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Tatu Marchesan GAPCW-EP Operator's Manual

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GAPCW-EP
GAPCW-EP
OPERATOR'S
MANUAL

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  • Page 1 GAPCW-EP GAPCW-EP OPERATOR’S MANUAL...
  • Page 2 IDENTIFICATION Dealer: Owner: Firm / Farm: City: State: No. of the Certificate of Guarantee: Serial / No.: Date: Invoice No.: Product: Notes:...
  • Page 3 Introduction The GAPCW-EP disk harrow was designed to work in any kind of soil, with excellent application on the soil preparation for annual crops, sugar cane etc. The heavy-duty structure with proper dimensioning is made of bent steel plates joined by a good penetration weld and fine finishing, with tough parts in the load concentration.

  • Page 4: Table Of Contents

    Table of contents 1. To the owner 2. To the operator 04 to 11 3. Data sheet 12 & 13 4. Components 5. Assembly 15 to 34 Using the set of wrenches Assembly of bearings and spacer spools 16 to 19 Disc gangs assembly sequence 20 &...

  • Page 5: To The Owner

    To the owner The acquisition of any Tatu product assures to the original purchaser the following rights: • Warranty certificate; • Operator's manual; • Technical assistance by the dealer on equipment delivery. However, the owner must check the condition of the equipment on delivery, as well as knowing the warranty terms.

  • Page 6: To The Operator

    To the operator Be careful with the environment Dear operator! Respect the ecology. Do not throw trash away. This gesture of goodwill helps to protect our environment. Products such as oil, fuel, filters, batteries and others are spilt over the soil and can penetrate to the underground layers, compromising nature.
  • Page 7 To the operator Never use your bare hands to check hydraulic leaks, the high pressure can cause injuries. Never attempt to change the adjustments, clean or lubricate the equipment when the same is switched on or in movement. Be careful while driving on slopes. Risk of overturn. Prevent that chemical products (i.e.: fertilizers and treated seeds) make any contact with your skin or clothes.
  • Page 8 To the operator • Only trained and qualified personnel are allowed to operate the equipment. • While working or during transportation, only the presence of the operator is allowed in the tractor. • Do not allow children to play or to get over the equipment while it is operating, during transportation or storage.
  • Page 9 To the operator Transportation over truck or trailer Marchesan does not advise the equipment traffic on highways, because this practice involves serious security risks and it is prohibited by the current traffic law. The transportation for long distances should be done on truck, trailer or others by following these safety guidelines: •...
  • Page 10 To the operator Working safety standards It is important to have knowledge not only about the functioning, operation of the equipment and its technology, but also about the working legal aspects when using the equipment, such as safety standards, operator's manual and working safety. The equipment and tools used on the rural area must be properly handled, otherwise health and safety of involved personnel may be compromised.
  • Page 11 To the operator Lifting points This equipment has adequate lifting points located on the frame. When lifting with a hoist, it is essential to hitch the cables to these points. • Use chains of at least 3 meters long to lift the equipment safely. •...
  • Page 12 To the operator Safety decals The safety decals warn about the equipment points that require more attention, and they should be kept in good repair. If these decals become damaged or illegible, replace them. Marchesan provide decals upon request and indication of the respective serial number. A A D D V V E E R R T T Ê...
  • Page 13 To the operator Safety decals Decal set Qty. Model Serial number 05.03.03.4603 GAPCW-EP decal TATU logotype decal 05.03.03.3795 Danger decal 05.03.03.1739 05.03.03.1827 Lubricate and tighten daily decal 05.03.03.4078 Lifting points decal Read the manual decal 05.03.03.1428 Warning decal 05.03.03.1738 05.03.03.3038...

