Amazone CatrosXL 4003-2TS Installation instructions

Original operating manual
Trailed compact disk 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 Presentations used 1
1.1.1 Warnings and signal words 1
1.1.2 Additional instructions 1
1.1.3 Instructions 2
1.1.4 Listings 3
1.1.5 Item numbers in illustrations 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 organization 5
2.1.3 Recognizing and avoiding dangers 10
2.1.4 Safe operation and handling of the
implement 11
2.1.5 Safe maintenance and modification 13
2.2 Safety routines 17
3Intended use 19
4 Product description 20
4.1 Implement overview 20
4.1.1 Implement with leading tool 20
4.1.2 Implement with support wheels 21
4.1.3 Implement with GreenDrill 22
4.2 Special equipment 22
4.3 Protective devices 23
4.3.1 Road safety bars 23
4.3.2 Brake valve for hydraulic brake
system 23
4.3.3 Brake valve for pneumatic brake
system 24
4.3.4 Parking brake 24
4.3.5 Wheel chocks 24
4.3.6 Safety chain 25
4.4 Lighting and identification for
road travel 25
4.4.1 Rear lighting and identification 25
4.4.2 Front identification 25
4.5 Warning symbols 26
4.5.1 Positions of the warning symbols 26
4.5.2 Structure of the warning symbols 27
4.5.3 Description of the warning symbols 28
4.6 Rating plates and CE marks 33
4.6.1 Rating plate on the implement 33
4.6.2 Additional rating plate 34
4.7 More information concerning the
implement 34
4.7.1 Information concerning the stop tap
on the hydraulic drawbar 34
4.8 GewindePack 34
5Technical data 35
5.1 Dimensions 35
5.2 Soil tillage tool 35
5.3 Permissible mounting categories 35
5.4 Optimal working speed 36
5.5 Capacity characteristics of the
tractor 36
5.6 Noise emission data 36
5.7 Drivable slope inclination 37
6Preparing the implement 38
6.1 Checking tractor suitability 38
6.1.1 Calculating the required tractor
characteristics 38
6.1.2 Determining the required coupling
devices 41
6.1.3 Comparing the permissible DC
value with the actual DC value 42
6.2 Calculating the permissible
payload 42
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6.3 Coupling the implement 43
6.3.1 Remove safeguard against
unauthorized use 43
6.3.2 Connecting the brake system 43
6.3.3 Coupling hydraulic hose lines 44
6.3.4 Coupling the power supply 47
6.3.5 Connecting the power supply for the
central lubrication 47
6.3.6 Disconnecting the lower link hitch 48
6.3.7 Connecting the ball hitch coupling
or drawbar eye 49
6.3.8 Fastening the safety chain 50
6.3.9 Removing wheel chocks 50
6.3.10 Releasing the parking brake 51
6.4 Preparing the implement for
operation 51
6.4.1 Unfolding sections 51
6.4.2 Mounting ballast weights 51
6.4.3 Adjusting the scraper to the roller 52
6.4.4 Adjusting central lubrication 53
6.4.5 Filling the GreenDrill hopper 53
6.5 Preparing the implement for road
travel 55
6.5.1 Lifting the implement 55
6.5.2 Securing the cutter roller 55
6.5.3 Attaching the road safety bars 55
6.5.4 Folding sections 56
6.5.5 Aligning implement 56
6.5.6 Locking tractor control units 57
7Using the implement 58
7.1 Unfolding sections 58
7.2 Removing the road safety bars 58
7.3 Adjusting the working depth 59
7.3.1 Adjusting the working depth of disks 59
7.3.2 Hydraulically adjusting the working
depth of the crushboard 61
7.3.3 Adjusting the working depth of the
straw harrow 61
7.3.4 Adjusting the working depth of the
side guide plates 62
7.4 Adjusting the trailing elements 63
7.5 Swinging up the running gear 64
7.6 Aligning the implement
horizontally 64
7.6.1 Aligning the implement horizontally
with support wheels 64
7.6.2 Aligning the implement horizontally
with lower link hitch 65
7.6.3 Aligning the implement horizontally
with hydraulic drawbar 65
7.7 Using the cutter roller 66
7.8 Switching on vibration
compensation 66
7.9 Driving on headlands 67
7.9.1 Turning on the roller in headlands 67
7.9.2 turning on the running gear on the
headlands 68
8 Rectifying faults 69
9Parking the implement 72
9.1 Applying the parking brake 72
9.2 Placing the wheel chocks 72
9.3 Uncoupling the lower link hitch 73
9.3.1 Swinging down the jack 73
9.3.2 Disconnecting the tractor's lower links 73
9.4 Disconnecting the ball hitch
coupling or drawbar eye 74
9.4.1 Swinging down the jack 74
9.4.2 Uncoupling the drawbar eye 74
9.4.3 Uncoupling the ball hitch coupling 75
9.5 Uncoupling the power supply 75
9.6 Uncoupling the hydraulic hose
lines 76
9.7 Disconnecting the brake system 76
9.7.1 Disconnecting the pneumatic brake
system 76
9.7.2 Disconnecting the hydraulic brake
system 77
9.8 Detaching the safety chain 77
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9.9 Attaching safeguard against
