Amazone KG 4002-2 Quick guide

Translation of the original operating instructions
Rotary cultivator
KG 4002-2
KG 5002-2
KG 6002-2
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 4
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 Safe operating organisation 5
2.1.2 Knowing and preventing dangers 9
2.1.3 Safe operation and handling of the
machine 11
2.1.4 Safe maintenance and modification 13
2.2 Safety routines 17
3Intended use 19
4 Product description 20
4.1 Implement overview 20
4.2 Function of the implement 21
4.3 Special equipment 22
4.4 Protective equipment 23
4.4.1 Universal joint shaft guard 23
4.4.2 Tool protection 23
4.4.3 Frame transport lock 24
4.4.4 Roller transport lock 24
4.5 Warning symbols 25
4.5.1 Positions of the warning symbols 25
4.5.2 Layout of the warning symbols 26
4.5.3 Description of the warning symbols 27
4.6 Threaded cartridge 32
4.7 3-point mounting frame 32
4.8 Rating plate on the implement 33
4.9 Universal operating tool 33
4.10 Universal joint shaft locking
mechanism 34
4.11 Lighting and identification for
road travel 34
4.11.1 Rear lighting and identification for
road travel 34
4.11.2 Front lighting and identification 35
4.11.3 Additional license plate 35
4.12 T-Pack tyre packer 36
4.13 Rollers 36
4.13.1 AMAZONE rollers 36
4.13.2 Packer rollers from other
manufacturers 37
4.14 Oil cooler 37
5Technical data 38
5.1 Dimensions 38
5.2 Permissible total weight 38
5.3 Mounting category 38
5.4 Working speed 38
5.5 Working depth 39
5.6 Performance characteristics of
the tractor 39
5.7 Noise development data 40
5.8 Drivable slope inclination 40
5.9 Lubricants 40
5.10 Oils and filling capacities 40
5.11 Maximum transport speed 42
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5.12 Permissible payload 42
6Preparing the machine 43
6.1 Calculating the required tractor
characteristics 43
6.2 Attaching the backstop profiles
for the lower links 46
6.3 Preparing the universal joint shaft 46
6.4 Installing the universal joint shaft
on the implement 47
6.5 Using the centre line eradicator 48
6.6 Using the hydraulic top link 48
6.7 Coupling the implement 49
6.7.1 Driving the tractor towards the
implement 49
6.7.2 Coupling the 3-point mounting frame 50
6.7.3 Coupling the hydraulic hose lines 50
6.7.4 Coupling the power supply 52
6.7.5 Coupling the universal joint shaft 52
6.7.6 Coupling the power supply for
additional fan 53
6.8 Preparing the implement for
operation 54
6.8.1 Adjusting the speed of the tines 54
6.8.2 Adjusting the section end position 56
6.8.3 Using the centre line eradicator 57
6.8.4 Manual adjustment of the tine
working depth 57
6.8.5 Hydraulic adjustment of the tine
working depth 60
6.8.6 Adjusting the working height of the
levelling board 61
6.8.7 Adjusting the working depth of the
side guide plates 62
6.8.8 Adjusting the T-Pack tyre packer 63
6.8.9 Preparing the wheel mark
eradicator for operation 64
6.8.10 Preparing the track marker for
operation 67
6.8.11 Adjusting the spring tension of the
side guide plates 69
6.8.12 Adjusting the scraper to the roller 70
6.9 Preparing the machine for road
travel 71
6.9.1 Folding in the track marker 71
6.9.2 Folding the implement 71
6.9.3 Coupling the transport frame 72
6.9.4 Transport width with installed
potato tines 73
6.9.5 Telescoping the track marker 74
6.9.6 Fixing the T-Pack tyre packer 74
7Using the machine 76
7.1 Uncoupling the transport frame 76
7.2 Unfolding the implement 77
7.3 Using the implement 77
7.4 Checking the set working depth 78
7.5 Turning on the headlands 78
7.6 Using the track marker 78
8Eliminating faults 79
9 Parking the machine 83
9.1 Unfolding the implement 83
9.2 Lowering the implement 84
9.3 Uncoupling the power supply 84
9.4 Uncoupling the additional fan
power supply 85
9.5 Disconnecting the hydraulic
hose lines 85
9.6 Uncoupling the universal joint
shaft 86
9.7 Uncoupling the 3-point mounting
frame 86
10 Repairing the machine 87
10.1 Maintaining the machine 87
10.1.1 Maintenance schedule 87
10.1.2 Checking the lower link pins and
top link pins 88
10.1.3 Checking the hydraulic hose lines 89
10.1.4 Checking the wheel bolt tightening
torque 89
10.1.5 Checking the tyre inflation pressure 90
10.1.6 Checking the tines 90
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10.1.7 Replacing the tines 91
10.1.8 Checking the oil level in the manual
transmission 92
10.1.9 Checking the oil level in the angular
gearbox 92
10.1.10 Checking the oil level in the spur
gear trough 93
10.1.11 Changing the oil of the manual
transmission 94
10.1.12 Changing the oil of the angular
gearbox 95
10.1.13 Replacing the oil filter 96
10.1.14 Checking the wheel mark
eradicator coulter 97
10.1.15 Ratchet clutch maintenance 97
10.1.16 Universal joint shaft maintenance 98
10.2 Lubricating the implement 99
10.2.1 Overview of lubrication points 100
10.3 Cleaning the implement 102
11 Disposing of the implement 103
12 Loading the implement 104
12.1 Loading the implement with a
crane 104
12.2 Lashing the implement 105
13 Appendix 106
13.1 Bolt tightening torques 106
13.2 Other applicable documents 107
14 Directories 108
14.1 Glossary 108
14.2 Index 109
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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
1.2.3.1 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
1.2.3.2 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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1.2.3.3 Alternative instructions
Alternative instructions are introduced with the word
"or".