  • Page 14: Data Sheet

    Data sheet Type: ......................Disk Harrow Model: ......................GAPCW-EP Spacing between disc blades (mm): ................340 Disc blades dimension: ......Ø 30" x 7.5 mm, Ø 30" x 9 mm, Ø 32" x 9 mm ............Ø 32" x 12 mm, Ø 34" x 9 mm Disc blade type: ..................Concave notched...
  • Page 15 Data sheet GAPCW-EP dimension (transport position) Height: ......................2,100 mm Width: ......................3,820 mm Length - 30 disc blades: .................. 6,700 mm - 32 disc blades: .................. 7,035 mm - 34 disc blades: .................. 7,370 mm - 40 disc blades: .................. 8,140 mm...

  • Page 16: Components

    Components GAPCW - EP 01 - Front frame 02 - Rear frame 03 - Junction 04 - Front stabilizer bar 05 - Rear stabilizer bar 06 - Hitch bar 07 - Upper and lower plates 08 - Drawbar 09 - Hose support 10 - Clevis hitch 11 - Jack 12 - Drawbar extensor...

  • Page 17: Assembly

    Assembly First of all, put the parts in a clean place to identify them easier. Check the parts using the list that comes inside the packing box. Using the set of wrenches Use two box end wrenches (A) to tighten the nuts of the disc gang, being one to hold the axle nut on one side while the other tighten the nut to the other end, thereby preventing the axle from rotating.

  • Page 18: Assembly Of Bearings And Spacer Spools

    Assembly Disc gangs assembly Before starting to assemble the disc gangs, check the correct position of the bearings and spacer spools. Assembly of bearings and spacer spools GAPCW - EP GAPCW - EP 30 disc blades 30 disc blades 12 bearings 12 bearings 12 spacer spools 12 spacer spools...
  • Page 19 Assembly Assembly of bearings and spacer spools GAPCW - EP GAPCW - EP 32 disc blades 32 disc blades 12 bearings 12 bearings 14 spacer spools 14 spacer spools Spacer spool Spacer spool Bearing Bearing GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU” S.A.
  • Page 20 Assembly Assembly of bearings and spacer spools GAPCW - EP GAPCW - EP 34 disc blades 34 disc blades 12 bearings 12 bearings 16 spacer spools 16 spacer spools Spacer spool Spacer spool Bearing Bearing GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU” S.A.
  • Page 21 Assembly Assembly of bearings and spacer spools GAPCW - EP GAPCW - EP 40 disc blades 40 disc blades 16 bearings 16 bearings 16 spacer spools 16 spacer spools Spacer spool Spacer spool Bearing Bearing GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU” S.A.

  • Page 22: Disc Gangs Assembly Sequence

    Assembly Disc gangs assembly sequence • Place the outer washer (A) along with the axle (B). • Tighten the nut (C) passing 5 mm from the axle face. • Place the disc blades (D), bearings (E) and spacer spools (F) following the instructions on the previous page.
  • Page 23 Assembly Disc gangs assembly sequence Torque table Axle diameter Ft. - lbs. 1.1/2" 2670 1.5/8" 2890 1.3/4" 3020 2" 3150 The axle threads (B) must be cleaned NOTE and greased before their assembly. 2.1/8" 3300 Check the torque table on the 'important 2.1/2"...

  • Page 24: Assembly Of The Disc Gangs On The Frame

    Assembly Assembly of the disc gangs on the frame IMPORTANT The rear gang turns earth to the left and the front gang turns earth to the right. In the gang assembly to the carriers, the bearing hangers should remain facing the disc blades concavity.
  • Page 25 Assembly Scrapers assembly Couple the fixation tube (A) to the frame using the plates (B), bolts (C), flat washers and nuts. Right after, assemble the scrapers (D) with the plates (E) that are coupled to the fixation tube (A) using bolts (F), flat washers and nuts.
  • Page 26 Assembly Junction extension assembly Install the junction extension (A), divide the thread center to center and determine a length of 1,150 mm (115 cm) from the center of the fixation pins. 1,150 mm 1,150 mm Shock absorber assembly Install the shock absorber (B) to the front frame using a bolt (C) and spring washer. GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU”...

