated drawbar up

Articulated drawbar down

3-10 10/04

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TIC QUANTUM Operation

2.2 Operation

Loading operation

Pick-up up/down

Manually changing the pick-up working width

To switch on the control unit, set the hydraulic system to the pressure

setting. The display shows the forage wagon. Switch on the pto shaft.

This button is used for lowering the pick-up to the float position.

The wagon is automatically loaded. Pressing this button again raises the pick-up and the loading process is stopped. With the pto switched on, the pick-up drive and the rotor are automatically switched off when raising the pick-up. They are restarted when lowering the pick-up.

In difficult ground and crop conditions, the pick-up can be raised

during loading by means of this button. The pick-up is no longer in the float position.

The pick-up is lowered again using this button.

Adjusting the load space filling

(up to serial no.)

Attention: From serial no. … there are no reed switches available for half-loading the front panel. However, the wiring loom remains unchanged = the plugs for the reed switches are available. The switching options include only “Full loading” and “Manual loading”.

This button can be used to vary the loading mode.

Its functions depends on the position of micro switch (3) located in the front part of the control box (4).

Micro switch (3) in lower position (OFF / standard setting):

This button on the control box enables switching back and forth

between full and half loading.

3 Micro switch 4 Control box For micro switch position see chapter 13 “Electric System”.

10/04 3-11

Page 26

Operation QUANTUM TIC

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Upper position (e.g. for loading dry fodder): The floor conveyor is switched on when the cover plates are raised. All 3 plates are linked with one another.

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Lower position (e.g. for loading green fodder and silage): The floor conveyor is switched on when the feelers at the front wall are lifted.

The floor conveyor will run until the feelers and/or the top plate are free

again.

Micro switch (3) in top position:

Using this button allows switching between fully loading the wagon

and deactivating the automatic filling.

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Upper position (e.g. for loading dry fodder): The floor conveyor is switched on when the centre top plate is raised.

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

The filling indicator disappears: The automatic filling mode is deactivated; the floor conveyor has to be operated manually.

To adjust the micro switch, switch off the control box and the oil supply

from the tractor. Then open the distributor box located in the front part of the wagon and switch over using a small screwdriver. Close the box and connect the oil supply to the tractor.

3-12 10/04

Page 27

TIC QUANTUM Operation

Adjusting the load space filling

(from serial no.)

Attention: From serial no. … there are no reed switches available for half-loading the front panel. However, the wiring loom remains unchanged = the plugs for the reed switches are available.

This button can be used to vary the loading mode. Its functions

depends on the position of micro switch (3) located in the front part of the control box (4).

Micro switch (3) in lower position (OFF / standard setting):

Using this button allows switching back and forth between fully

loading the wagon and manual loading (under visual control).

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Upper position (e.g. for loading dry fodder): The floor conveyor is switched on when the cover plates are raised. All 3 plates are linked with one another.

The floor conveyor will run until the feelers and/or the top plate are free

again or the manual actuation is shut down..

Micro switch (3) in top position:

Using this button allows switching between fully loading the wagon

and deactivating the automatic filling.

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Upper position (e.g. for loading dry fodder): The floor conveyor is switched on when the cover plates are raised. All 3 plates are linked with one another.

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

The filling indicator disappears: The automatic filling mode is deactivated; the floor conveyor has to be operated manually.

To adjust the micro switch, switch off the control box and the oil supply

from the tractor. Then open the distributor box located in the front part of the wagon and switch over using a small screwdriver. Close the box and connect the oil supply to the tractor.

10/04 3-13

Page 28

Operation QUANTUM TIC

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Floor conveyor End of loading operation

When the crop presses against the lower shredder drum, it is moved

backwards slightly. The switch (6) closes and the floor conveyor is automatically switched off. The filling indicator on the display is flashing. Raise the pick-up and switch off the universal drive shaft.

Manual operation of floor conveyor

If the automatic filling mode is not used or the load space is only to

be partially filled, the floor conveyor can be operated manually using this key. Here the floor conveyor speed is always as previously set.

3-14 10/04

Page 29

TIC QUANTUM Operation

Adjusting the floor conveyor speed

Pressing this button increases the floor conveyor speed of all further

runs.

Pressing this button decreases the floor conveyor speed of all further

runs.

The floor conveyor can also be reversed during loading by

simultaneously pressing both buttons. Reversing is always carried out at speed 9.

After the floor conveyor has been reversed, the floor conveyor speed

must be increased by pressing this button.

Open / close knife frame

The floor conveyor speed is displayed at the bottom left in the control panel display. It can be adjusted within the range from 0 to 9: 0 – 9 (standstill – fast)

Open the cutting frame by means of this button (1

pto to clear the blockage.

As soon as the conveyor channel is free, close the cutting frame by

pressing this key. Press this key until the display shows a totally closed knife frame.

If the knife frame is to be completely lowered (2

dismounting the rotor), this key must be pressed above the cutting trough.

Close the knife frame by pressing this key above the knife frame.

stage). Engage the

stage, e.g. for repairs or

Attention!

If the knife frame is totally open, it must be closed very carefully and

slowly. When folding up the frame, ensure that the cutting knives will not collide with the rotor tines.

10/04 3-15

Page 30

Operation QUANTUM TIC

The black filling bar ceases to apply from serial no. and installation of EPROM 350 812-5.

Unloading in silo operation

To switch on the control unit, set the hydraulic system to the pressure

setting. The display shows the forage wagon.

Press this button to raise the wagon over the articulated drawbar at the

front.

When unloading is complete, use this key to lower the wagon again. The

floor conveyor switches to the 4

Discharge of the load space

Switch on the pto shaft. Press this button for unloading. The tailgate

opens, the shredder drums start running and the floor conveyor is switched on after a short delay. To stop the unloading process, press this button again. Any blockage of the shredder drums (the cut-out clutch of the universal drive shaft is activated) by the material requires reversing the floor conveyor.

Press these buttons simultaneously to reversing the floor conveyor. After

the floor conveyor has been reversed, the floor conveyor speed must be increased by pressing the + button.

Pressing this button increases the floor conveyor speed. By increasing

the speed numbers up to speed 9 and pressing this key once again, an “S” appears in the control panel display = quick conveyor speed due to 2speed hydraulic motor.

Pressing this button decreases the floor conveyor speed.

stage.

When pressing this key during the whole unloading process, the adjusted

floor conveyor speed is saved for further unloading processes.

