Amazone KG 6002-2 Installation instructions

Original operating manual
Rotary cultivator
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 Diagrams 1
1.1.1 Warnings and signal words 1
1.1.2 Further instructions 1
1.1.3 Instructions 2
1.1.4 Lists 3
1.1.5 Item numbers in figures 3
1.2 Other applicable documents 4
1.3 Your opinion is important 4
2Safety and responsibility 5
2.1 Basic safety instructions 5
2.1.1 Safe operating organisation 5
2.1.2 Knowing and preventing dangers 10
2.1.3 Safe operation and handling of the
machine 13
2.1.4 Safe maintenance and modification 16
2.2 Safety routines 20
3Intended use 23
4 Product description 24
4.1 Implement overview 24
4.2 Function of the implement 25
4.3 Special equipment 26
4.4 Protective equipment 27
4.4.1 Universal joint shaft guard 27
4.4.2 Tool protection 27
4.4.3 Frame transport lock 28
4.4.4 Roller transport lock 28
4.5 Warning symbols 29
4.5.1 Positions of the warning symbols 29
4.5.2 Layout of the warning symbols 30
4.5.3 Description of the warning symbols 31
4.6 Threaded cartridge 35
4.7 3-point mounting frame 36
4.8 Rating plate on the implement 36
4.9 Universal operating tool 37
4.10 Universal joint shaft locking
mechanism 37
4.11 Lighting and identification for
road travel 38
4.11.1 Lighting and identification to the rear 38
4.11.2 Lighting and identification to the front 38
4.12 Additional license plate 39
4.13 Rollers 39
4.13.1 Wedge ring roller KW 39
4.13.2 Wedge ring roller with matrix tyre
profile 40
4.13.3 Tooth packer roller PW 40
4.13.4 Trapeze ring roller TRW 40
4.14 Oil cooler 41
5Technical data 42
5.1 Dimensions 42
5.2 Permissible total weight 42
5.3 Mounting category 42
5.4 Working speed 43
5.5 Working depth 43
5.6 Performance characteristics of
the tractor 43
5.7 Noise development data 44
5.8 Drivable slope inclination 44
5.9 Lubricants 44
5.10 Oils and filling capacities 45
6Preparing the machine 47
6.1 Calculating the required tractor
characteristics 47
6.2 Adjusting the 3-point mounting
frame 50
6.3 Installing the universal joint shaft
on the implement 50
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6.4 Using the centre line eradicator 51
6.5 Using the hydraulic top link 52
6.6 Coupling the implement 53
6.6.1 Coupling the 3-point mounting frame 53
6.6.2 Coupling the hydraulic hose lines 53
6.6.3 Coupling the power supply 55
6.6.4 Coupling the universal joint shaft 56
6.6.5 Coupling the power supply for
additional fan 56
6.7 Preparing the implement for
operation 57
6.7.1 Uncoupling the transport frame 57
6.7.2 Unfolding the implement 58
6.7.3 Manual working depth adjustment 59
6.7.4 Hydraulic adjustment of the working
depth 62
6.7.5 Adjusting the working depth of the
levelling board 63
6.7.6 Adjust the working depth of the side
guide plates 64
6.7.7 Adjusting the spring tension of the
side guide plates 64
6.7.8 Adjusting the scraper to the roller 65
6.7.9 Preparing the track marker for
operation 66
6.7.10 Preparing the wheel mark
eradicator for operation 68
6.7.11 Adjusting the speed of the tines 71
6.7.12 Adjusting the section end position 73
6.8 Preparing the machine for road
travel 74
6.8.1 Folding in the track marker 74
6.8.2 Folding the implement 74
6.8.3 Coupling the transport frame 75
6.8.4 Transport width with installed potato
tines 77
6.8.5 Telescoping the track marker 77
6.9 Calculating the permissible
payload 78
7Using the machine 79
7.1 Using the implement 79
7.2 Checking the set working depth 79
7.3 Using the track marker 80
7.4 Turning on the headlands 80
8Parking the machine 81
8.1 Unfolding the implement 81
8.2 Lowering the implement 82
8.3 Uncoupling the power supply 82
8.4 Disconnecting the hydraulic
hose lines 83
8.5 Uncoupling the 3-point mounting
frame 83
8.6 Uncoupling the universal joint
shaft 84
9Repairing the machine 85
9.1 Maintaining the machine 85
9.1.1 Maintenance schedule 85
9.1.2 Checking the top link pin and lower
link pin 86
9.1.3 Checking the hydraulic hose lines 87
9.1.4 Checking the wheel bolt tightening
torques 87
9.1.5 Checking the tines 88
9.1.6 Replacing the tines 88
9.1.7 Checking the oil level in the manual
transmission 89
9.1.8 Checking the oil level in the angular
gearbox 90
9.1.9 Checking the oil level in the spur
gear trough 90
9.1.10 Changing the oil of the manual
transmission 91
9.1.11 Changing the oil of the angular
gearbox 92
9.1.12 Replacing the oil filter 93
9.1.13 Checking the wheel mark eradicator
coulter 94
9.1.14 Ratchet clutch maintenance 95
9.1.15 Universal joint shaft maintenance 95
9.2 Lubricating the implement 96
9.2.1 Overview of lubrication points 97
9.3 Eliminating faults 99
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9.4 Cleaning the machine 102
10 Loading the machine 103
10.1 Lifting the implement 103
10.2 Lashing the machine 104
11 Appendix 105
11.1 Bolt tightening torques 105
11.2 Other applicable documents 106
12 Directories 107
12.1 Glossary 107
12.2 Index 108
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About this operating manual 1
1.1 Diagrams
1.1.1 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.
