Amazone ZA-X Perfect 602 User manual

Operating Manual
az
ZA-X Perfect 602
ZA-X Perfect 902
ZA-X Perfect 1402
ZA-XW Perfect 502
Fertiliser spreaders
MG2809
BAG0044.6
05.16
Prin
ted in Germany
Please read this operating
manual before first
commis
sioning.
Keep it in a safe place
for fu
ture use.
en

2
ZA-X BAG0044.6 05.16
Reading the instruction
Manual and following it should seem to be in-
convenient and superfluous as it is not
enough to hear from others and to realize that a
machine is good, to buy it and to believe that now
everything should work by itself. The person in
question would not only harm himself but also
make the mistake of blaming the machine for pos-
sible failures instead of himself. In order to ensure
success one should enter the mind of a thing,
make himself familiar with every part of the ma-
chine and get acquainted with how it's handled.
Only in this way could you be satisfied both with
the machine and with yourself. This goal is the
purpose of this instruction manual.
Leipzig-Plagwitz 1872.

Identification data
ZA
-X BAG0044.6 05.16
3
Identification data
Enter the machine identification data here. You will find the identifica-
tion data on the rating plate.
Machine identification number:
(ten-digit)
Type: ZA-X
Year of manufacture:
Basic weight (kg):
Permissible total weight (kg):
Maximum load (kg):
Manufacturer's address
AMAZONEN-WERKE
H. DREYER GmbH & Co. KG
Postfach 51
D-49202
Tel.:
E-mail:
Hasbergen
+ 49 (0)5405 501-0
[e-mail]
Spare part orders
Spare parts lists are freely accessible in the spare parts portal at
www.amazone.de.
Please send orders to your AMAZONE dealer.
Formalities of the operating manual
Document number:
MG2809
Compilation date:
09.15

Copyright AMAZONEN-WERKE H. DREYER GmbH & Co. KG, 2016
All rights reserved.
Reprinting, even of sections, only possible with the approval of AMA-
ZONEN-WERKE H. DREYER GmbH & Co. KG.

Foreword
4
ZA-X BAG0044.6 05.16
Foreword
Dear Customer,
You have chosen one of the quality products from the wide product
range of AMAZONEN-WERKE, H. DREYER GmbH & Co. KG. We
thank you for your confidence in our products.
On receiving the machine, check to see if it was damaged during
transport or if parts are missing. Using the delivery note, check that
the machine was delivered in full including the ordered special equip-
ment. Damage can only be rectified if problems are signalled immedi-
ately!
Before first commissioning, read and understand this operating man-
ual, and particularly the safety information. Only after careful reading
will you be able to benefit from the full scope of your newly purchased
machine.
Please ensure that all the machine operators have read this operating
manual before commissioning the machine.
Should you have any questions or problems, please consult this op-
erating manual or contact your local service partner.
Regular maintenance and timely replacement of worn or damaged
parts increases the lifespan of your machine.
User evaluation
Dear Reader,
We update our operating manuals regularly. Your suggestions for
improvement help us to create ever more user-friendly manuals.
AMAZONEN-WERKE
H. DREYER GmbH & Co. KG
Postfach 51
D-49202
Tel.:
E-mail:
Hasbergen
+ 49 (0)5405 501-0
[e-mail]