  • Page 27: Front And Rear Stabilizer Bars Assembly

    Assembly Front and rear stabilizer bars assembly Install the front (A) and rear (B) stabilizer bars using axles (C), flat washers, spring washers and bolts. Stabilizer bars cylinder assembly In the front stabilizer (A), install the hydraulic cylinder (B) and fasten using a junction axle (C) and cotter pin.

  • Page 28: Assembly Of The Wheelset Arms

    Assembly Assembly of the wheelset arms Install the wheelsets arms (A) to the bushings (B) using a ring (C), bolts (D), spring washers and nuts. Wheelset locks and cylinders assembly Install the wheelset cylinders (E), along with the wheelset lock (F) using an axle (G), cotter pin, axle (H) and the cotter pin that locks the wheelset arm (I) in a lifted position.
  • Page 29 Assembly Assembling the hubs to the wheelset arms Install the hubs (A) to the wheelset arms (B) using a bolt (C), spring washer and nut. Tires assembly Install the tires (D) on the hubs (A) using the nuts fixed on the hubs. GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU”...

  • Page 30: Traction Set Assembly

    Assembly Traction set assembly Couple the hitch bar (A) to the frame arms (B) using a junction axle (C) and cotter pin. Assemble the upper (D) and lower (E) plates, carefully observing their correct position. Avoid to put them inverted and lock them using an axle (F), flat washer, castle nut and cotter pin.
  • Page 31 Assembly Hose support and jack assembly Install the hose support (A) using flat washers and nuts; install the jack (B) using an axle and cotter pin. Drawbar articulation set assembly Assemble the hydraulic cylinder (A), the articulator (B) and the extensor (C), with their respective axles and cotter pins.

  • Page 32: Hydraulic Circuit Valves Assembly

    Assembly Hydraulic circuit valves assembly F a s t e n t h e f l o w divider valve (A) to the s u p p o r t o n t h e f r o n t frame (B) using a bolt, spring washer and nut.
  • Page 33 Assembly Hydraulic circuit assembly "Blue" "Blue" Return Return "Black" "Black" Lifting Lifting cylinders cylinders "Red" "Red" Pressure Pressure "Purple / Red" "Purple / Red" Opening cylinder Opening cylinder "Purple / Blue" "Purple / Blue" Opening cylinder Opening cylinder GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU”...

  • Page 34: Hydraulic Circuit

    Assembly Hydraulic circuit (30 - 32 disc blades) Number Description Qty. 1/2" x 800 TR-TC hose Pressure Pressure Return Return 1/2" x 900 TR-TC hose 1/2" x 5500 TR-TM hose Pressure Pressure 1/2" x 5500 TR-TM hose Return Return Pressure Pressure 3/8"...
  • Page 35 Assembly Hydraulic circuit (34 - 40 disc blades) Number Description Qty. 1/2" x 800 TR-TC hose Pressure Pressure Return Return 1/2" x 900 TR-TC hose 1/2" x 5500 TR-TM hose Pressure Pressure 1/2" x 5500 TR-TM hose Return Return Pressure Pressure 3/8"...

  • Page 36: Depth Stops Location

    Assembly Assembly of the hitch for transportation Install the complement (A) of the transport drawbar using the lock bushing (B), fixation washers (C) and bolts (D) with spring washers. SMV sign assembly Install the SMV sign (E) to the junction (F). Depth stops location The depth stops (G) must be placed on the opening cylinder rod.

  • Page 37: Set-Up Instructions

    Set-up instructions The following instructions must be carefully observed in order to get the best working performance. Preparing the tractor The addition of water ballasts in the tires and a set of weights on the front part and rear wheels of the tractor are the most used ways to increase the soil traction and give greater stability to the tractor.

  • Page 38: Hitching To The Tractor

    Set-up instructions Hitching to the tractor Approach the tractor and couple the hoses (A) to the quick couplers. To do so, shut down the engine, relieve the control valve pressure by activating the lever a couple of times and check if the quick couplers are clean.

