Tatu Marchesan GNCRP Operator'S Manual Download

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GNCRP / GNCRPE / GNCRPE 230 - Rev. 03 - Aug/22

8. Maintenance

Troubleshooting guide

- Only

CAPABLE

QUALIFIED

and

AUTHORIZED

personnel must carry out the

maintenance of the equipment.

IMPORTANT

PROBLEM

CAUSES

POSSIBLE SOLUTIONS

Hydraulic

cylinder leaking.

Damaged repairings.

Replace the repairings.

Damaged rod.

Replace the rod.

Oil with impurities.

Replace the oil, repairings and filter elements.

Working pressure superior

than the recommended one.

Adjust the control valve using the

relief valve with the aid of a pressure

gauge.
Normal pressure: 180 kgf/cm

Hoses leaking

with fixed

terminals.

Insufficient tightening.

Retighten carefully.

Lack of sealing material on the

thread.

Use thread sealing tape and retighten

carefully.

Damaged repairings.

Replace the repairings.

Locked disc

gangs.

Wet field.

Let the field dry out or penetrate the disc

blade superficially to help the drying

process.

Maximum angle on the disc

gangs adjustment.

Reduce the angle.

Deep penetration on wet soil.

Use the depth stops to decrease the

depth.

Lift the disc blade to reduce the

penetration.

Worn out / incorrectly

adjusted scrapers.

Adjust or change the scrapers when

necessary.

Summary of Contents for GNCRP

Page 1: ...OPERATOR S MANUAL GNCRP GNCRP GNCRPE GNCRPE GNCRPE 230 GNCRPE 230...

Page 2: ...Dealer Owner Firm Farm City State No of the Certificate of Guarantee Serial No Date Invoice No Product Notes IDENTIFICATION...

Page 3: ...ty This manual contains the necessary information for the best performance of your equipment The operator and the maintenance staff must carefully read the entire manual before working with the equipm...

Page 4: ...to 68 6 Set up instructions 69 to 75 Preparing the tractor Preparing the equipment 69 70 Hitching to the tractor hydraulic connection Hitching to the tractor 70 to 73 Jack position Important recommen...

Page 5: ...enance of the equipment The instructions in this manual indicates how to get the best performance and allow the operator to get maximum income increasing the equipment lifetime This manual should be r...

Page 6: ...and observed If the safety instructions are not being followed a serious accident or even death may occur Dear operator Respect the ecology Do not throw trash away This gesture of goodwill helps to pr...

Page 7: ...s and treated seeds make any contact with your skin or clothes Keep access and work places clean or free from oil and grease Risk of accidents Never transport the equipment on highways or paved roads...

Page 8: ...mble the tires Only capacitated personnel must do this job Never weld or heat a wheel The heat can cause increase in pressure with a risk of tire explosion When filling up the tires position yourself...

Page 9: ...hands and arms from the abrasive elements that may cause cuts or scratches Whenever assembling or elements that may cause cuts or scratches Whenever assembling or disassembling the equipment always u...

Page 10: ...ome entangled to the moving parts of the equipment 8 Never operate the equipment without its protective devices 9 Have full knowledge of the soil before starting to work Use the speed which is suitabl...

Page 11: ...suggest that you carefully read the manual as it will be a guide for periodic verifications that need to be done and will allow that you assure the maintenance of your equipment 20 Fasten the safety c...

Page 12: ...y by all overtaking and oncoming traffic 8 After 8 to 10 km transporting please inspect the load condition Repeat this procedure every 80 to 100 km Give more attention when transporting the equipment...

Page 13: ...work Regulatory Standard NR 12 This Regulatory Standard and its annexes provide technical references basic principles and protective measures to ensure the health and physical integrity of workers an...

Page 14: ...rotective gloves and other PPE as required Use chains of at least 3 meters long to lift the equipment safely Use the adequate points for lifting and be sure that the equipment is safe Avoid accidents...