Table of Contents
ZA
-X BAG0044.6 05.16
5
1User Information..........................................................................................8
1.1 Purpose of the document.........................................................................................................8
1.2 Locations in the operating manual...........................................................................................8
1.3 Diagrams used.........................................................................................................................8
2General safety instructions.........................................................................9
2.1 Obligations and liability............................................................................................................9
2.2 Representation of safety symbols..........................................................................................11
2.3 Organisational measures.......................................................................................................12
2.4 Safety and protection equipment...........................................................................................12
2.5 Informal safety measures.......................................................................................................12
2.6 User training...........................................................................................................................13
2.7 Safety measures in normal operation....................................................................................14
2.8 Dangers from residual energy................................................................................................14
2.9 Maintenance and repair work, fault elimination .....................................................................14
2.10 Constructive changes ............................................................................................................14
2.10.1 Spare and wear parts and aids..............................................................................................15
2.11 Cleaning and disposal............................................................................................................15
2.12 User workstation ....................................................................................................................15
2.13 Warning pictograms and other signs on the machine ...........................................................16
2.13.1 Positions of warning pictograms and other labels .................................................................17
2.14 Dangers if the safety information is not observed..................................................................22
2.15 Safety-conscious working......................................................................................................22
2.16 Safety information for users...................................................................................................23
2.16.1 General safety and accident prevention information .............................................................23
2.16.2 Hydraulic system....................................................................................................................26
2.16.3 Electrical system....................................................................................................................27
2.16.4 Universal joint shaft operation................................................................................................27
2.16.5 Fertiliser spreader operation..................................................................................................29
2.16.6 Cleaning, maintenance and repairs.......................................................................................29
3Loading and unloading .............................................................................30
4Product description...................................................................................30
4.1 Overview of subassemblies...................................................................................................31
4.2 Safety and protection equipment...........................................................................................32
4.3 Supply lines between the tractor and the machine................................................................32
4.4 Transportation equipment......................................................................................................32
4.5 Intended use ..........................................................................................................................33
4.6 Danger areas and danger points ...........................................................................................33
4.7 Rating plate and CE marking.................................................................................................34
4.8 Technical data........................................................................................................................35
4.9 Necessary tractor equipment.................................................................................................36
4.10 Noise production data............................................................................................................36
5Structure and function ..............................................................................37
5.1 Function .................................................................................................................................37
5.2 Guard and function screens in the hopper (protective device)..............................................38
5.3 Guard tube (protective device)...............................................................................................39
5.4 PTO shaft...............................................................................................................................40
5.4.1 Coupling the PTO shaft..........................................................................................................42
5.4.2 Uncoupling the PTO shaft......................................................................................................42
5.4.3 PTO shaft with friction clutch (optional) .................................................................................43
5.5 Hydraulic connections............................................................................................................44
5.5.1 Coupling the hydraulic hose lines..........................................................................................45

Table of Contents
6
ZA-X BAG0044.6 05.16
5.5.2 Uncoupling the hydraulic hose lines...................................................................................... 45
5.6 Spreading discs..................................................................................................................... 46
5.7 Agitator.................................................................................................................................. 46
5.8 Slider ..................................................................................................................................... 47
5.9 Two-way control.................................................................................................................... 48
5.10 Three-way control (optional) ................................................................................................. 49
5.11 3-point attachment frame...................................................................................................... 50
5.12 Boundary spreading/side spreading...................................................................................... 51
5.13 Calibration kit (optional)......................................................................................................... 52
5.14 Transport and parking device (removable, optional)............................................................. 53
5.15 Coupling device..................................................................................................................... 54
5.16 Hopper cover (optional)......................................................................................................... 54
5.17 Hopper extensions (optional) ................................................................................................ 55
5.18 Row spreading attachment for specialised crops ................................................................. 56
5.19 Setting chart .......................................................................................................................... 59
6Commissioning ......................................................................................... 61
6.1 Checking the suitability of the tractor.................................................................................... 62
6.1.1 Calculating the actual values for the total tractor weight, tractor axle loads and load
capacities, as well as the minimum ballast ........................................................................... 62
6.2 Installing the PTO shaft on the machine............................................................................... 66
6.3 Adjusting the length of the PTO shaft to the tractor.............................................................. 67
6.4 Securing the tractor / machine against unintentional start-up and rolling............................. 69
7Coupling and uncoupling the machine ................................................... 70
7.1 Coupling the machine............................................................................................................ 70
7.2 Uncoupling the machine........................................................................................................ 73
8Adjustments............................................................................................... 74
8.1 Adjusting the mounting height............................................................................................... 75
8.1.1 Late topdressing.................................................................................................................... 76
8.2 Setting the spread rate.......................................................................................................... 77
8.2.1 Setting the slider position using the setting lever.................................................................. 77
8.2.2 Setting the spread rate according to the setting chart .......................................................... 78
8.2.3 Determining the slider position using the calibration kit (optional)........................................ 79
8.3 Setting the working width ...................................................................................................... 82
8.3.1 Adjusting the spreading vane positions................................................................................. 83
8.4 Checking the working width using the mobile fertiliser test rig (optional) ............................. 85
8.5 Boundary, ditch and side spreading...................................................................................... 86
8.5.1 Boundary and side spreading with Limiter X (optional).................................................. 87
8.5.2 Boundary and side spreading with the Tele-Quick border spreading vane.......................... 89
8.5.3 Setting and installing the Tele-Quick border spreading vane ............................................... 89
8.5.4 Boundary spreading with border spread deflector (optional)................................................ 91
8.6 Switching the agitator head on and off.................................................................................. 92
8.7 Spreading pressure sensitive fertilisers ................................................................................ 92
9Transportation........................................................................................... 93
10 Use of the machine ................................................................................... 95
10.1 Filling the centrifugal broadcaster......................................................................................... 97
10.2 Spreading operation.............................................................................................................. 98
10.2.1 Complete discharging.......................................................................................................... 101
10.3 Recommendation for working in headlands........................................................................ 102
10.4 Notes for spreading slug pellets (e.g. Mesurol) .................................................................. 103
10.4.1 Spread rate check with the machine at a standstill............................................................. 104
11 Faults........................................................................................................ 106