unauthorized use 78
10 Maintaining the implement 79
10.1 Maintaining the implement 79
10.1.1 Maintenance schedule 79
10.1.2 Replacing the disks 80
10.1.3 Checking the disk carrier connection 81
10.1.4 Aligning the disk gangs relative to
each other 81
10.1.5 Checking the rollers 82
10.1.6 Checking lower link pins 82
10.1.7 Checking the hydraulic hose lines 83
10.1.8 Checking the wheels 83
10.1.9 Checking the hub bearing 84
10.1.10 Checking the brake pads 85
10.1.11 Checking the pneumatic brake
system 85
10.1.12 Dewatering the compressed air tank 86
10.1.13 Checking the compressed air tank 86
10.1.14 Cleaning the compressed air line filter 87
10.1.15 Checking the axle bolts 88
10.1.16 Checking the lower link hitch 88
10.1.17 Checking the ball hitch coupling 89
10.1.18 Checking the drawbar eye 89
10.1.19 Check the central lubrication system 90
10.2 Cleaning the implement 91
10.3 Lubricating the implement 92
10.3.1 Overview of lubrication points 93
10.3.2 Lubricating wheel hubs 95
11 Transporting the implement 96
11.1 Loading the implement 96
11.1.1 Loading the implement with a crane 96
11.1.2 Lashing the implement 97
11.2 Maneuvering implement with
hydraulic brake system 98
11.3 Maneuvering the implement with
pneumatic brake system 99
12 Appendix 101
12.1 Bolt tightening torques 101
12.2 Other applicable documents 103
13 Directories 104
13.1 Glossary 104
13.2 Index 105
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About this operating manual 1
1.1 Presentations used
1.1.1 Warnings and signal words
Warnings are indicated by a vertical bar with a
triangular safety symbol and a signal word. The
signal words "DANGER", "WARNING" or "CAUTION"
describe the severity of the potential danger and have
the following meanings:
DANGER
Indicates imminent danger with high risk of
severe physical injury, such as loss of limb
or death.
WARNING
Indicates a possible danger with moderate
risk of severe or fatal physical injury.
CAUTION
Indicates a danger with low risk of minor or
moderate physical injury.
1.1.2 Additional instructions
IMPORTANT
Indicates a risk of implement damage.
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ENVIRONMENTAL INFORMATION
Indicates a risk of environmental damage.
NOTE
Indicates application tips and instructions for
optimal use.
1.1.3 Instructions
Numbered instructions
Actions that must be performed in a specific
sequence are presented as numbered instructions.
The specified sequence of the actions must be
complied with.
Example:
1. Instruction 1
2. Instruction 2
1.1.3.1 Instructions and responses
Responses to instructions are indicated by an arrow.
Example:
1. Instruction 1
Response 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 are presented with an arrow.
Example:
Instruction
Instructions without a specific sequence
Instructions that do not require a specific sequence
are shown as a list with arrows.
Example:
Instruction
Instruction
Instruction
1.1.4 Listings
Listings without a mandatory sequence are shown as
a list with bullet points.
Example:
Point 1
Point 2
1.1.5 Item numbers in illustrations
A framed number in the text, e.g. a
1
, indicates an
item number in an adjacent figure.
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1.2 Other applicable documents
A list of other applicable documents is provided in the
Appendix.
1.3 Your opinion is important
Dear reader, our operating manuals are updated
regularly. Your suggestions for improvement help us
provide increasingly 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
Comply with the operating manual
The operating manual is an important document and it is part of the implement. It is intended for the user
and contains safety-related information. Only the procedures specified in the operating manual are safe.
Failure to comply with the operating manual can result in severe injury or death.
The safety section must be completely read and the instructions must be complied with before first use
of the implement.
In addition, read the relevant sections of the operating manual before starting work.
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 organization
2.1.2.1 Qualifications of personnel
2.1.2.1.1 Requirements imposed on all persons who work with the implement
If the implement 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 implement must meet the following minimum
requirements:
The person must be physically and mentally
capable of controlling the implement.
The person must be capable of safely performing
the tasks with the implement as specified in this
operating manual.
