Amazone Cenius 4002-2 Super User manual

Operating Manual
az
Mulch cultivator
Cenius 4002-2 Super
Cenius 4003
-2 Special
MG5449
BAG0154.0
11.15
Printed in Germa
ny
Read and observe this
operating manual before using
the machine for the first time!
Keep it in a safe place for
future use!
en

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Reading the instruc-
tion
manual and to adhere to it should not appear to
be inconvenient and superfluous as it is not
enough to hear from others and to realise that a
machine is good, to buy it and to believe that now
everything would work by itself. The person con-
cerned would not only harm himself but also
make the mistake of blaming the machine for the
reason of a possible failure instead of himself. In
order to ensure a good success one should go into
the mind of a thing or make himself familiar with
every part of the machine and to get acquainted
with its handling. Only this way, you would be
satisfied both with the machine as also with
yourself. To achieve this is the purpose of this in-
struction manual.
Leipzig-Plagwitz 1872.

Identification data
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3
Identification data
Manufacturer:
AMAZONEN-WERKE
H. DREYER GmbH & Co. KG
Machine identification no.:
Type:
Cenius
Permissible pressure of system
[bar]:
Year of manufacture:
Factory:
Basic weight (kg):
Approved total weight (kg):
Maximum load (kg):
Manufacturer's address
AMAZONEN-WERKE
H. DREYER GmbH & Co. KG
Postfach 51
D-49202
Phone:
E-mail:
Hasbergen
+ 49 (0) 5405 50 1-0
[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:
MG5449
Compilation date:
10.14

Copyright AMAZONEN-WERKE H. DREYER GmbH & Co. KG, 2015
All rights reserved.
Reprinting, even of sections, permitted only with the approval of
AMAZONEN-WERKE H. DREYER GmbH & Co. KG.

Foreword
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Foreword
Dear Customer,
You decided to purchase one of our high quality machines from the
comprehensive range of farm machinery produced by AMAZONEN-
WERKE, H. DREYER GmbH & Co. KG. We thank you for your confi-
dence 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. Replacement will be made only if a claim is filed immediately!
Please read and follow this operating manual—
in particular, the safety
instructions—before putting the machine into operation. 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 they put the machine into operation.
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
Phone:
E-mail:
Hasbergen
+ 49 (0) 5405 50 1-0
[e-mail]

Table of Contents
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1User information..........................................................................................7
1.1 Purpose of the document.........................................................................................................7
1.2 Locations in the operating manual...........................................................................................7
1.3 Diagrams used.........................................................................................................................7
2General safety instructions.........................................................................8
2.1 Obligations and liability............................................................................................................8
2.2 Representation of safety symbols..........................................................................................10
2.3 Organisational measures.......................................................................................................11
2.4 Safety and protection equipment...........................................................................................11
2.5 Informal safety measures.......................................................................................................11
2.6 User training...........................................................................................................................12
2.7 Safety measures in normal operation....................................................................................13
2.8 Dangers from residual energy................................................................................................13
2.9 Maintenance and repair work, fault elimination .....................................................................13
2.10 Constructive changes ............................................................................................................13
2.10.1 Spare and wear parts and aids..............................................................................................14
2.11 Cleaning and disposal............................................................................................................14
2.12 User workstation ....................................................................................................................14
2.13 Warning pictograms and other signs on the machine ...........................................................15
2.13.1 Positioning of warning pictograms and other labels ..............................................................15
2.14 Dangers of not observing safety instructions.........................................................................21
2.15 Safety-conscious working......................................................................................................21
2.16 Safety information for users...................................................................................................22
2.16.1 General safety and accident prevention information .............................................................22
2.16.2 Hydraulic system....................................................................................................................25
2.16.3 Electrical system....................................................................................................................26
2.16.4 Cleaning, maintenance and repairs.......................................................................................27
3Loading and unloading .............................................................................28
4Product description...................................................................................29
4.1 Overview of subassemblies...................................................................................................29
4.2 Safety and protection equipment...........................................................................................30
4.3 Transportation equipment......................................................................................................31
4.4 Intended use ..........................................................................................................................32
4.5 Danger area and danger points.............................................................................................33
4.6 Rating plate and CE marking.................................................................................................34
4.7 Technical data........................................................................................................................34
4.8 Necessary tractor equipment.................................................................................................36
4.9 Noise production data............................................................................................................36
5Structure and function ..............................................................................37
5.1 Tines ......................................................................................................................................38
5.2 Coulter Cenius 3002, 3502, 4002..........................................................................................39
5.3 Coulter C-Mix for Cenius 3003, 3503, 4003 ..........................................................................41
5.4 Coulter arrangement..............................................................................................................42
5.5 Levelling unit..........................................................................................................................43
5.6 Boundary discs / boundary tines............................................................................................44
5.7 Rollers....................................................................................................................................46
5.8 Rear harrow ......................................................................Fehler! Textmarke nicht definiert.
5.9 Hydraulic connections............................................................................................................49
5.9.1 Connecting hydraulic hoses...................................................................................................50
5.9.2 Disconnecting hydraulic hoses ..............................................................................................50