Table of Contents
ZA
-X BAG0044.6 05.16
7
11.1 Faults, causes and remedies...............................................................................................106
12 Cleaning, maintenance and repairs........................................................107
12.1 Cleaning...............................................................................................................................107
12.2 Lubrication instructions ........................................................................................................108
12.3 Maintenance plan – Overview..............................................................................................109
12.4 Removing the PTO shaft......................................................................................................110
12.5 Shear-off safety devices for PTO shafts..............................................................................110
12.6 Ventilate the friction clutch...................................................................................................110
12.7 Gearbox ...............................................................................................................................111
12.8 Replacing the spreading vanes and swivel blades..............................................................112
12.8.1 Replacing the spreading vanes............................................................................................112
12.8.2 Replacing the swivel blades.................................................................................................113
12.9 Check the clearances between the agitator finger/hopper wall and spreading vane/feed
plates....................................................................................................................................114
12.10 Checking and correcting the basic setting of the sliders .....................................................114
12.11 Hydraulic system..................................................................................................................116
12.11.1 Labelling of hydraulic hose lines..........................................................................................117
12.11.2 Maintenance intervals..........................................................................................................117
12.11.3 Inspection criteria for hydraulic hose lines...........................................................................117
12.11.4 Installation and removal of hydraulic hose lines..................................................................118
12.12 Electric lighting system ........................................................................................................119
12.13 Upper and lower link pins.....................................................................................................119
12.14 Hydraulic diagram................................................................................................................120
12.15 Screw tightening torques .....................................................................................................121

User Information
8
ZA-X BAG0044.6 05.16
1 User Information
The User Information section provides information on use of the oper-
ating manual.
1.1 Purpose of the document
This operating manual
•Describes the operation and maintenance of the machine.
•Provides important information on safe and efficient handling of
the machine.
•Is a component part of the machine and should always be kept
with the machine or the traction vehicle.
•Keep it in a safe place for future use.
1.2 Locations in the operating manual
All the directions specified in the operating manual are always seen
from the direction of travel.
1.3 Diagrams used
Handling instructions and reactions
Activities to be carried out by the user are given as numbered instruc-
tions. Always keep to the order of the handling instructions. The reac-
tion to the handling instructions is given by an arrow.
Example:
1. Handling instruction 1
→Machine reaction to handling instruction 1
2. Handling instruction 2
Lists
Lists without an essential order are shown as a list with bullets.
Example:
•Point 1
•Point 2
Number items in diagrams
Numbers in round bracket refer to items in diagrams. The first number
refers to the diagram and the second number to the item in the figure.
Example: (Fig. 3/6)
•Figure 3
•Item 6

