LUCAS Castor 134 User manual

22 rue du stade –85130 LA VERRIE –Tél. [phone] Réf : D370-019
INSTRUCTION MANUAL
INSTRUCTION MANUAL –MASTER VERSION
PLEASE READ CAREFULLY BEFORE USING THE MACHINE.

- 1 - D370-019
PREFACE
This machine is a semi mounted machine designed for feeding herds.
It provides :
. Storage of silage, complements and all types of straw, hay and wrapped bales.
. Mixing and, if necessary, cutting these different products.
. Transport of loaded products to the distribution site.
. The distribution of loaded products.
. Straw distribution for a herd's litter
This instructions manual provides all information required for correct operation of the
machine, as well as adjustment and maintenance procedures.
It has been drawn up for the CASTOR 134 and 185 line, please refer to the paragraphs
relating to your machine.
Some of the illustrations in this user's manual may have been made on the basis of
prototype machinery. The standard production models may differ with respect to certain
details.
TO OBTAIN TOP PERFORMANCE FROM YOUR MACHINE PLEASE READ CAREFULLY ALL
INSTRUCTIONS PROVIDED.
KEEP THESE INSTRUCTIONS TO HAND FOR LATER CONSULTATION AND PASS THEM ON
TO ANY OTHER USER, INCLUDING UPON SELLING THE MACHINE.
Information level
WARNING
Information relative to your safety.
IMPORTANT
Information concerning the risk of damaging your machine.
NOTE
Further information.

- 2 - D370-019
SAFETY RULES
1. The other chapters of the instruction leaflet contain further indications that you must also follow for
your own safety.
2. Comply at all times with the safety rules as set out in the pictograms glued onto the machine for that
purpose.
3. Remember that the watchwords for your safety are caution and vigilance.
4. Proper maintenance will ensure maximum safety, correct operation and a longer life for your machine.
5. Keep the safety devices in position at all times.
6. Do not wear loose clothing, long hair hanging free or jewellery liable to get caught or jammed in the
moving parts of the machine.
7. Rules and regulations relating to accident prevention and safety, industrial medicine, environmental
protection and road traffic must be followed at all times.
8. Whenever the machine is being moved, the hand brake lever must be connected to the tractor. When
driving on public roads, observe the highway code and particularly with the 25 kph or 40 kph speed
limit according homologation.
9. The machine must be controlled by a single person who has been trained to use it. In the event of use
by a trainee or a temporary outside worker, the owner must advise and train the user in the rules of
safety and correct use.
10. Ensure that the area around the machine is clear of people, animals and obstructions when starting up
and during operations.
11. It is strictly forbidden to use the machine for transporting people, animals, or objects of any kind.
12. Never attempt to remove matter from the machine until it and the tractor have both come to a
complete stop (this recommendation is highly important for jobs using the distribution outlet where
there is a risk of mutilating a finger or hand on the support plate or on the sections of the beater-bar).
Whatever the type of intervention to be carried out (greasing, adjusting, maintenance, ...), first stop
the tractor engine. Disconnect all energy sources (transmission shafts, hydraulic and electrical take-off).
13. Whenever you hear a sound or feel a vibration out of the ordinary, stop the machine, find and remove
the cause of the trouble before resuming work. If necessary, call your dealer.
14. Before doing any work on the machine, first ensure that it cannot be started up accidentally.
15. Before operating the machine, check that all screws, bolts and connectors are tight. Tighten where
necessary..
16. Before operating the machine, after any adjustment or maintenance operation, check that all protective
devices are in place and in an adequate state of repair, and that they are properly locked.
17. Do not step on any part of the machine other than areas designed for the purpose (ladder).
18. All remote controls (cable, hose, etc) must be positioned in their intended places so as to prevent them
from accidentally triggering some manoeuvre liable to cause an accident or other damage.
19. In case the machine is equipped with a magnetic extraction the persons wearing a cardiac simulator
must stand at least 2 m far from the distribution chute.
NOTE : All references to "right" and to "left" in this booklet concern the corresponding direction as
seen from the rear of the machine looking towards the front.