  • Page 39: Hitching The Equipment To The Tractor For Transportation

    Set-up instructions Hitching the equipment to the tractor for transportation Being the disk harrow retreated and locked with the pin (A) and cotter pin, proceed as follows: • Articulate the hitch bar (B) with the help of the cylinder (C) until reaching the transport position.
  • Page 40 Set-up instructions • Couple the hoses (G) that activate the wheelsets to the quick couplers of the tractor. To do so, shut down the engine, relieve the control valve pressure by activating the lever a couple of times and check if the couplers are clean. •...
  • Page 41 Set-up instructions • Place the transport locks (K) to the drawbar cylinder and place the locks (L) to the wheelset cylinders. ATTENTION Never loose or remove the hoses before relieving the control valve pressure. A speed of 30 km/h is safe for the transportation. Maintain the harrow leveled during transportation.

  • Page 42: Hitching To The Tractor To Operate The Harrow

    Set-up instructions Hitching to the tractor to operate the harrow Being the harrow in transport position and already at the working place, proceed as follows: • Relieve and remove the safety locks from the three cylinders (wheelsets and drawbar) and fasten them to the respective unused spots. •...

  • Page 43: Adjustments And Operations

    Adjustments and operations The GAPCW-EP harrow has an "OFFSET" profile and are well adjusted when the disc blades from the rear gang pass over the center of the spacing from the disc blades on the front gang and when their rotation are equivalent, that is, when they have the same number of rotations in a determined space.

  • Page 44: Tractor Position Related To The Previous Pass - Lateral Displacement

    Adjustments and operations 2) Drawbar angle The holes (B) in the upper and lower plates determine a greater or smaller cutting width, and also performs a small lateral displacement of the harrow. In normal working conditions, the drawbar must operate on the central hole of the upper and lower plates.

  • Page 45: Drawbar Articulation Extensor Adjustment

    Adjustments and operations Fixation holes on the hitch bar The fixation holes on the hitch bar (A) on the front frame are used to obtain a better drawbar leveling related to the height of the tractor drawbar. Drawbar articulation extensor adjustment The articulation extensor (B) adjustment is done on the field and being the disc blades with a normal working depth.

  • Page 46: Ways To Start The Harrowing

    Adjustments and operations Ways to start the harrowing Regardless of the format and size of the field, the harrowing is made basically in two ways: from outside to inside or from inside to outside. Entrance Entrance Entrance Entrance Harrowing in squares Harrowing in squares Harrowing in squares Harrowing in squares...

  • Page 47: Correct Harrowing

    Adjustments and operations Correct harrowing Correct Correct Incorrect Incorrect IMPORTANT • Never pass the tires over an already harrowed soil. GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU” S.A.

  • Page 48: Direction Of The Maneuvers

    Adjustments and operations Direction of the maneuvers As previously mentioned, the harrow provides several working angles to operate properly in all types of soil. However, this harrow requires certain care during operations, like never making maneuvers to the right, because the angle formed on its vertex transmits great effort to the equipment, overloading traction components such as the hitch bar, the drawbar and other fixation parts.

  • Page 49: Troubleshooting Guide

    Adjustments and operations Troubleshooting guide PROBLEM CAUSES POSSIBLE SOLUTIONS Too much angle on the front Reduce the angle from the front gang or gang or too small on the rear increase the angle from the rear gang. Tractor steering gang. wheel pulling to the right.
  • Page 50 Adjustments and operations Troubleshooting guide PROBLEM CAUSES POSSIBLE SOLUTIONS Quick couplers Different type of quick Use male and female quick couplers from do not adapt. couplers. the same type. Insufficient tightening. Retighten carefully. H o s e s l e a k i n g w i t h f i x e d Lack of sealing material on the...

  • Page 51: Operations - Important Points

    Adjustments and operations Operations - important points • Retighten nuts and bolts after the first day of work and check the conditions of all pins and cotter pins. Then, retighten every 24 operating hours. • Carefully observe the lubrication intervals. •...
  • Page 52 Adjustments and operations Operations - important points • To carry out any verification on the equipment, lower it to the ground and shut down the tractor engine. • Whenever unhitching the equipment, either in the field or shed, do it on a flat and firm place and use the jacks.

