Amazone Catros 4003-2TS Installation instructions

Original operating manual
Trailed compact disc harrow
CatrosXL 4003-2TS
CatrosXL 5003-2TS
CatrosXL 6003-2TS
SmartLearning
www.amazone.de

Please enter the identication data of the implement. The identication data can be found on
the rating plate.

TABLE OF CONTENTS
1 About this operating manual 1
1.1 Diagrams 1
1.1.1 Warnings and signal words 1
1.1.2 Further instructions 1
1.1.3 Instructions 2
1.1.4 Lists 3
1.1.5 Item numbers in figures 3
1.2 Other applicable documents 4
1.3 Your opinion is important 4
2Safety and responsibility 5
2.1 Basic safety instructions 5
2.1.1 Meaning of the operating manual 5
2.1.2 Safe operating organisation 5
2.1.3 Knowing and preventing dangers 10
2.1.4 Safe operation and handling of the
machine 12
2.1.5 Safe maintenance and modification 15
2.2 Safety routines 19
3Intended use 22
4 Product description 23
4.1 Implement overview 23
4.1.1 Implement with leading tools 23
4.1.2 Implement with support wheels 24
4.1.3 Implement with GreenDrill 25
4.2 Special equipment 25
4.3 Protective equipment 26
4.3.1 Road safety bars 26
4.3.2 Stop tap 27
4.3.3 Brake valve for hydraulic brake
system 27
4.3.4 Brake valve for pneumatic brake
system 27
4.3.5 Parking brake 28
4.3.6 Wheel chocks 28
4.3.7 Safety chain 28
4.4 Lighting and identification for
road travel 29
4.5 Warning symbols 30
4.5.1 Positions of the warning symbols 30
4.5.2 Layout of the warning symbols 32
4.5.3 Description of the warning symbols 32
4.6 Rating plates and CE marks 34
4.6.1 Rating plate on the implement 34
4.6.2 Rating plate on the running gear 34
4.7 Other information on the
implement 35
4.7.1 Information about the stop tap on
the hydraulic drawbar 35
4.8 Threaded cartridge 35
5Technical data 36
5.1 Dimensions 36
5.2 Soil tillage tool 36
5.3 Permitted mounting categories 36
5.4 Optimal working speed 37
5.5 Performance characteristics of
the tractor 37
5.6 Noise development data 37
5.7 Drivable slope inclination 38
6Preparing the machine 39
6.1 Checking the tractor suitability 39
6.1.1 Calculating the required tractor
characteristics 39
6.1.2 Determining the required coupling
devices 42
6.1.3 Comparing the permissible DC
value with actual DC value 43
6.2 Calculating the permissible
payload 43
6.3 Coupling the implement 44
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6.3.1 Removing the safety device against
unauthorised use 44
6.3.2 Coupling the brake system 44
6.3.3 Coupling the hydraulic hose lines 45
6.3.4 Coupling the power supply 48
6.3.5 Coupling the power supply for the
central lubrication 48
6.3.6 Coupling on the lower link hitch 49
6.3.7 Coupling the ball coupling or
drawbar eye 50
6.3.8 Routing the pull rope in the driver's
cab 51
6.3.9 Fastening the safety chain 51
6.3.10 Removing the wheel chocks 52
6.3.11 Releasing the parking brake 52
6.4 Preparing the implement for
operation 52
6.4.1 Unfolding the sections 52
6.4.2 Filling the hopper on the GreenDrill 53
6.4.3 Installing ballast weights 53
6.4.4 Adjusting the scraper to the roller 54
6.4.5 Adjusting the central lubrication 55
6.5 Preparing the machine for road
travel 56
6.5.1 Swivelling down the running gear 56
6.5.2 Securing the cutting roller 57
6.5.3 Putting on the road safety bars 57
6.5.4 Folding the sections 57
6.5.5 Aligning the implement horizontally 58
6.5.6 Locking the tractor control units 58
7Using the machine 59
7.1 Unfolding the sections 59
7.2 Swivelling up the running gear 59
7.3 Removing the road safety bars 60
7.4 Adjusting the working depth 60
7.4.1 Adjusting the working depth of the
discs 60
7.4.2 Adjusting the working depth of the
crushboard 62
7.4.3 Adjusting the working depth of the
straw harrow 63
7.4.4 Adjust the working depth of the side
guide plates 64
7.5 Adjusting the trailing elements 65
7.6 Aligning the implement
horizontally 66
7.6.1 Aligning the implement horizontally
with the support wheels 66
7.6.2 Aligning the implement horizontally
with lower link hitch 66
7.6.3 Aligning the implement horizontally
with hydraulic drawbar 67
7.7 Lowering the cutting roller 67
7.8 Switching on the vibration
compensation 68
7.9 Turning on the headlands 69
8 Eliminating faults 70
9Parking the machine 73
9.1 Applying the parking brake 73
9.2 Placing the wheel chocks 73
9.3 Uncoupling the lower link hitch 74
9.3.1 Swivelling down the jack 74