3-16 10/04

Page 31

TIC QUANTUM Operation

Unloading by means of cross conveyor belt

Pull out the cross conveyor belt before unloading and lock it to the lower

back cover. Connect the hydraulic hoses to the hydraulic motor.

Switch on the pto for unloading with the cross conveyor belt and press

this key. The shredder drums start running and the floor conveyor is switched on after a short delay. To stop the unloading process, press this button again. Any blockage of the shredder drums (the cut-out clutch of the universal drive shaft is activated) by the material requires reversing the floor conveyor.

Press these buttons simultaneously to reversing the floor conveyor.

Pressing this button increases the floor conveyor speed.

Pressing this button decreases the floor conveyor speed.

When pressing this key during the whole unloading process, the adjusted

floor conveyor speed is saved for further unloading processes.

This key enables changing the direction of rotation of the cross conveyor

belt. From serial no.: …. with solenoid valve 62, the trailing axle can be blocked with this key.

10/04 3-17

Page 32

Operation QUANTUM TIC

3.0 QUANTUM 4500 P / 5500 P / 5500 P-16 / 5500 P-18 / 5500 GT / 6800 P

Attention: 1. Electric System

Floor conveyor 2-stage motor

(option for P forage wagons)

Connect the control box to the forage wagon by means of the control cable. Plug the 2-pole plug (series equipment) into the socket outlet of the tractor and of the forage wagon. On-board voltage from the distributor box to the control box = 10.8 V min.

2. Hydraulic System To switch on the control unit, set the hydraulic system to the pressure setting (2 bar switch). The pump system of the tractor must be known (see chapter “Prior to operation”).

The self-loading forage wagon is equipped with a 2-stage motor to double

the speed of the conveyor and shorten the time needed to unload the remainder. When unloading starts, the floor conveyor is switched on by this button.

After about two thirds of the crop have been unloaded, the speed of the

floor conveyor can be doubled. To do this, press switch (7).

The second speed stage only runs as long as the switch is being pressed. When it is released, the conveyor continues to run at normal speed.

3-18 10/04

Page 33

TIC QUANTUM Operation

3.1 Control box short instructions

Loading operation

Pick-up down

Pick-up up. The pick-up does not switch off.

Floor conveyor ON/OFF when loading, tailgate must be closed.

Knife frame

Open knife frame

Close knife frame

When pressing both keys simultaneously, the knife frame is opened completely.

Unloading operation

Open tailgate

Close tailgate

Floor conveyor ON/OFF when unloading, tailgate must be open.

Articulated drawbar

Articulated drawbar up

Articulated drawbar down

10/04 3-19

Page 34

Operation QUANTUM TIC

Indicator lights (LEDs)

1 Green: Pick-up lowered – floating position

2 Red: Knife frame open

3 Red, flashing: Tailgate closed

4 Green, flashing: Tailgate open

5 Red (approx. 3 sec.): Oil in circulation, wagon is ready for use

6 Red, flashing: Wagon is 100% filled

3-20 10/04

Page 35

TIC QUANTUM Operation

3.2 Operation

Loading operation

Pick-up down

Press this key.

The pick-up is lowered and remains in floating position. The green indicator light on the control box is illuminated.

Pick-up up

Press this key.

The pick-up is raised – it does not switch itself off.

Hydraulic opening of the knife frame

If a blockage occurs in the conveyor channel (cut-out clutch of the

universal drive shaft is activated), switch off the pto.

Use this key to open the knife frame. The red indicator light is illuminated.

Re-engage the pto. As soon as the conveyor channel is free, close the

knife frame by pressing this key.

If the knife frame has to be totally lowered (e.g. for removing knives or the

rotor), press these two buttons simultaneously.

10/04 3-21

Page 36

Operation QUANTUM TIC

Press this key to close the knife frame again.

Important! If the knife frame is totally open, it must be closed very carefully and

slowly. When folding up the frame, ensure that the cutting knives will not collide with the rotor tines.

Engaging the floor conveyor for loading

Press this key to fill the load space. The floor conveyor will run to the rear

as long as the key is pressed.

The floor conveyor speed depends on the tractor’s pto speed.

Important! During the loading operation, the tailgate must be completely closed,

otherwise the floor conveyor cannot be operated with the push button.

As soon as the crop pushes the tailgate slightly to the rear, the floor conveyor is disengaged by a solenoid switch. The red LED (100%) on the control box starts flashing. The floor conveyor drive can only be reengaged after the tailgate has been opened.

3-22 10/04

Page 37

TIC QUANTUM Operation

Unloading operation

Opening the tailgate

Press this key until the tailgate is open.

The green indicator light on the control panel will flash.

Discharge of the load space

Press this key to discharge the load space.

The floor conveyor will travel to the rear as long as this key is pressed once more. Control the floor conveyor speed by means of the tractor’s speed.

Important! During the unloading operation the tailgate must be completely open and

the green indicator light must flash, otherwise the floor conveyor cannot be operated.

Closing the tailgate

Press this key until the red indicator light starts flashing.

The tailgate is lowered due to its weight (i.e. without hydraulic pressure) as long as this key is pressed. Release this key when the red indicator light on the control panel starts flashing. Hydraulic pressure builds up and the tailgate is locked. The red LED (100%) is no longer illuminated.

10/04 3-23

Page 38

Operation QUANTUM TIC

Floor conveyor 2-stage motor

(option for P forage wagons)

The self-loading forage wagon is equipped with a 2-stage motor to double

the speed of the conveyor and shorten the time needed to unload the remainder. When unloading starts, the floor conveyor is switched on by this button.

After about two thirds of the crop have been unloaded, the speed of the

floor conveyor can be doubled. To do this, press switch (7).

The second speed stage only runs as long as the switch is being pressed. When it is released, the conveyor continues to run at normal speed.