  • Page 53: Maintenance

    Maintenance Lubrication To reduce the wear caused by the friction caused by the moving parts of the equipment, it is necessary to carry out a proper lubrication, as indicated below: 1) Every 24 hours of service, lubricate every grease fitting. •...

  • Page 54: Lubrication / Lubrication Points

    Maintenance Lubrication points Lubricate every 24 hours of service. Lubricate every 100 hours of service. NOTE Lubricate the points shown above and all grease fittings as well. GAPCW - EP Marchesan Implementos e Máquinas Agrícolas “TATU” S.A.

  • Page 55: Wheelset Hubs Lubrication

    Maintenance Wheelset hubs lubrication The wheelset hubs must be lubricated every 150 hours. When the existence of any clearance is noticed, carry out a maintenance on the wheel hubs. Disassemble the hubs and remove their internal components. Clean all parts using diesel oil or kerosene.

  • Page 56: Hydraulic Cylinder Maintenance / Assembly

    Maintenance Hydraulic cylinder maintenance When cylinder repair is required, clean off the unit, disconnect hoses and plug ports before removing the cylinder. When removed, open the cylinder ports and drain the cylinder's hydraulic fluid. Examine the type of cylinder. Make sure you have the correct tools for the job. You may require the following tools: •...
  • Page 57 Maintenance Hydraulic cylinder assembly Reassembly: 1) Reinstall rod through gland (E) and end cap (A); 2) Secure piston (C) to rod with lock nut (D). Torque lock nut to proper value (consult torque table on the "important data" section); 3) Lube inside of barrel, piston seals and gland seals with hydraulic oil; 4) With cylinder body held gently, insert the inner assemblies (B) using a slight rocking motion;...

  • Page 58: Hydraulic Safety

    Maintenance Hydraulic safety Make sure that all components in the hydraulic system are kept in good condition and are clean. Carry out the maintenance of the hydraulic parts on a clean place, free from dust or contaminants. Otherwise, there may have malfunction or premature wear on the equipment.

  • Page 59: Disk Harrow Maintenance

    Maintenance Disk harrow maintenance • During offseason, wash the equipment, repair any damaged paintwork, protect the disc blades with oil, lubricate all grease fittings and store the disk harrow in a covered and dry place, avoiding the direct contact of the disc blades with the soil. •...

  • Page 60: Tires Inflation

    Maintenance Tires inflation The tires must always be properly inflated to avoid premature wear for excess or lack of pressure. Do not attempt to mount the tires without experience and adequate equipment. Maintain the correct tire pressure. Never inflate the tires beyond the recommended pressure.

  • Page 61: Important Data

    R = 6.096 x 6,000 x 0.90 10,000 R = The hourly income using a GAPCW-EP disk harrow with 40 disc blades will be approximately 3.29 hectares per hour. The harrow hourly income can vary by physical factors such as humidity,...

  • Page 62: Average Income Table

    To know how many hours will be spent to work a certain previously known area, it is necessary to divide the value of the area by the hourly income. Example: an area of 50 hectares to be worked using a GAPCW-EP with 40 disc blades (hourly income = 3.29 ha).

  • Page 63: Torque Table

    Important data Torque table The table below gives correct torque values for various bolts. Tighten all bolts to the torques specified in chart unless otherwise noted. Check the tightness of bolts periodically, using this bolt torque chart as a guide. Replace hardware with the same strength (grade/ class) bolt.

  • Page 64: Important

    Important MARCHESAN S/A reserves the right to make improvements in the design, ATTENTION material or specifications of machinery, equipment or parts at any time, without thereby becoming liable to make similar changes in machinery, equipment or parts previously sold. Images are for illustration purposes only. Some illustrations in this manual appear without the safety devices, removed to allow a better view and detailed instructions.
  • Page 66 www.marchesan.com.br...

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