Table of Contents
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5.10 Three-point hitch frame......................................................................................................... 51
6Commissioning ......................................................................................... 52
6.1 Checking the suitability of the tractor.................................................................................... 53
6.1.1 Calculating the actual values for the total tractor weight, tractor axle loads and load
capacities, as well as the minimum ballast ........................................................................... 53
6.2 Securing the tractor/machine against unintentional start-up and rolling............................... 57
7Coupling and uncoupling the machine ................................................... 58
7.1 Coupling the machine............................................................................................................ 59
7.2 Uncoupling the machine........................................................................................................ 61
8Adjustments............................................................................................... 62
8.1 Working depth of the tines .................................................................................................... 62
8.1.1 Mechanical depth adjustment ............................................................................................... 62
8.1.2 Hydraulic depth adjustment................................................................................................... 63
8.2 Working depth of the levelling unit........................................................................................ 64
8.2.1 Arbeitstiefe der Einebnungseinheit mechanisch einstellen................................................... 64
8.2.2 Arbeitstiefe der Einebnungseinheit hydraulisch einstellenFehler! Textmarke nicht definiert.
8.3 Adjusting the stripper............................................................................................................. 64
9Transportation........................................................................................... 65
9.1 Changing from working to transport position ........................................................................ 66
10 Use of the machine ................................................................................... 67
10.1 Changing from transport to working position ........................................................................ 67
10.2 Operation............................................................................................................................... 67
10.3 Headland............................................................................................................................... 67
11 Faults.......................................................................................................... 68
12 Cleaning, maintenance and repairs......................................................... 69
12.1 Cleaning ................................................................................................................................ 70
12.2 Lubrication instructions.......................................................................................................... 70
12.3 Maintenance plan - overview ................................................................................................ 72
12.4 Installing and removing the tines........................................................................................... 73
12.5 Changing the coulters ........................................................................................................... 73
12.5.1 Changing the Vario-Clip coulters .......................................................................................... 74
12.5.1 Changing the C-Mix coulter................................................................................................... 74
12.6 Replace the tension springs of the overload safety device (workshop work)....................... 74
12.7 Installing and removing the disc segments (workshop work)................................................ 75
12.8 Replacing discs (workshop work).......................................................................................... 75
12.9 Tine connection..................................................................................................................... 76
12.10 Roller connection................................................................................................................... 76
12.11 Disc carrier connection.......................................................................................................... 76
12.12 Hydraulic cylinder for folding Cenius-2........................................................................... 76
12.13 Hydraulic system (workshop work) ....................................................................................... 77
12.13.1 Labelling hydraulic hose lines............................................................................................... 78
12.13.2 Maintenance intervals ........................................................................................................... 78
12.13.3 Inspection criteria for hydraulic hose lines............................................................................ 78
12.13.4 Installation and removal of hydraulic hose lines ................................................................... 79
12.14 Lower link pins....................................................................................................................... 79
13 Hydraulic circuit diagram ......................................................................... 80
13.1 Screw tightening torques....................................................................................................... 82