3-24 10/04

Page 39

TIC QUANTUM Brakes

1.0 Compressed air circuit diagrams.........................................................................................................2

1.1

QUANTUM 5500P/S-16 40 km/h, 16 to, (steering axle)..........................................................................2

1.2

QUANTUM 2500K/P, 3500P/S/K, 3800K/P, 4500S/P 40 km/h (steering axle).......................................4

1.3

5500P/S 40 km/h, 13 to, (steering axle) ..................................................................................................6

1.4

5500P-18/S –18, 60 km/h ........................................................................................................................8

1.5

5500P/S 80 km/h (ABS) ........................................................................................................................10

1.5.1 Functional test.............................................................................................................................12

1.6

Compressed air system with level regulating valve...............................................................................14

1.6.1 up to serial no. ............................................................................................................................14

1.6.2 from serial no. .............................................................................................................................16

1.7

5500 P/S 50/60 km/h .............................................................................................................................18

1.8

5500 S, 40/60 km/h................................................................................................................................20

Adjustments .........................................................................................................................................22

2.0

2.1

Diaphragm cylinder................................................................................................................................22

2.2

Adjusting the rod adjuster......................................................................................................................23

2.2.1 Standard rod adjuster .................................................................................................................23

2.2.2 Automatic rod adjuster................................................................................................................24

2.3

Brake-power regulator (ALD).................................................................................................................25

2.4

Air suspension .......................................................................................................................................26

2.4.1 Lifting and lowering device .........................................................................................................26

2.4.2 Air suspension valve...................................................................................................................27

10/04 10-1

Page 40

Brakes QUANTUM TIC

1.0 Compressed air circuit diagrams

1.1 QUANTUM 5500P/S-16 40 km/h, 16 to, (steering axle)

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter 4 Trailer brake valve 5 Compressed air accumulator (40 litres) 6 Dewatering valve, manual 7 ALB (automatic load-dependent brake-power), mechanically controlled 8 ALB (automatic load-dependent brake-power), pneumatically controlled 9 Simulation connection (when using item 8) 10 Release valve 11 Link joint (round hole) 12 Diaphragm cylinder (20”) 13 Link joint (elongated hole) 14 Diaphragm cylinder (16”) 15 Test port (M16x1.5) for cylinder pressure 16 Test port (M22x1.5) 17 Test port (M12x1.5) 18 Dummy coupler 19 Block spring (when using item 7 only)

10-2 10/04

Page 41

TIC QUANTUM Brakes

5500P/S-16 40 km/h, 16 to, (Steering axle)

10/04 10-3

Page 42

Brakes QUANTUM TIC

1.2 QUANTUM 2500K/P, 3500P/S/K, 3800K/P, 4500S/P 40 km/h (steering axle)

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter 4 Dummy coupler 5 Trailer brake valve with release valve 6 Compressed air accumulator (20 litres) 7 Dewatering valve, manual 8 Test port (M22x1.5) 9 ALB (automatic load-dependent brake-power), mechanically controlled 11 Test port 12 Adjusting valve 13 Link joint 14 Diaphragm cylinder (20”) 15 Link joint 16

Piston cylinder ∅ 80 17 Test port (M16x1.5) 18 Test port (M12x1.5) 19 Block spring

10-4 10/04

Page 43

TIC QUANTUM Brakes

2500K/P, 3500P/S/K, 3800K/P, 4500S/P 40 km/h (steering axle)

10/04 10-5

Page 44

Brakes QUANTUM TIC

1.3 5500P/S 40km/h, 13 to, (steering axle)

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter for piping 4 Trailer brake valve 5 Compressed air accumulator (20 litres) 6 Dewatering valve, manual 7 ALB (automatic load-dependent brake-power), mechanically controlled 8 Adjusting valve 9 Dummy coupler 10 Release valve 11 Link joint 12 Diaphragm cylinder (20”) 13 Link joint (elongated hole) 14 Diaphragm cylinder (20”) 15 Test port (M16x1.5) 16 Test port (M22x1.5) 17 Test port (M12x1.5) 18 Block spring for dual-axle steering 19

Tension band ∅ 206

10-6 10/04

Page 45

TIC QUANTUM Brakes

5500P/S 40 km/h, 13 to, (steering axle)

10/04 10-7

Page 46

Brakes QUANTUM TIC

1.4 5500P-18/S –18, 60 km/h

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter for piping 4 Trailer brake valve 5 Compressed air accumulator (60 litres) 6 Dewatering valve, manual 7 ALB (automatic load-dependent brake-power), mechanically controlled 8 Adjusting valve 9 Dummy coupler 10 Release valve 11 Link joint 12 Diaphragm cylinder (24”) 13 Link joint (elongated hole) 14 Diaphragm cylinder (24”) 15 Test port (M16x1.5) 16 Test port (M22x1.5) 17 Test port (M12x1.5) 18 Block spring for dual-axle steering

10-8 10/04

Page 47

TIC QUANTUM Brakes

5500 P-18/ S-18, 60 km/h

10/04 10-9

Page 48

Brakes QUANTUM TIC

1.5 5500P/S 80 km/h (ABS)

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter 4 Trailer brake valve with release valve 5 ALB (automatic load-dependent brake-power), mechanically controlled

(alternative to item 6) 6 ALB (automatic load-dependent brake-power), pneumatically controlled

(alternative to item 5) 7 Simulation connection (when using item 6 only) 8 Test port (M16x1.5) 9 Compressed air accumulator (60 litres) 10 Dewatering valve, manual 11 Link joint (elongated hole) 12 Diaphragm cylinder (24”) 13 Link joint (elongated hole) 14 Diaphragm cylinder (24”) 15 Test port (M16x1.5) 16 Test port (M22x1.5) 17 Pole and sensor 18 4S/2M – module kit (ABS control unit) 19 12 m power supply cable (ISO 7638) for drawbar trailer / forage wagon 20 12 m power supply cable (ISO 1186) option 21 Warning lamp, green 22 12 m cable for warning lamp 23 Dummy coupler

10-10 10/04

Page 49

TIC QUANTUM Brakes

5500P/S 80 km/h (ABS)

10/04 10-11

Page 50

Brakes QUANTUM TIC

1.5.1 Functional test

Time of testing?

• After assembly of the ABS (anti-lock braking system) on the vehicle

• § 29 inspection of vehicles and trailers (S.I. = Safety inspection)

• In Germany as of 11.2000 / HU)

• When control lamp lights up (see a workshop to find the fault)

Testing possibilities

• with an external test device

• with a multimeter.

10-12 10/04

Page 51

TIC QUANTUM Brakes

• Fault indication via an integrated LED display in the control device. If an error LED lights up, contact the service dept. of HALDEX in Denkendorf.

10/04 10-13

Page 52

Brakes QUANTUM TIC

1.6 Compressed air system with level regulating valve

1.6.1 Up to serial no. 1 Overflow valve (6 bar) 2 Compressed air reservoir 3 Tension band with support 4 Filter 5 Dewatering valve, manual 6 Test port (M22x1.5) 7 Compressed air valve 8 Articulation (axle) 9 Test port (M12x1.5) 10 Simulation connection

BBA (service braking system) = Compensating line

10-14 10/04

Page 53

TIC QUANTUM Brakes

Compressed air system with level regulating valve, up to serial no.