The person must understand the implement's
mode of operation as it relates to their tasks and
must be able to recognize and avoid the dangers
associated with the work.
The person must have understood the operating
manual and can implement the information that is
provided in the operating manual.
The person must know how to drive vehicles
safely.
For road travel, the person must know the
relevant road traffic regulations and must have the
prescribed driver's license.
2.1.2.1.2 Qualification levels
The following qualification levels are the
prerequisites for working with the implement:
Farmer
Agricultural helper
The activities described in this operating manual can
always be performed by persons with the qualification
level, "Agricultural helper".
2.1.2.1.3 Farmer
Farmers use agricultural machines to cultivate fields.
They decide on the use of an agricultural machine for
a specific objective.
Farmers are categorically familiar with work
involving agricultural machines and can instruct
agricultural helpers in how to use the machines, if
necessary. They can perform specific, simple repairs
and maintenance tasks on agricultural machines
themselves.
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For example, farmers can be:
Farmers with higher education or training from a
technical college
Farmers by experience (e.g. inherited farm,
extensive practical knowledge)
Contractors who work on behalf of farmers
Activity example:
Safety instruction of agricultural helpers
2.1.2.1.4 Agricultural helper
Agricultural helpers use agricultural machines on
behalf of the farmer. They are instructed in the use
of the machine by the farmer, and work independently
according to the farmer's work order.
For example, agricultural helpers can be:
Seasonal workers and laborers
Prospective farmers in training
Employees of the farmer (e.g. tractor driver)
Members of the farmer's family
Activity examples:
Driving the machine
Adjusting the working depth
2.1.2.2 Workstations and persons accompanying the driver
Persons accompanying the driver
Persons accompanying the driver can fall due to implement movements, be run over and suffer severe or
fatal injuries. Objects thrown upward by the tractor or implement can hit and injure persons accompanying
the driver.
Never allow persons to ride on the implement.
Never allow people to climb onto the moving implement.
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2.1.2.3 Danger for children
Children in danger
Children cannot assess dangerous situations and may behave unpredictably. As a result, children are
particularly at risk.
Keep children at a safe distance.
When you drive out or activate implement movements,
ensure 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 implements
Operational safety of the implement is only ensured with proper preparation as specified in this operating
manual. This can result in accidents and persons can be severely injured or killed.
Prepare the implement as specified in this operating manual.
Danger due to implement damage
Implement damage can impair the operational safety of the implement and cause accidents. This can result
in severe or fatal injuries.
If you suspect or determine that there is damage,
secure the tractor and implement.
Immediately repair damage that can affect safety.
Repair the damage as specified in this operating manual.
Any damage that you cannot repair yourself as specified in this operating manual must be repaired by a
qualified specialist workshop.
Comply with the technical limit values
Failure to comply with the technical limits values of the implement can cause accidents and serious
personal injury or death. Moreover, the implement can be damaged. The technical limit values are provided
in the Technical data.
Comply with the technical limit values.
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2.1.2.4.2 Personal protective equipment
Personal protective equipment
Wearing personal protective equipment is an important safety component. Missing or unsuitable personal
protective equipment increases the risk of health impairment or personal injury. Personal protective
equipment includes: work gloves, safety footwear, protective clothing, respiratory protection, hearing
protection, face protection, and eye protection
Determine the personal protective equipment required for each job and have it ready.
Use only personal protective equipment that is in proper condition and offers effective protection.
Adjust the personal protective equipment to the person, for example, adapt it to the size of the person.
Comply with the manufacturer's instructions regarding operating materials, seed, fertilizer, crop
protection products and cleaning agents.
Wear suitable clothing
Loosely worn clothing increases the risk of catching or entanglement on rotating parts or protruding parts.
This can result in severe or fatal injuries.
Wear tight-fitting clothing.
Never wear rings, necklaces or other jewelry.
If you have long hair,
wear a hair-net.
2.1.2.4.3 Warning symbols
Keep warning symbols legible
Warning symbols on the implement warn of hazards in danger areas and are an important component of
the implement's safety equipment. Missing warning symbols increase the risk of serious or fatal injury.
Clean dirty warning symbols.
Immediately replace any damaged or illegible warning symbols.
Affix the intended warning symbols on spare parts.
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2.1.3 Recognizing and avoiding dangers
2.1.3.1 Recognizing and avoiding dangers
Fluids under pressure
Escaping pressurized hydraulic fluid can penetrate into the body through the skin and cause serious
injuries. Even a hole the size of a needle prick can result in serious injuries.
Before uncoupling hydraulic hose lines or check for damage,
depressurize the hydraulic system.
If you suspect that a pressure system is damaged,
have the pressure system checked by a qualified specialist workshop.
Never search for leaks with your bare hand.
