Amazone CatrosXL 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 Copyright 1
1.2 Diagrams 1
1.2.1 Warnings and signal words 1
1.2.2 Further instructions 2
1.2.3 Instructions 2
1.2.4 Lists 3
1.2.5 Item numbers in figures 4
1.2.6 Direction information 4
1.3 Other applicable documents 4
1.4 Digital operating manual 4
1.5 Your opinion is important 4
2 Safety 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 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 tools 20
4.1.2 Implement with support wheels 21
4.1.3 Implement with GreenDrill 22
4.2 Function of the implement 22
4.3 Special equipment 22
4.4 Warning symbols 24
4.4.1 Positions of the warning symbols 24
4.4.2 Layout of the warning symbols 26
4.4.3 Description of the warning symbols 27
4.5 Lighting and identification for
road travel 32
4.5.1 Rear lighting and identification 32
4.5.2 Front lighting and identification 32
4.6 Threaded cartridge 33
4.7 Rating plates 33
4.7.1 Rating plate on the implement 33
4.7.2 Additional rating plate 33
4.8 Other information on the
implement 34
4.8.1 Information about the stop tap on
the hydraulic drawbar 34
4.8.2 Information on the float position of
hydraulic valves 34
4.8.3 Information on the switch tap for
traction assistance 34
4.9 Single-circuit hydraulic brake
system 35
4.10 Setting lever for the trailing
elements 35
5 Technical data 37
5.1 Dimensions 37
5.2 Soil tillage tool 37
5.3 Permitted mounting categories 37
5.4 Optimal working speed 38
5.5 Performance characteristics of
the tractor 38
5.6 Noise development data 38
5.7 Drivable slope inclination 39
6Preparing the machine 40
6.1 Checking the tractor suitability 40
6.1.1 Calculating the required tractor
characteristics 40
6.1.2 Determining the required coupling
devices 43
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6.1.3 Comparing the permissible DC
value with actual DC value 44
6.2 Coupling the implement 44
6.2.1 Removing the safety device against
unauthorised use 44
6.2.2 Driving the tractor towards the
implement 45
6.2.3 Fastening the safety chain 45
6.2.4 Coupling the hydraulic hose lines 45
6.2.5 Coupling the power supply 47
6.2.6 Coupling the power supply for the
central lubrication 47
6.2.7 Coupling the brake system 48
6.2.8 Connecting the coupling device 50
6.2.9 Removing the wheel chocks 52
6.2.10 Releasing the parking brake 52
6.3 Preparing the implement for
operation 52
6.3.1 Unfolding the sections 52
6.3.2 Adjusting the trailing elements 53
6.3.3 Installing ballast weights 58
6.3.4 Adjusting the scraper to the roller 58
6.3.5 Adjusting the central lubrication 59
6.4 Preparing the machine for road
travel 60
6.4.1 Securing the cutting roller 60
6.4.2 Moving the harrow into transport
position 61
6.4.3 Putting on the road safety bars 63
6.4.4 Folding the sections 63
6.4.5 Aligning the implement at transport
height 64
6.4.6 Locking the tractor control units 65
7Using the machine 66
7.1 Unfolding the sections 66
7.2 Removing the road safety bars 66
7.3 Adjusting the working depth 67
7.3.1 Adjusting the working depth of the
discs 67
7.3.2 Hydraulic adjustment of the
crushboard working depth 69
7.3.3 Adjust the working depth of the side
guide plates 69
7.4 Lifting the running gear and
using the vibration compensation 70
7.5 Lifting the running gear and not
using the vibration compensation 70
7.6 Aligning the implement
horizontally 71
7.6.1 Aligning the implement horizontally
with the support wheels 71
7.6.2 Aligning the implement horizontally
with lower link hitch 71
7.6.3 Aligning the implement horizontally
with hydraulic drawbar 72
7.7 Lowering the cutting roller 72
7.8 Driving on the headlands 73
7.8.1 Turning on the roller on the
headlands 73
7.8.2 Turning on the running gear on the
headlands 74
8Eliminating faults 75
9 Parking the machine 78
9.1 Applying the parking brake 78
9.2 Placing the wheel chocks 78
9.3 Disconnecting the coupling device 79
9.3.1 Uncoupling the lower link hitch 79
9.3.2 Uncoupling the ball coupling or
drawbar eye 80
9.4 Driving the tractor away from the
implement 81
9.5 Uncoupling the brake system 81
9.5.1 Uncoupling the dual-circuit
pneumatic brake system 81
9.5.2 Uncoupling the single-circuit
hydraulic brake system 82
9.6 Uncoupling the power supply 82
9.7 Disconnecting the hydraulic
hose lines 83
9.8 Releasing the safety chain 83
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9.9 Putting on the safety device
against unauthorised use 84
10 Repairing the machine 85
10.1 Maintaining the implement 85
10.1.1 Maintenance schedule 85
10.1.2 Replacing the discs 86
10.1.3 Checking the disc carrier connection 87
10.1.4 Aligning the disc gangs relative to
each other 87
10.1.5 Checking the rollers 88
10.1.6 Checking the lower link pins 88
10.1.7 Checking the hydraulic hose lines 89
10.1.8 Checking the wheels 90
10.1.9 Checking the hub bearing 90