Air bellows

line

Compensating

LB controller

line

Compensating

Air bellows

system

volume from

Accumulator

service brake

10/04 10-15

Page 54

Brakes QUANTUM TIC

1.6.2 From serial no. 1 Overflow valve (6 bar) 2 Compressed air reservoir 3 Tension band with support 4 Filter 5 Dewatering valve, manual 6 Test port (M22x1.5) 7 Compressed air valve 8 Articulation (axle) 9 Raise/lower control valve 10 Test port (M12x1.5) 11 Simulation connection

10-16 10/04

Page 55

TIC QUANTUM Brakes

Compressed air system with level regulating valve, from serial no.

10/04 10-17

Page 56

Brakes QUANTUM TIC

1.7 5500 P/S 50/60 km/h

1 Red service line hose coupler “Accumulator” 2 Yellow service line hose coupler “Brake” 3 Filter 4 Trailer brake valve 5 Compressed air accumulator (60 litres) 6 Dewatering valve, manual 7 ALB (automatic load-dependent brake-power), mechanically controlled 8 Adjusting valve 9 Dummy coupler 10 Release valve 11 Link joint (round hole) 12 Diaphragm cylinder 13 Link joint (elongated hole) 14 Diaphragm cylinder 15 Test port (M16x1.5) for cylinder pressure 16 Test port (M22x1.5) 17 Test port (M12x1.5) 18 Block spring (M16x1.5)

10-18 10/04

Page 57

TIC QUANTUM Brakes

5500 P/S 50/60 km/h

10/04 10-19

Page 58

Brakes QUANTUM TIC

1.8 5500 S, 40/60 km/h

10-20 10/04

Page 59

TIC QUANTUM Brakes

5500 S 40/60 km/h

10/04 10-21

Page 60

Brakes QUANTUM TIC

2.0 Adjustments

2.1 Diaphragm cylinder

With half a piston stroke (H/2), the piston rod must be placed at right

angles (90°) to the brake lever in order to obtain a good mechanical efficiency. When the brake is appropriately adjusted, the piston stroke must not exceed 1/3 to 1/2 of the overall stroke when fully braking the machine.

10-22 10/04

Page 61

TIC QUANTUM Brakes

2.2 Adjusting the rod adjuster

2.2.1 Standard rod adjuster Every 1000 operating hours

Checking and adjusting the operating clearance of the wheel brakes

• continuous checks needed

• every 1 to 3 weeks, depending on operating hours

Operate the rod adjuster by hand in direction of pressure. If the free play

of the diaphragm cylinder pressure rod is 35 mm max., the wheel brake needs to be re-adjusted. The adjustment is made on the re-adjusting hexagon of the rod adjuster. Set the free play “a” to 10 ... 12% of the connected brake lever length „B“. Example: Lever length B = 150 mm corresponds to a free play of 15 ... 18 mm.

With automatic rod adjusters, the re-adjustment of the wheel brake is made automatically when the brake cams have twisted by approx. 15%.

10/04 10-23

Page 62

Brakes QUANTUM TIC

2.2.2 Automatic rod

adjuster

Checking and adjusting the operating clearance of the wheel brakes

Every 1000 operating hours

The basic adjustment is the same as for the standard rod adjuster. The

adjustment is made automatically when the brake cams have twisted by approx. 15°. The ideal lever adjustment (if the cylinder attachment cannot be influenced) is approx. 15% before reaching the right angle. The empty stroke “a” should be approx. 10% of the lever arm.

Functional check

Each time the brake linings are changed, at least once a year. Remove

the rubber cap. Turn back the adjusting screw (arrow) using a ring spanner by approx. 3/4 turns. The free play should be at least 45 mm, with a lever length of 150 mm. Operate the brake lever several times by hand. The automatic adjustment must run smoothly, i.e. you will hear the gear coupling lock in and the adjusting screw will turn slightly clockwise on the reverse stroke. Fit the cap. Grease it using ECO-Li 91.

10-24 10/04

Page 63

TIC QUANTUM Brakes

2.3 Brake-power regulator (ALD)

Identification plate (left) for ALB regulator and air suspension

The automatic load-dependent brake-power regulator (ALB) has the

function of automatically adjusting the brake pressure applied, depending on the load condition of the forage wagon.

To compensate setting of the vehicle’s springs, a 5 mm washer (S) has been placed under the tension spring of the brake cable. When the vehicle’s spring has set by approx. 5 mm, this washer (S) can be removed.

The lever length (dimension L, see identification plate of ALB regulator) has to be adjusted according to the manufacturer’s instructions.

10/04 10-25

Page 64

Brakes QUANTUM TIC

2.4 Air suspension

2.4.1 Lifting and lowering

device

Forage wagons with air-suspension axles are equipped with valves for

lifting and lowering operations. Actuate the valve via the rotary slide (3) in order to remove foreign objects between the rubber bellows (1) and the spring bell (2) (Fig. 18).

After operating the lifting and lowering device, the valve should be set to the “travel” position before starting. The travelling height is regulated automatically.

Rotary slide positions: I Lifting

II Stop III Travelling IV Stop V Lowering

10-26 10/04

Page 65

TIC QUANTUM Brakes

2.4.2 Air suspension valve

1 Frame support 2 Valve lever 3 Adjusting screw 4 Drive link

AF Rebounding EF Compression + FH Driving height = from lower edge of frame to the centre of the axle body FR Direction of travel

Check the driving height (FH) given on the identification plate (on the

right-hand side of the axle frame) of the air-suspended assembly at regular intervals.

The driving height must not be changed, otherwise damage could occur to the components of the axle assembly.

The angle α (< 90°) between the valve lever and the drive link (4) must be adjusted in a way so that the valve rod does not turn over if the airsuspended bellows completely rebounds. The driving height can be adjusted at the adjusting screw (3).