General safety instructions
ZA
-X BAG0044.6 05.16
9
2 General safety instructions
This section contains important information on safe operation of the
machine.
2.1 Obligations and liability
Comply with the instructions in the operating manual
Knowledge of the basic safety information and safety regulations is a
basic requirement for safe handling and fault-free machine operation.
Obligations of the operator
The operator is obliged only to let those people work with/on the ma-
chine who
•Are aware of the basic workplace safety information and acci-
dent prevention regulations.
•Have been trained in working with/on the machine.
•Have read and understood this operating manual.
The operator is obliged
•To keep all the warning pictograms on the machine in a legible
state.
•To replace damaged warning pictograms.
If you still have queries, please contact the manufacturer.
Obligations of the user
Before starting work, anyone charged with working with/on the ma-
chine is obliged
•To comply with the basic workplace safety instructions and acci-
dent prevention regulations.
•To read and follow the "General safety information" section of
this operating manual.
•To read the "Warning pictograms and other labelling on the ma-
chine" section of this operating manual and to follow the safety
instructions of the warning pictograms when operating the ma-
chine.
•To get to know the machine.
•To read the sections of this operating manual, important for car-
rying out your work.
If the user discovers that a function is not working properly, then they
must eliminate this fault immediately. If this is not the task of the user
or if the user does not possess the appropriate technical knowledge,
then they should report this fault to their superior (operator).

General safety instructions
10
ZA-X BAG0044.6 05.16
Risks in handling the machine
The machine has been constructed to the state-of-the art and the
recognised rules of safety. However, there may be risks and re-
strictions which occur when operating the machine
•For the health and safety of the user or third persons,
•For the machine,
•For other goods.
Only use the machine
•For the purpose for which it was intended.
•In a perfect state of repair.
Eliminate any faults immediately which could impair safety.
Guarantee and liability
Our "General conditions of sales and delivery" are always applicable.
These shall be available to the operator, at the latest on the comple-
tion of the contract. Guarantee and liability claims for damage to peo-
ple or goods will be excluded if they can be traced back to one or
more of the following causes:
•Improper use of the machine.
•Improper installation, commissioning, operation and mainte-
nance of the machine.
•Operation of the machine with defective safety equipment or
improperly attached or non-functioning safety equipment.
•Non-compliance with the instructions in the operating manual
regarding commissioning, operation and maintenance.
•Independently-executed construction changes to the machine.
•Insufficient monitoring of machine parts which are subject to
wear.
•Improperly executed repairs.
•Disasters through the impact of foreign bodies and acts of God.

General safety instructions
ZA
-X BAG0044.6 05.16
11
2.2 Representation of safety symbols
Safety instructions are indicated by the triangular safety symbol and
the highlighted signal word. The signal word (DANGER, WARNING,
CAUTION) describes the gravity of the risk and has the following sig-
nificance:
DANGER
Indicates an immediate high risk which will result in death or
serious physical injury (loss of body parts or long term damage)
if not avoided.
If the instructions are not followed, then this will result in imme-
diate death or serious physical injury.
WARNING
Indicates a medium risk, which could result in death or (serious)
physical injury if not avoided.
If the instructions are not followed, then this may result in death
or serious physical injury.
CAUTION
Indicates a low risk which could cause minor or medium level
physical injury or damage to property if not avoided.
IMPORTANT
Indicates an obligation to special behaviour or an activity re-
quired for proper machine handling.
Non-compliance with these instructions can cause faults on the
machine or in the environment.
NOTE
Indicates handling tips and particularly useful information.
These instructions will help you to use all the functions of your
machine to the optimum.

General safety instructions
12
ZA-X BAG0044.6 05.16
2.3 Organisational measures
The operator must provide the necessary personal protective equip-
ment, such as:
•Protective glasses
•Protective shoes
•Protective suit
•Skin protection agents, etc.
The operating manual
•Must always be kept at the place at which the machine is oper-
ated.
•Must always be easily accessible for the user and maintenance
personnel.
Check all the available safety equipment regularly.
2.4 Safety and protection equipment
Before each commissioning of the machine, all the safety and protec-
tion equipment must be properly attached and fully functional. Check
all the safety and protection equipment regularly.
Faulty safety equipment
Faulty or disassembled safety and protection equipment can lead to
dangerous situations.
2.5 Informal safety measures
As well as all the safety information in this operating manual, comply
with the general, nationa
l regulations pertaining to accident prevention
and environmental protection.
When driving on public roads and routes, then you should comply with
the statutory road traffic regulations.