- 3 - D370-019
IDENTIFICATION OF THE MACHINE
This machine is identified by a "MAKER'S" plate located on the right-hand side of the
machine.
You can note down your machine characteristics below.
Kits are identified too by a “MAKER’s” plate
located on the kit edge.
DO NOT REMOVE THE PLATES MOUNTED ON YOUR MACHINE.
WHAT TO DO IN THE EVENT OF A BREAKDOWN
In the event of a failure or breakdown with your machine, you should contact your
dealer :
LUCAS.G
To avoid any confusion when ordering spare parts you will be asked to give the serial
number of your machine.
NOTE
Spare parts that have been disassembled will not be covered by the warranty.

- 4 - D370-019
CONTENTS
PREFACE......................................................................................................................... 1
SAFETY RULES ................................................................................................................ 2
IDENTIFICATION OF THE MACHINE................................................................................ 3
WHAT TO DO IN THE EVENT OF A BREAKDOWN.............................................................. 3
CONTENTS ...................................................................................................................... 4
DESCRIPTION OF THE SAFETY PICTOGRAMS .................................................................. 5
DESCRIPTION OF THE OPERATION PICTOGRAMS ........................................................... 6
TECHNICAL CHARACTERISTICS ...................................................................................... 7
1 - START-UP .................................................................................................................. 9
1.1. HANDLING AND STORAGE ............................................................................................... 9
1.2. TRACTOR FITTINGS ....................................................................................................... 9
1.3. COUPLING ............................................................................................................... 10
1.4. CHECKING HYDRAULIC FUNCTIONS.......................................................................... 11
1.5. CHECKING ROTATING PARTS .......................................................................................... 23
2 - OPERATION............................................................................................................. 24
2.1. LOADING................................................................................................................. 24
2.2. LOADING USING THE HYDRAULIC DOOR (OPTIONAL)............................................................... 25
2.3. TRANSPORT -STORAGE ............................................................................................... 27
2.4. DISTRIBUTION .......................................................................................................... 27
2.5. STRAW SPREADING..................................................................................................... 31
2.6. OPERATING FAILURES AND REMEDIES................................................................................ 33
2.7 WEIGHING................................................................................................................ 37
3 - MAINTENANCE ........................................................................................................ 38
3.1. MAINTENANCE POINTS ................................................................................................. 38
3.2. LUBRIFICATION PLAN................................................................................................... 41
3.3. MAINTENANCE METHODS .............................................................................................. 42
3.4. REMOVAL AND STORAGE ............................................................................................... 46
3.5. DISMANTLING AND DISPOSAL......................................................................................... 46

- 5 - D370-019
DESCRIPTION OF THE SAFETY PICTOGRAMS
Caution : rotating parts.
Before carrying out any
maintenance please wait a
minute and a half until the
rotating elements are
completely stopped, which is
indicated either by the clicking
sound of the transmission free
wheel or by the gearbox handle
rotation.
Risk of objects being
discharged or projected.
Keep at a safe distance
from the projection area
while the machine is
running.
Read the user manual.
It is absolutely forbidden
to climb into the machine
body.
Danger of chopping off fingers
or the whole hand between the
fan blades and the back plate or
the sections of the beater-bar.
Use some implement when
clearing jammed material.
During operation, no one
must stand close to the
machine
Risk of crushing the fingers or
the whole hand.
Never move your hand towards
running mechanisms.
Stop the engine and
remove the key before
carrying out any
maintenance work.
Maximum authorised speed in
Kph

- 6 - D370-019
DESCRIPTION OF THE OPERATION PICTOGRAMS
Maximum permitted
rotation frequency at
the machine input.
Grease according to frequencies
indicated in the maintenance
paragraph in the user manual.
Periodically check the tightness of the
wheels and the tyre pressures.
Keep warning notices and pictograms clean and visible at all times. Ask your dealer for fresh
stickers if they become damaged. The part number is indicated on the bottom right side of the
sticker.
When making repairs, ensure that spare parts carry the same stickers as the original parts.