10/04 10-27

Page 66

Brakes QUANTUM TIC

10-28 10/04

Page 67

TIC QUANTUM Hydraulics

1.0 LS pump .................................................................................................................................................4

1.1

Initial position (Motor Off).....................................................................................................................4

1.2

Low pressure standby..........................................................................................................................6

1.3

A control device is actuated = start of LS pump delivery.....................................................................8

1.4

Constant volume flow.........................................................................................................................10

1.5

Downstroking .....................................................................................................................................12

1.6

Maximum pressure limitation (pressure relief valve function)............................................................14

1.7

Connecting the self-loading forage wagon (hydraulic supply) ...........................................................16

1.7.1 Hydraulic supply via the power beyond port...............................................................................16

1.7.2 Hydraulic supply via the power beyond port...............................................................................17

QUANTUM 3500K / 3800K / 3500P / 3500S ........................................................................................18

2.0

2.0.1 Prior to operation ........................................................................................................................18

2.0.1 Fixed displacement pump...........................................................................................................18

2.0.3 Constant-pressure pump ............................................................................................................19

2.0.4 Power beyond port......................................................................................................................19

2.1

3500K, 2500K, 3800K........................................................................................................................20

2.1.1 Circuit Diagram ...........................................................................................................................20

2.1.2 One-way restrictor valve .............................................................................................................22

2.2

3500P, 2500P, 3800P........................................................................................................................24

2.2.1 Circuit Diagram ...........................................................................................................................24

2.2.2 One-way restrictor valve .............................................................................................................26

2.3

3500S.................................................................................................................................................28

2.3.1 Circuit Diagram ...........................................................................................................................28

2.3.2 One-way restrictor valve .............................................................................................................30

2.3.3 Flow control valve with shut-off tap (only on 3500S)..................................................................32

2.3.4 Shut-off tap .................................................................................................................................34

3.0

QUANTUM 4500S / 5500S / S-16 / S-18 / 6800S.................................................................................36

3.0.1 Prior to operation ........................................................................................................................36

3.0.2 Fixed displacement pump...........................................................................................................36

3.0.3 Constant-pressure pump ............................................................................................................37

3.0.4 Power beyond port......................................................................................................................37

3.1

Survey ................................................................................................................................................38

3.1.1 Without 2-speed floor conveyor motor........................................................................................38

3.1.2 With 2-speed floor conveyor motor.............................................................................................40

3.2

Circuit Diagram ..................................................................................................................................42

3.2.1 Without cross conveyor belt (without 2-speed floor conveyor motor).........................................42

3.2.1 Without cross conveyor belt (with 2-speed floor conveyor motor)..............................................46

3.2.3 Without cross conveyor belt (without 2-speed floor conveyor motor).........................................48

3.3

Control block ......................................................................................................................................50

3.4

4/3 way solenoid valve (knife frame, raise/lower articulated drawbar) ..............................................54

3.5

3/3 way solenoid valve (open/close tailgate) .....................................................................................56

3.6

Valve block (pick-up and shredder drum) ..........................................................................................58

10/04 11-1

Page 68

Hydraulics QUANTUM TIC

3.7 Pick-up and shredder drum engagement cylinder ............................................................................ 60

3.8

DANFOSS OMR 125 floor conveyor hydraulic motor (single-speed motor)..................................... 62

3.9

2-speed motor ................................................................................................................................... 64

3.10

3 way cross conveyor belt flow control valve .................................................................................... 68

3.11

4/3 way solenoid valve (cross conveyor belt).................................................................................... 70

3.12

3/2 way solenoid valve (cross conveyor belt) QUANTUM S............................................................. 72

QUANTUM 4500P / 5500P / 5500 P-16 / 5500 P-18 / 5500GT / 6500P / 6800P ............................... 73

4.0

4.0.1 Prior to operation........................................................................................................................ 73

4.1

Circuit Diagram.................................................................................................................................. 76

4.2

Function............................................................................................................................................. 78

4.2.1 Free circulation (solenoids not energized)................................................................................ 78

4.2.2 Loading and unloading the wagon (floor conveyor On)............................................................. 78

4.2.3 Close knife frame ....................................................................................................................... 80

4.2.4 Open knife frame........................................................................................................................ 80

4.2.5 Raise pick-up ............................................................................................................................. 82

4.2.6 Pick-up lower.............................................................................................................................. 82

4.2.7 Floating position ......................................................................................................................... 82

4.2.8 Raise articulated drawbar .......................................................................................................... 84

4.2.9 Lower articulated drawbar.......................................................................................................... 84

4.2.10 Open tailgate.............................................................................................................................. 86

4.2.11 Close tailgate ............................................................................................................................. 86

4.3

Circulation valve with pressure relief valve ....................................................................................... 88

4.4

4/3 way Proportional solenoid valve.................................................................................................. 90

4.5

4/3 way solenoid valve ...................................................................................................................... 92

4.6

2/2 way solenoid valve (seated valve) .............................................................................................. 94

4.6.1 Up to serial no. ........................................................................................................................... 94

4.6.2 From serial no. ........................................................................................................................... 96

4.7

DANFOSS OMR 125 hydraulic motor............................................................................................... 98

4.8

Faults and remedies.......................................................................................................................... 99

4.8.1 Control system (LP/LM08 with SV02) ........................................................................................ 99

4.8.2 No working function LP/LM08 .................................................................................................. 100

4.8.3 No working function with multiple actuation............................................................................. 101

4.8.4 Consumers lower ..................................................................................................................... 101

4.8.5 Oil heating-up........................................................................................................................... 101

4.8.6 External oil leaks ...................................................................................................................... 101

4.9

Arresting cylinder for trailing axle .................................................................................................... 102

5.0

QUANTUM 6800................................................................................................................................. 103

5.1

Forced steering ............................................................................................................................... 103

5.1.1 Function ................................................................................................................................... 103

11-2 10/04

Page 69

TIC QUANTUM Hydraulics

10/04 11-3

Page 70

Hydraulics QUANTUM TIC

1.0 LS pump

1.1 Initial position

(Motor Off)

2 Working hydraulics pump (LS pump) 6 Compensating valve 7 Input (load pressure from signal network) 8 Volume flow controller 14 Control ram 15 Control spring 16 Pump drive 17 Swash plate 18 Ram 19 Pump input 20 Pump output (in the bottom plate of the control devices) 21 Compression spring (margin pressure)

11-4 10/04

Page 71

TIC QUANTUM Hydraulics

As the motor is shut down, there is no pressure in the hydraulic system.

The compression spring (21) has pushed the volume flow controller (8) to the end stop on the right. Due to this position, the upper side of the control ram (14) is connected with the tank via the volume flow controller (8).

The control spring (15) has moved the swash plate (17) to its maximum position.