1.1.2 Further instructions
IMPORTANT
Indicates a risk for damage to the
implement.
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ENVIRONMENTAL INFORMATION
Indicates a risk for environmental
damage.
NOTE
Indicates application tips and instructions for
optimal use.
1.1.3 Instructions
Numbered instructions
Actions that have to be performed in a specific
sequence are represented as numbered instructions.
The specified sequence of the actions must be
observed.
Example:
1. Instruction 1
2. Instruction 2
1.1.3.1 Instructions and responses
Reactions to instructions are marked with an arrow.
Example:
1. Instruction 1
Reaction to instruction 1
2. Instruction 2
1.1.3.2 Alternative instructions
Alternative instructions are introduced with the word
"or".
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Diagrams
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Example:
1. Instruction 1
or
Alternative instruction
2. Instruction 2
Instructions with only one action
Instructions with only one action are not numbered,
but rather shown with a arrow.
Example:
Instruction
Instructions without sequence
Instructions that do not require a specific sequence
are shown as a list with arrows.
Example:
Instruction
Instruction
Instruction
1.1.4 Lists
Lists without an essential order are shown as a list
with bullets.
Example:
Point 1
Point 2
1.1.5 Item numbers in figures
A framed number in the text, e.g. a
1
, indicates an
item number in an adjacent figure.
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Diagrams
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1.2 Other applicable documents
A list of other applicable documents can be found in
the Appendix.
1.3 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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Other applicable documents
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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 all persons working with the machine
If the machine is used improperly, people can
be injured or killed. To prevent accidents due
to improper use, every person who works with
the machine must meet the following minimum
requirements:
The person is physically and mentally capable of
controlling the machine.
The person can safely perform work with the
machine within the scope of this operating
manual.
The person understands the functioning of the
machine within the scope of their work and can
recognise and prevent dangers arising during
operation.
The person head understood the operating
manual and can implement the information that is
conveyed in the operating manual.
The person must be familiar with safe driving of
vehicles.
For road travel, the person knows the relevant
road traffic regulations and has the prescribed
driving permit.
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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 implement.
Immediately fix any damage that can affect
safety.
Fix the damage according to this operating
manual.
Any damage that you cannot fix yourself
according to this operating manual must be
fixed by a qualified specialist workshop.
Observe the technical limit values
Non-observance of the technical limits values of
the machine can result in accidents and serious
personal injury or even death. Moreover, the
machine can be damaged. The technical limit
values can be found in the Technical Data.
Comply with the technical limit values.
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2.1.1.4.2 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.
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.
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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 machine
Liquids under pressure
Escaping high pressure hydraulic fluid can
penetrate into the body through the skin and
cause serious personal injuries. A hole the size
of a needle can already result in serious personal
injuries.
Before you uncouple hydraulic hoses or
check them 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 angled
down too much, the implement can be damaged,
parts can be ejected at high speed, and persons
can be injured.
Maintain sufficient coverage of the profile
tube and universal joint shaft guard.
Allow the universal joint shaft locks to
engage.
Secure the universal joint shaft guard against
rotating by attaching the chains.
If the universal joint shaft is angled down
too much,
switch off the universal joint shaft.
If you do not need the universal joint shaft,
switch off the universal joint shaft.
Observe the section "Preparing the universal
joint shaft".
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 to 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.
If the implement is coupled to the 3-point
power lift of the tractor,
make sure that the mounting categories of
the tractor and implement are compatible.
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 payload of 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.
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