10.1.10 Checking the brake pads 91
10.1.11 Checking the pneumatic brake
system 91
10.1.12 Draining the compressed air tank 92
10.1.13 Checking the compressed air tank 92
10.1.14 Cleaning the compressed air line filter 93
10.1.15 Checking the axle bolts 94
10.1.16 Checking the lower link hitch 94
10.1.17 Checking the ball hitch coupling 95
10.1.18 Checking the drawbar eye 95
10.1.19 Checking the central lubrication 96
10.2 Cleaning the implement 97
10.3 Lubricating the implement 98
10.3.1 Overview of lubrication points 99
10.3.2 Lubricating the wheel hubs 101
11 Preparing the implement for
transport 102
11.1 Manoeuvring the implement 102
11.1.1 Manoeuvring the implement with
dual-circuit pneumatic brake system 102
11.1.2 Manoeuvring an implement with
single-circuit hydraulic brake system 103
11.2 Loading the machine 104
11.2.1 Manoeuvring the implement onto a
transport vehicle 104
11.2.2 Loading the implement with a crane 104
11.2.3 Lashing the implement 105
12 Disposing of the implement 106
13 Appendix 107
13.1 Bolt tightening torques 107
13.2 Other applicable documents 108
14 Directories 109
14.1 Glossary 109
14.2 Index 110
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About this operating manual 1
1.1 Copyright
Reprinting, translation and reproduction in any form,
including excerpts, require the written approval of
AMAZONEN-WERKE.
1.2 Diagrams
1.2.1 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.
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1.2.2 Further instructions
IMPORTANT
Indicates a risk for damage to the
implement.
ENVIRONMENTAL INFORMATION
Indicates a risk for environmental damage.
NOTE
Indicates application tips and instructions for
optimal use.
1.2.3 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
1.2.3.1 Instructions and responses
Reactions to instructions are marked with an arrow.
Example:
1. Instruction 1
Reaction to instruction 1
2. Instruction 2
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1.2.3.2 Alternative instructions
Alternative instructions are introduced with the word
"or".
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
1.2.4 Lists
Lists without an essential order are shown as a list
with bullets.
Example:
Point 1
Point 2
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1.2.5 Item numbers in figures
A framed number in the text, e.g. a
1
, indicates an
item number in an adjacent figure.
1.2.6 Direction information
Unless otherwise specified, all directions are always
seen in the direction of travel.
1.3 Other applicable documents
A list of other applicable documents can be found in
the Appendix.
1.4 Digital operating manual
The digital operating manual and e-learning can be
downloaded from the Info Portal on the AMAZONE
website.
1.5 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.
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.
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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.
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.
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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 permitted payload for 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.
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".
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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.
2.1.5 Safe maintenance and modification
2.1.5.1 Changes on the implement
Only authorised design changes
Design changes and extensions can impede the functioning and operational safety of the machine. This
can result in serious injury or death.
Have any design changes and extensions performed only by a qualified specialist workshop.
To ensure 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 Work on the machine
Only work on the machine when it is at a standstill
If the machine is not standing still, part can move unintentionally or the machine can be set in motion. This
can result in serious injury or death.
Before performing any work on the machine, shutdown and secure the machine.
To immobilise the machine,
perform the following tasks.
If necessary, secure the machine against rolling away with wheel chocks.
Lower lifted loads down to the ground.
Relieve the pressure in the hydraulic hose lines.
If you have to work on or under raised loads,
lower the loads or secure raised machine parts with a hydraulic or mechanical locking device.
Switch off all drives.
Actuate the parking brake.
Particularly on slopes, additionally secure the machine against rolling away with wheel chocks.
Remove the ignition key and carry it with you.
Remove the key from the battery circuit breaker.
Wait until all parts that are still running come to a stop and that hot parts cool down.
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