User information
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1 User information
The "User information" section supplies information on using the op-
erating 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 viewed
in the direction of travel.
1.3 Diagrams used
Instructions for action and reactions
Tasks to be carried out by the user are presented as numbered in-
structions. Always keep to the order of the instructions. The reaction
to instructions is given by an arrow. Example:
1. Instruction for action 1
→Reaction of the machine to instruction for action 1
2. Instruction for action 2
Lists
Lists without a mandatory sequence a presented as a list with bullet
points. Example:
• Point 1
• Point 2
Item numbers in diagrams
Numbers in round brackets refer to the item numbers in the diagrams.
The first digit refers to the diagram; the second digit, to the item num-
ber in the illustration.
Example (Fig. 3/6)
• Figure 3
• Item 6

General safety instructions
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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 introduced to 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.
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 observe the section "General safety information" of
this operating manual.
•To read the section "Warning symbols and other labels on the
machine" (page 16) of this operating manual and to follow the
safety instructions represented by the warning symbols when
operating the machine.
•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
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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 that could impair safety immediately.
Guarantee and liability
Our "General conditions of sales and business" 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 that are subject to wear.
•Improperly executed repairs.
• Catastrophic events as a result of the impact of foreign objects
or force majeure.

General safety instructions
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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 incur 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
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2.3 Organisational measures
The operator must provide the necessary personal protective equip-
ment, such as:
•Protective goggles,
•Safety shoes,
•Protective overall,
•Skin protection cream, etc..
The instruction manual
• Must always be kept at the place at which the machine is
operated.
• Must always be easily accessible for the user and mainte-
nance 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, nat
ional 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
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2.6 User training
Only trained and instructed persons should be allowed to work with/on
the machine. The responsibilities of the operating and maintenance
personnel must be clearly defined.
People being trained may only work with/on the machine under the
supervision of an experienced person.
People
Activity
Particularly
trained
persons1)
Instructed
operator 2) Persons with specialist
training
(authorised workshop) 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 shall be considered as a
specialist. 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 specifically designated "Work-
shop work". The personnel of a specialist workshop shall possess the
appropriate 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
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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 at the machine.
Use appropriate measures to inform the operating 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 a
timely manner.
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 authorisation 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 operating permit,
for example, remains valid in accordance with national and interna-
tional 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 being crushed, cut, caught, drawn in or struck if support-
ing parts break.
It is forbidden to:
• Drill holes in the frame or on the chassis.
•Increasing the size of existing holes on the frame or the chassis.
•Welding support parts.

General safety instructions
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2.10.1 Spare and wear parts and aids
Immediately replace any machine parts which are not in a perfect
state.
Use only genuine AMAZONE spare and wear parts or parts ap
proved
by AMAZONEN-WERKEN to ensure that the operating permit retains
its validity in accordance with national and international regulations. If
you use wear and spare parts from third parties, there is no guar
antee
that they have been designed and manufactured in such a way as to
meet the requirements placed on them.
AMAZONEN-WERKE accepts no liability for damage arising from the
use of unapproved spare parts, wear parts or auxiliary materials.
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 must be operated by only one person from the driver's
seat of the tractor.

General safety instructions
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2.13 Warning pictograms and other signs on the machine
2.13.1 Positioning of warning pictograms and other labels
The following diagrams show the arrangement of the warning picto-
grams on the machine.
Fig. 1
Fig. 2
Always keep all the warning pictograms of the machine clean and in a
legible state. Replace ill
egible warning pictograms. You can obtain the
warning pictograms from your dealer using the order number
(e.g. MD078).

General safety instructions
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Warning pictograms - structure
Warning pictograms indicate danger areas on the machine and warn
of residual dangers. Permanent or unexpected dangers exist in these
areas.
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 nonobservance of the risk-avoidance in-
structions.
For example: causes serious injuries to fingers or hands.
3. Risk-avoidance instructions.
For example: only touch machine parts when they have come to
a complete standstill.