General safety instructions
ZA
-X BAG0044.6 05.16
13
2.6 User training
Only those people who have been trained and instructed may work
with/on the machine. The operator must clearly specify the responsi-
bilities of the people charged with operation, maintenance and repair
work.
People being trained may only work with/on the machine under the
supervision of an experienced person.
People
Activity
Person special-
ly trained for the
activity 1)
Trained person2)
Person with specialist
training (specialist work-
shop)3)
Loading/Transport X X X
Commissioning -- X --
Set-up, tool installation -- -- X
Operation -- X --
Maintenance -- -- X
Troubleshooting and fault elimina-
tion -- X X
Disposal X -- --
Legend: X..permitted --..not permitted
1) A person who can assume a specific task and who can carry out
this task for an appropriately qualified company.
2) Instructed persons are those who have been instructed in their
assigned tasks and in the possible risks in the case of improper
behaviour, have been trained if necessary, and have been in-
formed about the necessary protective equipment and
measures.
3) People with specialist technical training will be considered spe-
cialists. Due to their specialist training and their knowledge of
the appropriate regulations, they can evaluate the work with
which they have been charged and detect possible dangers.
Comment:
A qualification equivalent to specialist training can be obtained
through long term activity in the appropriate field of work.
Only a specialist workshop may carry out maintenance and repair
work on the machine if such work is additionally marked "Workshop
work". The personnel of a specialist workshop shall possess the ap-
propriate knowledge and suitable aids (tools, lifting and support
equipment) for carrying out the maintenance and repair work on the
machine in a way which is both appropriate and safe.

General safety instructions
14
ZA-X BAG0044.6 05.16
2.7 Safety measures in normal operation
Only operate the machine if all the safety and protection equipment is
fully functional.
Check the machine at least once a day for visible damage and check
the function of the safety and protection equipment.
2.8 Dangers from residual energy
Note that there may be residual mechanical, hydraulic, pneumatic and
electrical/electronic energy on the machine.
Use appropriate measures to inform the op
erating personnel. You can
find detailed information in the relevant sections of this operating
manual.
2.9 Maintenance and repair work, fault elimination
Carry out prescribed setting, maintenance and inspection work in
good time.
Secure all media such as compressed air and the hydraulic system
against unintentional start-up.
Carefully fix and secure larger subassemblies to lifting gear when
carrying out replacement work.
Regularly check that bolted connections are firmly secured and tight-
en if necessary.
When the maintenance work is completed, check the function of the
safety devices.
2.10 Constructive changes
You may make no changes, expansions or modifications to the ma-
chine without the approval of AMAZONEN-WERKE. This is also valid
when welding support parts.
Any expansion or modification work shall require the written approval
of AMAZONEN-WERKE. Only use the modification and accessory
parts released by AMAZONEN-WERKE, so that the type approval
remains valid according to the national and international regulations.
Vehicles with an official type approval or with equipment connected to
a vehicle with a valid type approval or approval for road transport
according to the German road traffic regulations must be in the state
specified by the approval.
WARNING
Risk of contusions, cuts, dragging, catching or knocks from
support parts.
It is forbidden to:
•Drill holes in the frame or on the running gear.
•
Increase the size of existing holes on the frame or the running gear.
•Weld support parts.

General safety instructions
ZA
-X BAG0044.6 05.16
15
2.10.1 Spare and wear parts and aids
Immediately replace any machine parts which are not in a perfect
state.
Only use AMAZONE spare and wear parts released by AMAZONEN-
WERKE, so that the type approval remains valid according to the
national and international regulations. The use of wear and spare
parts from third parties does not guarantee that they have been con-
structed in a way as to meet the requirements placed on them.
AMAZONEN-WERKE shall accept no liability for damage caused by
the use of unreleased spare and wear parts or aids.
2.11 Cleaning and disposal
Handle and dispose of any materials used carefully, in particular
•When carrying out work on lubrication systems and equipment
and
•When cleaning using solvents.
2.12 User workstation
The machine may only be operated by one person sitting in the driv-
er's seat of the tractor.