- 7 - D370-019
TECHNICAL CHARACTERISTICS
CASTOR 134
Recommended power (CV) :
Frame interior dimensions
Loading capacity (m3)
80
4.2 X 1.65 X 1.84
13
Empty weight (kg)
Gross vehicle weight rating (kg)
4 600
11 000
Toothed beater-bar
Side for distribution
Straw spreading side Standard
Option
Drive
Road lighting
2 fan rotation speeds
at 540 rpm Pto
Braking
Standard tyre fitting
Noise Db(A)
Maximum authorised speed (kph)
3
Right
Right
270° spreading area
Power take off
540 rpm.
Yes
278 /540
hydraulic
315 / 80 –R22.5
77
25

- 8 - D370-019
CASTOR 185
Recommended power (CV) :
Frame interior dimensions
Loading capacity (m3)
80
5.6 x 1.65 x 1.84
18
Empty weight (kg)
Gross vehicle weight rating (kg)
5 100
11 000
Toothed beater-bar
Side for distribution
Straw spreading side Standard
Option
Drive
Road lighting
2 fan rotation speeds
at 540 rpm Pto
Braking
Standard tyre fitting
Noise Db(A)
Maximum authorised speed (kph)
3
Right
Right
270° spreading area
Power take off
540 rpm.
Yes
278 / 540
hydraulic
31/80 –R 22.5
77
25

- 9 - D370-019
1 - START-UP
1.1. HANDLING AND STORAGE
The machine must be stored taking a minimum of precautions :
- Machine on the ground, stable
- Rear door closed and chute in the low position.
- Ensure stems on all actuators are greased when kept in storage. Prior to operation,
these same rods should be cleaned with a cloth moistened with diesel fuel and then
dried with a clean, dry cloth.
- Once uncoupled, the transmission must not be laid on the ground, but must rest on the
mounting provided for the purpose.
- The parking brake on.
1.2. TRACTOR FITTINGS
Hydraulic fittings
* Hydraulic source
. A single-acting hydraulic distributor (+ return) or a double-acting one (two female ½ clack valves).
. Distributor maintained in continuous pumping.
. Direct return to the tank recommended so as to reduce oil heating.
. For self-regulating pumps, compulsory return to the bowl.
* Nominal flow rate : L8: 30 l - M8: 40 l - H8: 50 l (L - Low, M - Medium, H - High)
* Maximum pressure (bar) : 160.
* Circuit tape :
. The machines are factory set for open centre hydraulics.
* Closed centre hydraulics adaptation : Consult us
IMPORTANT
The machine is capable of handling flows of up to 100 l/min. However, in order to save fuel, it is
recommended that you adapt the flow to the belt advance rate being used (L, M, H). Above 55
l/min, the additional flow will be unusable and will use up energy.
IMPORTANT
In order for the controls to work in the right direction, make sure never to connect the hoses blue
and red mark on the tractor the wrong way around.
OIL POLLUTION IS NOT COVERED BY THE WARRANTY, KEEP THE VALVES CLEAN
ELECTRIC FITTINGS
Standard 12V 7 contact
connector (European
code)
POWER TAKE-OFF
6 straight 1"3/8
splines
EYE BOLT COUPLING
with safety pin or fork
joint coupling
ELECTRICAL
CONNECTION
3 pin 12 volt DIN 9680 for
power supply
CAUTION : Current
required 25 A
HYDRAULIC BRAKE
CONNECTOR

- 10 - D370-019
1.3. COUPLING
1.3.1 Fixed coupling gear
Position the machine horizontally on level ground or on a level in relation to the ground.
Ensure that the coupling ring is at the same height as the tractor coupling.
If this is not the case, make the necessary adjustment with the holed plates connecting
to the coupling jib by turning the jib a hole.
WARNING
Before coupling the machine, make sure the front axle ballasting on the tractor is adequate.
IMPORTANT
Ballasting weights must be inserted into the holders provided for the purpose in accordance
with the tractor manufacturer's instructions. The load on the front axle must not be less
than 20% of the tractor's empty weight.
WARNING
Take precautions to avoid getting trapped between the tractor and the machine. When using
the machine during travel, no one will be found placed between the tractor and the
machine.
WARNING
Check that both the tractor and the machine brakes are really on.
1.3.2. Checking the transmission shaft
Follow instructions contained in the maker's transmission instructions manual delivered
with your machine.
WARNING
To avoid any damage the turning circle tractor/machine must always been less than the
angle the shaft drive transmission does accept (80° in standard and 60° in wide angle
option).
WARNING
To avoid damage to the transmission shaft, do no raise the lifting mechanism too high.