9.3.2 Uncoupling the tractor's lower link 74
9.4 Uncoupling the ball coupling or
drawbar eye 75
9.4.1 Swivelling down the jack 75
9.4.2 Uncoupling the drawbar eye 75
9.4.3 Uncoupling the ball coupling 76
9.5 Uncoupling the power supply 76
9.6 Disconnecting the hydraulic
hose lines 77
9.7 Uncoupling the brake system 77
9.7.1 Uncoupling the pneumatic brake
system 77
9.7.2 Uncoupling the hydraulic brake
system 78
9.8 Releasing the safety chain 78
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9.9 Putting on the safety device
against unauthorised use 79
10 Repairing the machine 80
10.1 Maintaining the machine 80
10.1.1 Maintenance schedule 80
10.1.2 Replacing the discs 81
10.1.3 Checking the disc carrier connection 82
10.1.4 Aligning the disc gangs relative to
each other 82
10.1.5 Checking the rollers 83
10.1.6 Checking the lower link pins 83
10.1.7 Checking the hydraulic hose lines 84
10.1.8 Checking the hub bearing 85
10.1.9 Checking the brake pads 86
10.1.10 Checking the pneumatic brake
system 86
10.1.11 Draining the compressed air tank 87
10.1.12 Checking the compressed air tank 87
10.1.13 Cleaning the compressed air line filter 88
10.1.14 Checking the axle bolts 89
10.1.15 Checking the tyre inflation pressure 89
10.1.16 Checking the lower link hitch 89
10.1.17 Checking the ball coupling 90
10.1.18 Checking the drawbar eye 91
10.1.19 Checking the central lubrication 92
10.2 Cleaning the machine 92
10.3 Lubricating the implement 94
10.3.1 Overview of lubrication points 95
10.3.2 Lubricating the wheel hubs 97
11 Transporting the machine 98
11.1 Loading the machine 98
11.1.1 Loading the implement with a crane 98
11.2 Manoeuvring the implement 100
12 Appendix 101
12.1 Bolt tightening torques 101
12.2 Other applicable documents 102
13 Directories 103
13.1 Glossary 103
13.2 Index 104
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About this operating manual 1
1.1 Diagrams
1.1.1 Warnings and signal words
Warnings are marked with a vertical bar with a
triangular safety symbol and the signal word. The
signal words "DANGER", "WARNING" or "CAUTION"
describe the severity of the potential danger and have
the following meanings:
DANGER
Indicates a direct threat with high risk for
severe physical injury, such as loss of
limbs or death.
WARNING
Indicates a possible threat with moderate
risk for severe physical injury or death.
CAUTION
Indicates a threat with low risk for light or
moderately severe physical injuries.
1.1.2 Further instructions
IMPORTANT
Indicates a risk for damage to the
implement.
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ENVIRONMENTAL INFORMATION
Indicates a risk for environmental
damage.
NOTE
Indicates application tips and instructions for
optimal use.
1.1.3 Instructions
Numbered instructions
Actions that have to be performed in a specific
sequence are represented as numbered instructions.
The specified sequence of the actions must be
observed.
Example:
1. Instruction 1
2. Instruction 2
1.1.3.1 Instructions and responses
Reactions to instructions are marked with an arrow.
Example:
1. Instruction 1
Reaction to instruction 1
2. Instruction 2
1.1.3.2 Alternative instructions
Alternative instructions are introduced with the word
"or".
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Example:
1. Instruction 1
or
Alternative instruction
2. Instruction 2
Instructions with only one action
Instructions with only one action are not numbered,
but rather shown with a arrow.
Example:
Instruction
Instructions without sequence
Instructions that do not require a specific sequence
are shown as a list with arrows.
Example:
Instruction
Instruction
Instruction
1.1.4 Lists
Lists without an essential order are shown as a list
with bullets.
Example:
Point 1
Point 2
1.1.5 Item numbers in figures
A framed number in the text, e.g. a
1
, indicates an
item number in an adjacent figure.
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Diagrams
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1.2 Other applicable documents
A list of other applicable documents can be found in
the Appendix.
1.3 Your opinion is important
Dear reader, our operating manuals are updated
regularly. Your suggestions for improvement help us
to create ever more user-friendly operating manuals.
Please send us your suggestions by post, fax or
email.