10/04 11-5

Page 72

Hydraulics QUANTUM TIC

1.2 Low pressure standby

2 Working hydraulics pump (LS pump) 6 Compensating valve 7 Input (load pressure from signal network) 8 Volume flow controller 14 Control ram 15 Control spring 17 Swash plate 18 Ram 19 Pump input 20 Pump output (in the bottom plate of the control devices) 21 Compression spring (margin pressure) 25 Control edge

AA Oil supply BB Pressure-reduced oil EE Feed oil from the feed pump LL Tank (pressureless)

11-6 10/04

Page 73

TIC QUANTUM Hydraulics

All control units are in their neutral position. At the beginning, the swash

plate (17) is in its maximum swung-out position (see also “Motor OFF”)

As soon as the motor is started, the pump delivers the maximum volume flow to the spools of all control units.

As the spools completely shut off the flow, the pressure rises the acts upon the right side of the volume flow controller (8) which is moved to the left against the compression spring (21). The control edge (25) is now opened, enabling the pressure to access the top face of the control ram (14). Now the swash plate (17) is moved to the “Minimum pump capacity” position against the control spring (15). This process takes 10 milliseconds.

In this pump position, the following happens: Only such a volume flow is generated that is enough to compensate leakage losses; The pressure required for actuation of a consumer is maintained.

Since each control unit is in its neutral position, the load pressure input (7) is pressureless (connected to the tank). To move the volume flow controller, the pump pressure only has to overcome the spring (21). The pressure required for this is xxx bar (see technical data of tractor) and is referred to as the “Low-pressure standby”.

The pump remains in the “Low-pressure standby” position until a control unit is actuated. In this position, the pump requires only little drive energy.

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1.3 A control device is actuated = start of LS pump delivery

AA Oil supply BB Pressure-reduced oil EE Feed oil from the feed pump LL Tank (pressureless)

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When a control device is actuated, requiring an increased flow from the

pump, the pump pressure drops slightly.

The following condition results at the volume flow controller (8): the pump pressure acts on the right-hand face end the load pressure + the spring force of the compression spring act in the spring space (Margin pressure) (21).

Since the load pressure + the spring force of the compression spring (Margin pressure) (21) is higher than the pump pressure on the right face end, the volume flow controller (8) is moved to the right up to the stop. As a consequence: the free circulation of the pump pressure to the control ram is blocked. the control ram (14) is connected to the tank (no pressure on ram face). the swash plate (17) is tilted aside by the control spring (15).

The pump now pumps a higher volume flow. This process is referred to as “Upstroking”. The volume flow of the pump is determined by the restrictor effect of the open spool cross-section or by the setting of the flow divider of an additional control unit.

Reduced flow requirement

When the spool cross-section is reduced (the volume flow is to be reduced), the load pressure at the input (7) drops. This changes the force ratio at the volume flow controller (8), actuating the volume flow controller to the left against the spring, according to the pressure drop. The control ram (14) is pressurized and the swash plate (17) is set to a more horizontal position - the pump performs a downstroke until the volume flow requirement is met.

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1.4 Constant volume flow

2 Working hydraulics pump (LS pump) 6 Compensating valve 7 Input (load pressure from signal network) 8 Volume flow controller 14 Control ram 15 Control spring 17 Swash plate 20 Pump output (in the bottom plate of the control devices) 21 Compression spring (margin pressure) 22 Adjusting screw

AA Oil supply BB Pressure-reduced oil DD Control oil EE Feed oil from the feed pump LL Tank (pressureless)

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When a constant load is required from a port (constant consumer), the

volume flow controller (8) is actuated to a stable position. This keeps both the pressure on the top face of the control ram (14) and the position of the swash plate (17) constant. As long as the position of the swash plate (17) remains unchanged, the pump delivers a constant flow.

The following pressures now result on the volume flow controller (8): the load pressure (signal) + spring force of the compression spring (margin pressure) (21) on the left side. Pump pressure on the right side.

The difference in pressure is the differential pressure corresponding to the spring force of the compression spring (21).

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1.5 Downstroking

AA Oil supply BB Pressure-reduced oil DD Control oil EE Feed oil from the feed pump LL Tank (pressureless)

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Downstroking of the LS pump is performed under the following conditions:

• a control unit is set to the neutral position. No volume flow is required.

• an additional control unit is set to the fine control range. A smaller volume flow is required.

• in parallel operation, a control unit is actuated to the neutral position or to the fine control range. A smaller volume flow is required.

The pump must perform a downstroke whenever a smaller volume flow is needed. This will always happen when the pressure on the right face end of the volume flow controller (8) is higher than on the left face (in the spring space). In this case, the volume flow controller (8) is moved to the left against the compression spring (21), opening the control edge (25). This results in a rising pressure on the top face of the control ram (14) that sets the swash plate (17) to a more vertical position against the control spring (15) – the volume flow is reduced.

When the spool cross-section is reduced (fine control range), the load pressure at the input (7) drops. This changes the force ratio at the volume flow controller (8) so that the volume flow controller is actuated to the left against the spring, according to the pressure drop. The control edge (25) is opened, thus pressurizing the control ram (14). The swash plate (17) is set to a more horizontal position and the pump performs a downstroke until the volume flow requirement is met. A pump downstroke is triggered not only by the change of load pressure (signal).

An example: When operating two control units in parallel, the load pressure values are 140 bar and 100 bar. The pump pressure adjusts to a load pressure of 140 bar + spring pressure (spring 21). Both the volume flow controller (8) and the swash plate (17) are in a constant position. The pump delivers the volume flow required for both consumers. When the second control unit (load pressure 100 bar) is now set to the neutral position, the volume flow must decrease since only the first hydraulic circuit needs to be supplied. This is achieved by disconnecting a hydraulic circuit, leading to a shorttime increase of the pump pressure. The volume flow controller (8) is now actuated to the left, the control edge (25) opens and the pressure on the top face of the control ram rises. The swash plate (17) is set to a more horizontal position, thus reducing the volume flow.

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1.6 Maximum pressure limitation (pressure relief valve function)

2 Working hydraulics pump (LS pump) 6 Compensating valve 7 Input (load pressure from signal network) 8 Volume flow controller 9 Pressure controller 14 Control ram 15 Control spring 17 Swash plate 20 Pump output (in the bottom plate of the control devices) 21 Compression spring (margin pressure) 23 Adjusting screw 24 Compression spring 26 Control edge

AA Oil supply BB Pressure-reduced oil DD Control oil EE Feed oil from the feed pump LL Tank (pressureless)

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The pressure in the tractor’s hydraulic system is limited e.g. to 200 bar in

order to prevent component damage. This function is ensured by pressure controller (9).

During normal operation (working pressure < max. pressure), the pressure controller (9) is pushed to the right up to the stop by compression spring (24).