Example:
1. Instruction 1
or
Alternative instruction
2. Instruction 2
1.2.3.4 Instructions with only one action
Instructions with only one action are not numbered,
but rather shown with a arrow.
Example:
Instruction
1.2.3.5 Instructions without sequence
Instructions that do not require a specific sequence
are shown as a list with arrows.
Example:
Instruction
Instruction
Instruction
1.2.3.6 Workshop work
WORKSHOP WORK
Identifies maintenance work that must be
performed at a workshop that is adequately
equipped in terms of agricultural technology,
safety and environmental technology by
specialist personnel with appropriate training.
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1.2.4 Lists
Lists without an essential order are shown as a list
with bullets.
Example:
Point 1
Point 2
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 Safe operating organisation
2.1.1.1 Personnel qualification
2.1.1.1.1 Requirements for persons working with the implement
If the implement is used improperly, people can
be injured or killed: To prevent accidents due
to improper use, every person who works with
the implement must meet the following minimum
requirements:
The person is physically and mentally capable of
checking the implement.
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.
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2.1.1.1.2 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".
2.1.1.1.3 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.
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
2.1.1.1.4 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
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Activity examples:
Driving the machine
Adjusting the working depth
2.1.1.2 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.
2.1.1.3 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.
2.1.1.4 Operational safety
2.1.1.4.1 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.
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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 machine.
Repair safety-relevant damage immediately.
Fix the damage according to this operating manual.
If you are not able to  the damage according to this operating manual yourself:
Have the damage repaired 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.
2.1.1.4.2 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.
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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.
2.1.1.4.3 Warning symbols
Keep warning symbols legible
Warning symbols on the machine warn you of risks in danger areas and are an important element of
the machine's safety equipment. Missing warning symbols increase the risk of serious and lethal personal
injury.
Clean dirty warning symbols.
Immediately replace any damaged and illegible warning symbols.
Put the intended warning symbols on spare parts.
2.1.2 Knowing and preventing dangers
2.1.2.1 Safety hazards on the implement
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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Risk of injury on the universal joint shaft
Persons can be caught, pulled in and severely injured by the universal joint shaft and driven components. If
the universal joint shaft is overloaded, the implement can be damaged, parts can be ejected at high speed,
and persons can be injured.
Maintain sufficient coverage of the profile tube, universal joint shaft guard and PTO shaft protective
cap.
Maintain the direction of rotation and the permissible speed of the universal joint shaft.
If the universal joint shaft is angled down too strongly:
Switch off the universal joint shaft drive.
If you do not need the universal joint shaft:
Switch off the universal joint shaft drive.
Risk of injury on the PTO shaft
Persons can be caught, pulled in and severely injured by the PTO shaft and driven components. If the PTO
shaft is overloaded, the implement can be damaged, parts can be ejected at high speed, and persons can
be injured.
Maintain sufficient coverage of the profile tube, universal joint shaft guard and PTO shaft protective
cap.
Allow the locks on the PTO shaft to engage.
To secure the universal joint shaft guard against rotating:
Hook on the safety chains.
To secure the coupled hydraulic pump against rotating:
Put on the torque support.
Maintain the direction of rotation and the permissible speed of the PTO shaft.
To prevent implement damage due to torque peaks:
Slowly couple the PTO shaft at low tractor engine speed.
Danger due to machine parts still running
When the drives are switched off, machine parts can continue running and cause serious personal injury or
death.
Before approaching the machine, wait until any machine parts that are still running have come to a
stop.
Only touch machine parts that are standing still.
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2.1.2.2 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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2.1.3 Safe operation and handling of the machine
2.1.3.1 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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2.1.3.2 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.
2.1.4 Safe maintenance and modification
2.1.4.1 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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2.1.4.2 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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