Fax: [phone]
Postfach 51
AMAZONEN-WERKE H. Dreyer SE & Co. KG
Technische Redaktion
D-49202 Hasbergen
E-Mail: [email protected]
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Safety and responsibility 2
2.1 Basic safety instructions
2.1.1 Meaning of the operating manual
Observe the operating manual
The operating manual is an important document
and a part of the implement. It is intended for
the user and contains safety-related information.
Only the instructions provided in the operating
manual are reliable. If the operating manual is not
observed, it can result in serious injury or death.
The safety section must be completely read
and observed before initial operation of the
implement.
Before starting work, also read and observe
each section of the operating manual.
Keep the operating manual in a safe place.
Keep the operating manual available.
Hand over the operating manual to the
subsequent user.
2.1.2 Safe operating organisation
2.1.2.1 Personnel qualification
2.1.2.1.1 Requirements for all persons working with the machine
If the machine is used improperly, people can
be injured or killed. To prevent accidents due
to improper use, every person who works with
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the machine must meet the following minimum
requirements:
The person is physically and mentally capable of
controlling the machine.
The person can safely perform work with the
machine within the scope of this operating
manual.
The person understands the functioning of the
machine within the scope of their work and can
recognise and prevent dangers arising during
operation.
The person head understood the operating
manual and can implement the information that is
conveyed in the operating manual.
The person must be familiar with safe driving of
vehicles.
For road travel, the person knows the relevant
road traffic regulations and has the prescribed
driving permit.
2.1.2.1.2 Qualification levels
For working with the machine, the following
qualification levels are provided:
Farmer
Agricultural helper
As a matter of principle, the activities described in this
operating manual can be performed by persons with
the qualification level "Agricultural helper".
2.1.2.1.3 Farmer
Farmers use agricultural implement to cultivate fields.
They decide on the use of an implement for a specific
purpose.
Farmers are basically familiar with working with
agricultural implements and can instruct agricultural
helpers in how to use the implements if necessary.
They can perform odd tasks and simple maintenance
and repair work on agricultural implements
themselves.
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Farmers can be e.g.:
Farmers with higher education or training from a
technical college
Farmers by experience (e.g. inherited farm,
comprehensive practical knowledge)
Contractors who work by order of farmers
Activity example:
Safety training for agricultural helpers
2.1.2.1.4 Agricultural helpers
Agricultural helpers use agricultural implements by
order of the farmer. They are instructed on the use of
the implement by the farmer, and work independently
according to the work assignment from the farmer.
Agricultural helpers can be e.g.:
Seasonal workers and labourers
Prospective farmers in training
Employees of the farmer (e.g. tractor driver)
Family members of the farmer
Activity examples:
Driving the machine
Adjusting the working depth
2.1.2.2 Workplaces and passengers
Passengers
Passengers can fall, be run over and severely
injured or killed due to machine movements.
Ejected objects can hit and injure passengers.
Do not let anybody ride on the machine.
Do not let anybody climb onto the driving
machine.
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2.1.2.3 Danger for children
Danger for children
Children cannot assess dangerous situations and
can behave unpredictably. As a result, children
are at a higher risk.
Keep children away.
When you drive out or actuate machine
movements,
make sure that there are no children in the
danger area.
2.1.2.4 Operational safety
2.1.2.4.1 Perfect technical condition
Only use properly prepared machines
Without correct preparation according to this
operating manual, operational safety of the
machine is not ensured. This can result in
accidents and serious personal injury or even
death.
Prepare the machine according to this
operating manual.
Danger due to damage to the machine
Damage to the machine can impede the
operational safety of the machine and cause
accidents. This can result in serious injury or
death.
If you suspect or observe damage,
secure the tractor and implement.
Immediately fix any damage that can affect
safety.
Fix the damage according to this operating
manual.
Any damage that you cannot fix yourself
according to this operating manual must be
fixed by a qualified specialist workshop.
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Observe the technical limit values
Non-observance of the technical limits values of
the machine can result in accidents and serious
personal injury or even death. Moreover, the
machine can be damaged. The technical limit
values can be found in the Technical Data.
Comply with the technical limit values.
2.1.2.4.2 Personal protective equipment
Personal protective equipment
Wearing personal protective equipment is an
important safety element. Missing or unsuitable
personal protective equipment increases the risk
of damage to health and personal injury. Personal
protective equipment includes: work gloves,
safety shoes, protective clothing, breathing
protection, hearing protection, face protection,
and eye protection
Determine the personal protective equipment
required for each job and have it ready.
Use only protective equipment that is
in proper condition and offers effective
protection.
Adjust the personal protective equipment to
the person, e.g. the size.