When e.g. a control unit is actuated and the cylinder reaches its limit position, the load pressure at input (7) rises until it is equal to the pressure at the pump output (20).

Under such pressure conditions:

• the volume flow controller (8) is pushed to the right up to the stop by compression spring (21).

• the pressure controller (9) is pushed to the left up to the stop against compression spring (24). This movement occurs at a pressure of e.g. 200 bar. The control edge (26) is now opened, enabling the pump pressure to act upon the top face of the control ram (14). The swash plate (17) is now actuated against the control spring (15) to its end position “Min. delivery”.

The LS pump now delivers the lowest volume flow against the maximum pressure. The hydraulic system remains at the max. pressure level as long as the additional control unit is set to the neutral position.

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1.7 Connecting the self-loading forage wagon (hydraulic supply)

1.7.1 Hydraulic supply via the power beyond port

Item Designation Remark

A Power beyond port On the tractor. Directs the volume flow from the pump directly

to the forage wagon. B Coupler socket On the tractor. Is not used. C Additional control unit (e) On the tractor. Is not used. D LS signal line Directs the load pressure from a port on the forage wagon to

the LS pump. E LS signal port On the tractor. The signal line (load pressure) of the forage

wagon is connected here. F Shuttle valve Is pressed down by the signal pressure. The signal pressure

is directed to the pump via the signal line (D). G Pressureless return line On the tractor. Directs the returning oil flow to the tractor.

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1.7.2 Hydraulic supply via the power beyond port

The connection points between forage wagon and tractor are:

Pressureless return line (G) = oil return from forage wagon to tractor Coupler socket (B) = oil supply via additional control unit

Item Designation Remark

A Power beyond port On the tractor. Is not used (closed). B Coupler socket On the tractor. Directs the volume flow from the LS pump to

the forage wagon (via the additional control unit).

C Additional control unit On the tractor. Controls the volume flow from the pump via the

coupler socket (B) to the forage wagon. In the neutral position, the LS signal line (D) is connected to the tank = no pressure build-up is possible.

In working position:

• the volume flow from the pump is directed to the forage wagon

• the load pressure of a consumer on the forage wagon is directed into the LS pump via the LS signal line (D).

D LS signal line Directs the load pressure from a port on the forage wagon to

the LS pump. E LS signal port On the tractor. Is not used. F Shuttle valve Is pressed up by the signal pressure. The signal pressure is

directed to the pump via the signal line (D). G Pressureless return line On the tractor. Directs the returning oil flow to the tractor.

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2.0 QUANTUM 3500K / 3800K / 3500P / 3500S

2.0.1 Prior to operation As the various tractor types are equipped with different hydraulic

Important:

QUANTUM 3500S only

systems, it is imperative to observe the Operator’s Manual of the tractor. This is the only way to avoid damage to the hydraulic system of the tractor.

• Absolutely avoid any overheating of the tractor hydraulic system.

• Do not disregard any warning signals possibly appearing on the

tractor.

• The forage wagon hydraulic system must be adapted to the tracto hydraulic system.

This is done using shut-off tap 27. In its ex-works delivery condition, the forage wagon hydraulic system is set to suit tractors with an open hydraulic system (standard system).

2.0.1 Fixed displacement pump

Tractors with fixed displacement pump = open hydraulic system (standard

system on forage wagons).

The shut-off tap (1) is set counterclockwise to the left-hand limit stop = Free circulation of oil.

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2.0.3 Constant-pressure

pump

2.0.4 Power beyond port Adjust shut-off tap (1) clockwise to the right limit stop = Oil flow stopped.

Tractors with constant-pressure pump = closed hydraulic system

(e.g. John Deere 50/55 series): Adjust shut-off tap (1) clockwise to the right limit stop = Oil flow stopped.

Observe the tractor manufacturer’s connection instructions.

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2.1 3500K, 2500K, 3800K

2.1.1 Circuit Diagram 1 2/2 way raise/lower pick-up directional solenoid valve

7 Pump with pressure relief valve

Swing up the knife frame

- Press the key

2 2/2 way raise/lower articulated drawbar directional solenoid valve 3 2/2 way raise/lower knife frame directional solenoid valve 4 2/2 way dry crop top type P directional solenoid valve 5 2/2 way raise/lower tailgate directional solenoid valve

T Tractor

8 4/3-way valve 9 3/3-way valve

10 Hydraulic motor 100 cm³ 12 One-way restrictor valve 13 Oil pressure switch 30 bar (knife frame up), not on 2500 K 14 Dry crop cylinder 15 Articulated drawbar cylinder 16 Hydraulically pilot-controlled non-return valve (lock-up valve unit) 17 Accumulator 40 bar (second accumulator added on serial no.) 19 Tailgate cylinder 20 Knife frame cylinder 21 Raise / lower pick-up cylinder

The cylinders (20) are actuated in order to swing up the cutting frame.

In this process a pressure is built up that is detected by oil pressure switch (13). When the pressure rises above 30 bar, the oil pressure switch is actuated and directs the signal to the CCT (CLAAS Control Terminal). The signal from the oil pressure switch overrides the reed switch signal so the knife frame can completely swing up. Otherwise the knife frame would only swing up to the reed switch position.

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3500 K, 2500 K, 3800 K

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2.1.2 One-way restrictor valve

One-way restrictor valves are hydraulic components for controlling

consumer speeds.

Speeds can be influenced only by modifying the volume flow:

• a low volume flow results in low speed,

• a high volume flow results in high speed.

Item Designation Remark

1 Valve Designed as a hexagon, the hexagon areas allow the free circulation

and the hexagon points guide the valve in the bore. 2 Restrictor Designed as a notch in the valve seat. A Port When the volume flow enters via port (A), the valve (1) is forced open

and a high volume flow passes unrestrictedly over the hexagon areas of

valve (1) to port (B). B Port When the volume flow enters via port (B), the valve (1) is pressed onto

the seat so that only a low volume flow passes over the restrictor (2) to

port (A).

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2.2 3500P, 2500P, 3800P

2.2.1 Circuit Diagram 1 2/2 way raise/lower pick-up directional solenoid valve

7 Pump with pressure relief valve

Swing up the knife frame

- Press the key

T Tractor

8 4/3-way valve 9 3/3-way valve

The cylinders (20) are actuated in order to swing up the cutting frame.

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3500 K, 2500 K, 3800 P

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2.2.2 One-way restrictor valve

One-way restrictor valves are hydraulic components for controlling

consumer speeds.

Speeds can be influenced only by modifying the volume flow: a low volume flow results in low speed a high volume flow results in high speed.