- 11 - D370-019
1.4. CHECKING HYDRAULIC FUNCTIONS
WARNING
Before using it, even empty, make sure there are no foreign bodies in the tank. Also
make sure that nobody is near the equipment when it is being inspected or in use.
1.4.1. Machines with INTUITIVE PRO control
1.4.1.1. Tractor equipment
For optimum use of the control unit, you must fit the control in the cabin using the stand
provided.
1.4.1.2. Components of the INTUITIVE PRO control system
The control is located in the cabin, mounted on the stand provided. It is comprised of:
Green LED (1)
Buzzer
Shortcut buttons (Supply (2), Diagnostic (3), Information (4), Menu (5))
Screen control buttons (6 to 15)
1 joystick
Key + (17) / - (16)
2 3 4 5
1
6 7
8 9
10 11
12 13
14 15
16 17

- 12 - D370-019
1.4.1.3 - On/Off
Once all of the electrical connections have been made, the interface screen will be lit (all
white) when it is first switched on.
1.4.1.3.1 - Switch on
To turn on the control unit, you must hold down the "Supply" button (button 1) for 1
second
After 1 second, the screen will be supplied and will:
Emit a short "beep".
The icons on the screen will appear.
The green LED will flash.
1.4.1.3.2 - Stop
Once you have used the machine, you must switch off the control.
In order to switch off the control and the machine, you must hold down the "Supply"
button (button 1) for 2 seconds
After 2 seconds, the computer will take into account the shutdown request and will:
Emit a short "beep".
Switch off the screen
Switch off the LED
The supply for the computer will be cut after 1 second.
1.4.1.4 –General cases
1.4.1.4.1 - Return automatically to the control page
If the buttons and the joystick on the interface are inactive for a period of 10 minutes, the
display will automatically switch over to the manual control page.
This setting can be adjusted (see procedure by an accredited individual).

- 13 - D370-019
1.4.1.4.2 - Menu pages
You can still access the menu using the shortcut button (button n°4).
Menu page 1 Menu page 2
You can switch between pages using the buttons corresponding to "<" and ">"
Icon
Description
Details
Inform
Lets you access information, such as the software version,
etc.
Control
Used to control the different functions of the machine
Diagnostic
Lets you access the machine's error codes
Configure
Lets you access the machine configuration
Inspect
Gives you different information, such as the machine
configuration, the status of inputs/outputs, etc.
Adjust
Lets you adjust certain machine parameters
Maintenance
Lets you approve maintenance once performed
Secure
Access the interface safeties
Transfer
Transfer images from the ECU to the interface (for
accredited personnel only. It takes roughly 3 minutes to
transfer images - during this time, the LED will flash and
you will hear beeping sounds)

- 14 - D370-019
1.4.1.4.3 - Control pages
What is displayed on the control pages may differ depending on how the machine is
configured and which options are selected.
Right chute
The right chute is controlled using the joystick on the control.
To raise the chute, pull and hold the joystick up (Y+).
To lower the chute, pull and hold the joystick down (Y-).
When released, the joystick will go back to neutral and control will stop.
If your machine is equipped with a claw, please refer to this section.
Swivel chute
The swivel chute is controlled using the joystick on the control unit
To raise the chute, pull and hold the joystick up (Y+).
To lower the chute, pull and hold the joystick down (Y-).
To turn it left, pull and hold the joystick left (X-).
To turn it right, pull and hold the joystick right (X+).
Please note: you can move on two axes at the same time, e.g. raise up and rotate left,
etc.
When you release it, the joystick will go back to neutral and control will stop.
If your machine is equipped with a claw, please refer to this section.
Tip the chute
You can tip the chute using the buttons next to the screen.
To tip the chute, you must press and hold down on the button to the right of the icon
To get the chute back in position, press and hold down on the button to the left of the icon
Inactive
Active
When the buttons are released, the functions will return to inactive state.