Observe the manufacturer's instructions
regarding operating materials, seed, fertiliser,
crop protection products, and cleaning
agents.
Wear suitable clothing
Loosely worn clothing increases the risk of
getting caught or entangled on rotating parts and
getting stuck on protruding parts. This can result
in serious injury or death.
Wear close-fitting, snag-free clothes.
Never wear rings, necklaces and other
jewellery.
If you have long hair,
wear a hairnet.
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2.1.2.4.3 Warning symbols
Keep warning symbols legible
Warning symbols on the machine warn you of
risks in danger areas and are an important
element of the machine's safety equipment.
Missing warning symbols increase the risk of
serious and lethal personal injury.
Clean dirty warning symbols.
Immediately replace any damaged and
illegible warning symbols.
Put the intended warning symbols on spare
parts.
2.1.3 Knowing and preventing dangers
2.1.3.1 Safety hazards on the machine
Liquids under pressure
Escaping high pressure hydraulic fluid can
penetrate into the body through the skin and
cause serious personal injuries. A hole the size
of a needle can already result in serious personal
injuries.
Before you uncouple the hydraulic hose lines
or check for damage,
depressurise the hydraulic system.
If you suspect damage on a pressure system,
have the pressure system checked by a
qualified specialist workshop.
Never look for leaks with your bare hands.
Keep your body and face away from leaks.
If liquids penetrate the body,
consult a doctor immediately.
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2.1.3.2 Danger areas
Dangers areas on the machine
The following basic dangers are encountered in
the danger areas:
The implement and its work tools move during
operation.
Hydraulically raised machine parts can descend
unnoticed and slowly.
The tractor and implement can roll away
unintentionally.
Materials or foreign objects can be ejected out of
or away from the implement.
If the danger area is not observed, it can result in
serious personal injury or death.
Keep people out of the danger area of the
machine.
If people enter the danger area,
immediately switch off the engines and
drives.
Before you work in the danger area of the
implement,
secure the tractor and implement. This also
applies for quick checking work.
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2.1.4 Safe operation and handling of the machine
2.1.4.1 Coupling implements
Coupling the implement on the tractor
Incorrectly coupling of the implement to the
tractor results in hazards that can cause serious
accidents.
There are crushing and shear points in the area
of the coupling points between the tractor and the
implement.
If you couple or uncouple the implement to
or from the tractor,
be very careful.
Use only suitable tractors for coupling and
transporting the implement.
When the implement is coupled onto the
tractor,
make sure that the tractor's connecting
device meets the implement requirements.
Couple the implement properly to the tractor.
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2.1.4.2 Driving safety
Risk when driving on roads and fields
Any mounted or towed implement as well as front
or rear ballast weights on the tractor influence the
driving behaviour and the steering and braking
power of the tractor. The driving characteristics
also depend on the operating condition, the fill
level of the load, and on the ground. If the
driver does not take account of changing driving
characteristics, he can cause accidents.
Always ensure that the tractor's steering and
braking systems are operating correctly.
The tractor must provide the required brake
lag for the tractor and mounted implement.
Check the function of the brakes before
moving off.
The tractor front axle must always be
loaded with at least 20 % of the empty
tractor weight to ensure  steering
power.
Use front ballast weights if necessary.
Always attach the front or rear ballast weights
properly on the specified fixing points.
Calculate and observe the payload of the
mounted or towed implement.
Observe the permissible axle loads and
drawbar loads of the tractor.
Observe the permissible drawbar load of the
hitch device and drawbar.
Drive in such a way that you always have
full control over the tractor with the mounted
or towed implement. In so doing, take your
personal abilities into account, as well as the
road, traffic, visibility and weather conditions,
the driving characteristics of the tractor, and
the influence of the mounted implement.
When driving on roads, risk of accident
caused by uncontrolled lateral motions of the
implement
Lock the tractor lower links for road travel.
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Preparing the machine for road travel
If the machine is not properly prepared for road
travel, it can result in serious traffic accidents.
Check the lighting and identification for road
travel for proper function.
Remove coarse dirt from the implement.
Follow the instructions in the section
"Preparing the implement for road travel".
Parking the implement
The parked machine can tip over. People can be
crushed and killed.
Only park the machine on stable and even
ground.
Before you perform setting or maintenance
work,
make sure that the implement is in a stable
position. In case of doubt, support the
implement.
Follow the instructions in the section "Parking
the implement".
Unsupervised parking
Parked tractors with coupled implements that are
insufficiently secured and unsupervised represent
danger for people and playing children.
Before you leave the machine,
shutdown the tractor and the implement.
Secure the tractor and machine.
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