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Order number and explanation
Warning pictograms
MD078
Risk of crushing of fingers/hand by accessi-
ble, moving parts of the machine!
This danger can cause extremely serious injuries
resulting in the loss of limbs.
Never reach into the danger area when the trac-
tor engine is running with the PTO shaft or hy-
draulic/electrical system connected.
MD079
Risk of materials or foreign objects being
flung away by or out of the machine!
These dangers can cause extremely serious and
potentially fatal injuries.
•Keep a sufficient safety distance from the
machine as long as the tractor engine is
running.
•Ensure that all other persons also keep a
sufficient safety distance from the danger
area of the machine as long as the tractor
engine is running.
MD084
Risk of crushing the entire body due to re-
maining in the swivel range when machine
parts are being lowered!
This can cause extremely serious
and potentially
fatal injuries.
It is forbidden to stand in the swivel range when
machine parts are being lowered.
Instruct all persons to leave the swivel range of
any machine parts which can be lowered before
you lower the parts.

General safety instructions
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MD089
Risk of crushing of whole body in the danger
area of suspended loads/machine parts!
This can cause extremely serious and potentially
fatal injuries.
The presence of persons under suspended
loads/machine parts is prohibited.
Maintain a sufficient safety clearance between
you and any suspended loads/machine parts.
Ensure that all personnel maintain a sufficient
safety clearance from suspended loads/machine
parts.
Direct persons out of the danger area of sus-
pended loads/machine parts.
MD095
Read and understand the operating manual safe-
ty information before starting up the machine!
MD096
Risk of hydraulic fluid escaping under pres-
sure from leaking hydraulic lines!
This can inflict serious injuries with potentially
fatal consequences if hydraulic fluid escaping at
high pressure passes through the skin and into
the body.
• Never attempt to plug leaks in hydraulic
lines using your hand or fingers.
•Read and observe the information in the
operating manual before carrying out
maintenance and repair work on hydraulic
lines.
• If you are injured by hydraulic fluid, contact
a doctor immediately.

General safety instructions
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MD097
Risk of crushing and contusions between the
rear of the tractor and the machine when
coupling and uncoupling the machine!
These dangers can cause extremely serious and
potentially fatal injuries.
•It is forbidden to actuate the three-point
hydraulic system of the tractor as long as
persons are standing between the rear of
the tractor and the machine.
•Actuate the operator controls for the trac-
tor's three-point hydraulic system
οOnly from the intended workstation
alongside the tractor.
οOnly when you are outside the danger
area between the tractor and the ma-
chine.
MD100
This symbol indicates attachment points for lifting
gear for loading the machine.
MD102
Dangerous situations for the operator due to
unintentional starting / rolling of the machine
during all work on the machine, e.g. installa-
tion, adjustment, troubleshooting, cleaning or
maintenance.
The potential dangers can inflict severe and po-
tentially fatal injuries on all parts of the body.
•Secure the tractor and the machine against
unintentional start-up and rolling before any
intervention in the machine.
•Depending on the type of intervention, read
and understand the information in the rele-
vant sections of this operating manual.
MD114
This pictogram indicates a lubrication point

General safety instructions
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MD199
The maximum operating pressure of the hydrau-
lic system is 210 bar.
MD201
The torque for the bolt connection is 325 Nm.
MD217
Hazard resulting from the machine folded in
and coupled tipping over.
This hazard can result in extremely serious and
potentially fatal injuries.
On no account uncouple the machine when it is
folded in!.
MD225
Risk of crushing of the entire body due to
standing in the swivel range of the drawbar
between the tractor and the attached ma-
chine!
Causes serious, potentially fatal injuries any-
where on the body.
•Standing or walking in the danger area be-
tween the tractor and machine is prohibited
whenever the tractor engine is running and
the tractor is not secured against uninten-
tional rolling.
•Instruct people to leave the danger area
between the tractor and the machine when-
ever the engine of the tractor is running and
the tractor is not secured against uninten-
tional rolling.