General safety instructions
16
ZA-X BAG0044.6 05.16
2.13 Warning pictograms and other signs on the machine
Always keep all the warning pictograms of the machine clean and in a
legible state. Replace illegible warning pictograms. You can obtain the
warning pictograms from your dealer using the order number (e.g. MD
075).
Warning pictograms - structure
Warning pictograms indicate dangers on the machine and warn
against residual dangers. At these points, there are permanent or
unexpected dangers.
A warning pictogram consists of two fields:
Field 1
is a pictogram describing the danger, surrounded by triangular safety
symbol.
Field 2
is a pictogram showing how to avoid the danger.
Warning pictograms - explanation
The column Order number and explanation provides an explanation
of the neighbouring warning pictogram. The description of the warning
pictograms is always the same and specifies, in the following order:
1. A description of the danger.
For example: danger of cutting!
2. The consequence of non-compliance with the danger protection
instructions.
For example: causes serious injuries to fingers or hands.
3. Instructions for avoiding the danger.
For example: only touch machine parts when they have come to
a complete standstill.

General safety instructions
ZA
-X BAG0044.6 05.16
17
2.13.1 Positions of warning pictograms and other labels
Warning pictograms
The following diagrams show the arrangement of the warning picto-
grams on the machine.
Fig. 1
Fig. 2
Fig.
3
Fig. 4

General safety instructions
18
ZA-X BAG0044.6 05.16
Order number and explanation
Warning pictograms
MD 075
Risk of cutting or severing fingers and hands
owing to accessible moving parts involved in
the work process!
This danger can cause extremely serious injuries
and loss of limbs.
•Never reach into the danger area when the
tractor engine is running with PTO shaft /
hydraulic system / electronic system con-
nected.
•Wait for complete standstill of all moving
parts of the machine before reaching into
the danger area.
MD 078
Danger of crushing fingers or hands owing to
accessible moving parts of the machine!
This danger can cause extremely serious injuries
and loss of limbs.
Never reach into the danger area when the trac-
tor engine is running with PTO shaft / hydraulic
system / electronic system connected.
MD 079
Danger from materials or foreign objects that
are thrown from or ejected by the machine at
high speeds.
These dangers can cause extremely serious to
any part of the body.
•Keep a sufficient safety distance from the
machine danger area.
•Ensure that bystanders maintain a sufficient
safety distance from the machine danger
area as long as the tractor engine is run-
ning.

General safety instructions
ZA
-X BAG0044.6 05.16
19
Order number and explanation
Warning pictograms
MD 082
Danger from falling when travelling on tread
surfaces or platforms!
This danger can cause extremely serious and
potentially fatal injuries.
It is forbidden to ride on the machine or climb the
running machine. This also applies to machines
with tread surfaces or platforms.
Make sure that nobody is riding on the machine.
MD 083
Danger of pulling in or entrapment for arms
owing to moving parts involved in the work
process!
This danger can cause extremely serious injuries
and loss of limbs.
Never open or remove safety equipment while
the tractor engine is running with PTO shaft /
hydraulic system / electronic system connected.
MD 089
Risk of crushing the entire body due to
standing under suspended loads or raised
machine parts.
This danger can cause extremely serious and
potentially fatal injuries.
•It is forbidden to stand under suspended
loads or raised machine parts.
•Maintain an adequate safety distance from
any suspended loads or raised machine
parts.
•Ensure that all personnel maintain an ade-
quate safety distance from suspended
loads or raised machine parts.
MD 095
Read and follow the operating manual and safety
information before starting up the machine!

General safety instructions
20
ZA-X BAG0044.6 05.16
Order number and explanation
Warning pictograms
MD 096
Danger from escaping high-pressure hydrau-
lic fluid due to leaking hydraulic hose lines.
This danger may cause serious injuries, perhaps
even resulting in death, if escaping high-
pressure
hydraulic fluid passes through the skin and into
the body.
•Never attempt to plug leaks in hydraulic
hose lines using your hand or fingers.
•Read and observe the information in the
operating manual before carrying out
maintenance work on the hydraulic hose
lines.
•If you are injured by hydraulic fluid, contact
a doctor immediately.
MD 097
Risk of crushing the entire body due to
standing in the stroke area of the three-point
suspension when the three-point hydraulics
are actuated.
This danger can cause extremely serious and
potentially fatal injuries.
•Personnel are prohibited from entering the
stroke area of the three-point suspension
when the three-point hydraulics are actuat-
ed.
•Only actuate the operator controls for the
tractor's three-point hydraulic system
οfrom the intended workstation.
οif you are outside of the stroke area
between the tractor and the machine.
MD 100
This symbol indicates anchorage points for fas-
tening slinging gear when loading the machine.