Item Designation Remark

1 Valve Designed as a hexagon, the hexagon areas allow the free circulation

and the hexagon points guide the valve in the bore. 2 Restrictor Designed as a notch in the valve seat. A Port When the volume flow enters via port (A), the valve (1) is forced open

and a high volume flow passes unrestrictedly over the hexagon areas of

valve (1) to port (B). B Port When the volume flow enters via port (B), the valve (1) is pressed onto

the seat so that only a low volume flow passes over the restrictor (2) to

port (A).

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2.3 3500S

2.3.1 Circuit Diagram 1 2/2 way raise/lower pick-up directional solenoid valve

7 Pump with pressure relief valve

Swing up the knife frame

- Press the key

2 2/2 way raise/lower articulated drawbar directional solenoid valve 3 2/2 way raise/lower knife frame directional solenoid valve 4 2/2 way dry crop top type P directional solenoid valve 5

T Tractor

8 4/3-way valve 9 3/3-way valve

10 Hydraulic motor 100 cm³ 12 One-way restrictor valve 13 Oil pressure switch 30 bar (knife frame up), not on 2500 K 14 Dry crop cylinder 15 Articulated drawbar cylinder 16 Hydraulically pilot-controlled non-return valve (lock-up valve unit) 17 Accumulator 40 bar 18 Shredder drums On coupler cylinder = Pressure/Off S-type 19 Tailgate cylinder 20 Knife frame cylinder 21 Raise / lower pick-up cylinder 22 24 Lubricating pump option 26 Flow control valve 27 Shut-off tap (John-Deere screw = constant P or LS system)

The cylinders (20) are actuated in order to swing up the cutting frame.

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3500 S

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2.3.2 One-way restrictor valve

One-way restrictor valves are hydraulic components for controlling

consumer speeds.

Speeds can be influenced only by modifying the volume flow:

• a low volume flow results in low speed

• a high volume flow results in high speed.

Item Designation Remark

1 Valve Designed as a hexagon, the hexagon areas allow the free circulation

and the hexagon points guide the valve in the bore. 2 Restrictor Designed as a notch in the valve seat. A Port When the volume flow enters via port (A), the valve (1) is forced open

and a high volume flow passes unrestrictedly over the hexagon areas of

valve (1) to port (B). B Port When the volume flow enters via port (B), the valve (1) is pressed onto

the seat so that only a low volume flow passes over the restrictor (2) to

port (A).

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2.3.3 Flow control valve with shut-off tap (only on 3500S)

1 Emergency operation 3 Control block 26 Flow control valve 27 Shut-off tap (system screw = constant pressure or LS system). Close tap

on constant pressure or LS hydraulic systems.

The flow control valve (26) controls the rotational speed of the hydraulic

floor conveyor motor. The solenoid coil of the flow control valve (26) is controlled via a potentiometer in the CCT. According to the potentiometer position, a constant volume flow to the hydraulic motor is defined. A constant volume flow generates a constant speed of the hydraulic motor. The adjusting plate (1) is fastened in the bore (E) with pin (S).

Emergency operation If the electric system fails, the forage wagon functions may be operated

using the flow control valve (2) and the control block (3). Turn the screw (1) on the flow control valve (26) in until it is flush. Set the double-acting control valve for the floor conveyor on the tractor under pressure.

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2.3.4 Shut-off tap Tractors with fixed displacement pump or LS pump without control line =

open hydraulic system (standard system): The shut-off tap (1) is adjusted counterclockwise to the left limit stop (exworks setting) = Free circulation of oil.

1 Shut-off tap 26 Flow control valve (QUANTUM 3500S only)

Important: In the two following systems, the pressure relief valve of the forage

wagon must be set higher than the pressure relief valve of the tractor:

• Tractor with constant-pressure pump = closed hydraulic system. Adjust shut-off tap (1) clockwise to the right limit stop = Oil circulation blocked. To this end, slacken off screws (2), turn shut-off tap (1) to the right and fasten screws again.

• Tractor with LS pump and directional control valve port: Adjust shut-off tap clockwise to the right limit stop = Oil flow stopped. To this end, slacken off screws (2), turn shut-off tap (1) to the right and fasten screws again.

11-34 10/04

Claas QUANTUM 3500, QUANTUM 6800 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapters

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3500 P, 3800 K, 3800 P

1.1 QUANTUM 3500 K, 3500 P, 3500 S, 3800 K, 3800 P, 2500 K, 2500 P

1.2 QUANTUM 5500 S-18, 5500 S-16, 5500 S, 4500 S, 6800 S

1.3 QUANTUM 6800 P, 6500 P, 5500 P-18, 5500 GT, 5500 P, 4500 P

TIC QUANTUM Operation

1.0 QUANTUM 2500 K, 2500 P, 3500 K, 3800 K, 3800 P, 3500 S

1.1 Control box short instructions

1.2 Operation

2.0 QUANTUM 4500 S / 5500 S / S-16 / S-18 / 6800 S

2.1 Control box short instructions

2.2 Operation

3.0 QUANTUM 4500 P / 5500 P / 5500 P-16 / 5500 P-18 / 5500 GT / 6800 P

3.1 Control box short instructions

3.2 Operation

TIC QUANTUM Brakes

1.0 Compressed air circuit diagrams

1.1 QUANTUM 5500P/S-16 40 km/h, 16 to, (steering axle)

1.2 QUANTUM 2500K/P, 3500P/S/K, 3800K/P, 4500S/P 40 km/h (steering axle)

1.3 5500P/S 40km/h, 13 to, (steering axle)

1.4 5500P-18/S –18, 60 km/h

1.5 5500P/S 80 km/h (ABS)

1.6 Compressed air system with level regulating valve

1.7 5500 P/S 50/60 km/h

1.8 5500 S, 40/60 km/h

2.0 Adjustments

2.1 Diaphragm cylinder

2.2 Adjusting the rod adjuster

2.3 Brake-power regulator (ALD)

2.4 Air suspension

TIC QUANTUM Hydraulics

1.0 LS pump

1.2 Low pressure standby

1.3 A control device is actuated = start of LS pump delivery

1.4 Constant volume flow

1.5 Downstroking

1.6 Maximum pressure limitation (pressure relief valve function)

1.7 Connecting the self-loading forage wagon (hydraulic supply)

2.0 QUANTUM 3500K / 3800K / 3500P / 3500S

2.1 3500K, 2500K, 3800K

2.2 3500P, 2500P, 3800P

2.3 3500S