- 15 - D370-019
Picker door
The picker door is controlled using the buttons next to the screen.
To raise the door, press and hold down on the button to the right of the icon
Inactive
Active
To lower the door, press and hold down on the button to the left of the icon
Inactive
Active
When the buttons are released, the functions will return to inactive state.
Articulated comb (hydraulic)
The articulated barrier/blade is controlled using the buttons next to the screen.
To move the comb forward, press and hold down on the button to the right of the icon
Inactive
Active
To move the comb backwards, press and hold down on the button to the left of the
icon
Inactive
Active
When the buttons are released, the functions will return to inactive state.

- 16 - D370-019
Integrating hopper
Mixing auger
The hopper can be switched on or off using the buttons next to the screen.
To switch on the auger, press the button to the right of the icon
To stop the screw, press the button to the left of the icon
Inactive
Active
When the buttons are released, the functions will remain active or inactive.
Distribution hatch
The distribution hatch can be controlled using the buttons next to the screen.
To open the hatch, press and hold down on the button to the right of the icon
Inactive
Active
To close the hatch, press and hold down on the button to the left of the icon
Inactive
Active
When the buttons are released, the functions will return to inactive state.

- 17 - D370-019
Adjustable loading floor
The loading floor can be adjusted - speeds go up in increments between 0-9, following 3 different
curves. At speed 0, the floor will not move; at 9, it will move at top speed.
Strart-up
1. Switch the power grip on
2. Press then release button 14 next to the icon .
Inactive
Active
3. When the loading floor has been activated, use the buttons 16 (+) and 15 (-) to increase or
decrease the speed of the floor. The speed will change when the button is released.
Note :
Holding down on the buttons:
Button (+) for 2 seconds will switch to max speed when the button is held down. When the
button is released, the speed will go back to the previous speed.
Button (-) for 2 seconds will switch (after decelerating) to reverse and to max speed when
the button is held down. The information "R" will be displayed while in reverse.
When the button is released, the speed will return to its previous speed minus 1.
Stop
Press then release button 14 to the right of the icon .
Particularities
Speed curves
M 3
Corresponds to curve M and speed 3
This system has 3 programmed speed curves, called "L", "M" and "H": "Low", "Medium" and "High"
respectively.
These curves do not change the maximum speed, which is reached at 9 (identical on 3 curves).
The 3 curves are linear, enabling the user to make more precise adjustments.
With curve L, the differences in speed at low speed will be low.
With curve H, the differences in speed at low speed will be higher, and the acceleration higher.
To change curve, press button 13 - the curves switch in the order L->M->H->L, etc.

- 18 - D370-019
If the available speeds don't correspond to the products you're using, you can modify the gears on
the right, which drive the loading floor.
To do so:
-Loosen and disassemble the chain
-Reverse the direction of the drive sprocket
-Replace the chain
-Tighten the chain (see maintenance chapter
Shredder frequency too low
If the rotation frequency is too low, the letter "E" will be displayed instead of the speed
for a few seconds and the speed of the loading floor will return to 0.
In this case,
Check if power grip has been activated; if not, switch it on safely
Check the status and the functioning of the shredder rotation sensor
…

- 19 - D370-019
Atomiser
The atomiser is an optional extra for projecting liquid during mulching in order to reduce the
emission of dust.
Strart-up
1.Press then release the button closest to the icon .
Inactive
Active
2.Once the atomiser is ready, it will only be triggered if the loading floor is active and turning in
a forward direction. If the loading floor stops, the atomiser will be disengaged (stopping the
propulsion of liquid) but will remain active until you deactivate it. If the loading floor starts
moving again, atomisation will began again without you having to do anything.
Stop
1.To deactivate the atomiser (when it is active), press on the same button as for deactivation.
Inactive
Active
Second control box
The second control post is a remote control post for the control. While the second post function is
active, no functions (which can be controlled from the secondary post) can be used on the main
control unit. Similarly, if the function has not been activated, the remote controls will be inactive.
To activate the remote controls, press and release the button next to the icon
Inactive, remote control
not possible
Active, remote control possible
To deactivate the remote controls and to regain control over the main control unit, press and release
the button to the left of the icon