Keep your body and face away from leaks.
If liquids penetrate into the body,
seek medical attention immediately.
2.1.3.2 Danger areas
Danger areas on the implement
The following significant hazards are present in
the danger areas:
The implement and its work tools move in
operation.
Hydraulically lifted implement parts can lower
unnoticed and slowly.
The tractor and implement can roll unintentionally.
Materials or foreign objects can be ejected out of
or away from the implement.
Failure to comply with instructions concerning the
danger area can result in severe or fatal injury.
Keep people out of the danger area of the
implement.
If people enter the danger area,
immediately switch off motors and drives.
Before working in the danger area of the
implement,
secure the tractor and implement. This also
applies for quick inspection tasks.
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2.1.4 Safe operation and handling of the implement
2.1.4.1 Coupling the implement
Coupling the implement to the tractor
Incorrectly coupling the implement to the tractor results in hazards that can cause serious accidents.
There are crush points and shear points in the area of the coupling points between the tractor and the
implement.
If you couple the implement or uncouple the implement from the tractor,
be very careful.
Only couple and transport the implement with suitable tractors.
When the implement is coupled on the tractor,
ensure that the tractor's connecting device meets the implement requirements.
Carefully couple the implement to the tractor.
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2.1.4.2 Driving safety
Hazards when driving on roads and fields
Any implements or front/rear weights attached to the tractor influence the driving behavior and the steering
and braking capacity of the tractor. Driving characteristics also depend on the operating condition, the fill
level or load and on the substrate. If the driver does not take changed driving characteristics into account,
he can cause accidents.
Always ensure that the tractor has sufficient steering and braking capacity.
The tractor must provide the prescribed brake lag for the tractor and mounted implement.
Check the braking effect before moving off.
The tractor front axle must always be loaded with at least 20% of the empty tractor weight to
ensure  steering capacity.
If necessary, use front weights.
Always fasten the front weights or rear weights on the prescribed fastening points provided for this
purpose.
Calculate the payload and comply with the payload specifications for the mounted or towed implement.
Comply with the permissible axle loads and drawbar loads of the tractor.
Comply with the permissible drawbar load of the hitch device and drawbar.
Drive in such a manner that you always have full control of the tractor with the mounted or trailed
implement. In so doing, take your personal abilities into account, as well as the road, traffic, visibility
conditions and weather conditions as well as the driving characteristics of the tractor and the influence
of the mounted implement.
When driving on roads, there is risk of accident due to uncontrolled lateral movements of the
implement
Lock the tractor lower links in place for road travel.
Preparing the implement for road travel
If the implement is not properly prepared for road travel, it can cause serious traffic accidents.
Check the lighting and identification for road travel for proper function.
Remove coarse contaminants from the implement.
Follow the instructions in the section "Preparing the implement for road travel".
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Parking the implement
The parked implement can tip over. People can be crushed and killed.
Only park the implement on stable and level ground.
Before performing adjustment tasks or maintenance tasks,
ensure that the implement is stable. If in doubt, support the implement.
Follow the instructions in the section "Parking the implement".
Unsupervised parking
Parked tractors with coupled implements that are insufficiently secured or unsupervised pose a hazard for
people and for children at play.
Before leaving the implement:
Bring the tractor and the implement to a standstill.
Secure the tractor and the implement.
2.1.5 Safe maintenance and modification
2.1.5.1 Modifications on the implement
Only authorized modifications
Structural modifications or extensions can impair the functionality and operational safety of the implement.
This can result in severe or fatal injuries.
Have any structural modifications or extensions performed only by a qualified specialist workshop.
This ensures that the operating permit remains valid in accordance with national and international
regulations.
Ensure that the specialist workshop only uses conversion parts, spare parts, and special equipment
approved by AMAZONE.
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2.1.5.2 Tasks on the implement
Only work on the implement after it has come to a complete standstill
If the implement is not at standstill, parts can move unintentionally or the implement can be set in motion.
This can result in severe or fatal injuries.
Before performing any tasks on the implement, bring the implement to a standstill and secure it.
To bring the implement to a standstill,
perform the following tasks
If necessary, use wheel chocks to prevent the implement from rolling.
Lower lifted loads to the ground.
Discharge the pressure in the hydraulic hose lines.
If you must work on or under raised loads,
lower the loads or secure raised implement parts with a hydraulic device or mechanical locking device.
Switch off all drives.
Apply the parking brake.
Particularly on slopes, in addition, use wheel chocks to prevent the implement from rolling.
Remove the ignition key and keep it with you.
Remove the key from the battery circuit breaker.
Wait until all parts still in motion after the unit is switched off have come to a stop and until hot parts
have cooled down.
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