Page 15: ...ion of the respective serial number Para evitar acidentes instale as travas dos cilindros antes do transporte ou antes de efetuar servi os no equipamento In order to avoid accidents activate cylinder...

Page 16: ...06 2027 2 GNCRPE GNCRPE 230 decal 05 03 03 4007 2 Tatu logotype decal 05 03 03 4070 1 Warning decal 05 03 03 1738 4 Lifting points decal 05 03 03 4078 1 Read the manual decal 05 03 03 1428 1 Lubricat...

Page 17: ...e of the equipment The GNCRP GNCRPE and GNCRPE 230 disk harrows were designed to carry out harrowing complementation on the soil clod breaking it evenly and leaving it in conditions for plantation and...

Page 18: ...Data sheet GNCRP Model Model Number of Number of disc blades disc blades Cutting width Cutting width mm mm Approximated Approximated weight kg weight kg Tractor required Tractor required power cv pow...

Page 19: ...ar Working speed 7 to 12 km h Transport speed 30 km h 3 Data sheet GNCRPE NOTE The weights above were quoted using 22 x 4 5 mm notched disc blades The tractor required engine power may change accordin...

Page 20: ...sheet GNCRPE 230 NOTE The weights above were quoted using 24 x 6 mm mixed disc blades The tractor required engine power may change according to the conditions of the field Model Model Number of Numbe...

Page 21: ...19 GNCRP GNCRPE GNCRPE 230 Rev 03 Aug 22 3 Data sheet Dimensions for transportation and storage GNCRP 32 to 60 disc blades GNCRPE 36 to 60 disc blades A A B B C C D D...

Page 22: ...50 60 1260 1450 6250 6070 Model Model Number of Number of disc blades disc blades A A B B C C D D GNCRPE 36 1260 1450 5260 3660 40 1260 1450 5300 4140 44 1260 1450 6060 4490 48 1260 1450 6115 4890 52...

Page 23: ...21 GNCRP GNCRPE GNCRPE 230 Rev 03 Aug 22 GNCRP 64 to 72 disc blades GNCRPE 230 28 to 72 disc blades 3 Data sheet Dimensions for transportation and storage A A B B C C D D...

Page 24: ...910 56 1400 1570 8300 6380 60 1400 1570 8360 6830 64 1400 1570 8430 7275 68 1400 1570 8500 7720 72 1400 1570 8550 8160 GNCRP 64 to 72 disc blades GNCRPE 230 28 to 72 disc blades 3 Data sheet Dimension...

Page 25: ...sc blades 01 Frame 08 Hoses 02 Front frame 09 Wheel 03 Rear frame 10 Hydraulic cylinder 04 Stabilizer bar 11 Front disc gang 05 Hitch bar 12 Rear disc gang 06 Drawbar 13 Hose support 07 Spindle 03 03...

Page 26: ...7 Spindle 02 Front frame 08 Hose support 03 Rear frame 09 Wheel 04 Stabilizer bar 10 Hydraulic cylinder 05 Hitch bar 11 Front disc gang 06 Drawbar 12 Rear disc gang GNCRP 40 to 60 disc blades 03 03 01...

Page 27: ...afety chain 02 Front frame 08 Hose support 03 Rear frame 09 Wheel 04 Stabilizer bar 10 Hydraulic cylinder 05 Drawbar 11 Front disc gang 06 Jack 12 Rear disc gang GNCRP 64 to 72 disc blades 03 03 10 10...

Page 28: ...7 Spindle 02 Front frame 08 Hose support 03 Rear frame 09 Wheel 04 Stabilizer bar 10 Hydraulic cylinder 05 Hitch bar 11 Front disc gang 06 Drawbar 12 Rear disc gang GNCRPE 36 to 60 disc blades 03 03 0...

Page 29: ...1 Frame 07 Wheel 02 Front frame 08 Hydraulic cylinder 03 Rear frame 09 Front disc gang 04 Stabilizer bar 10 Rear disc gang 05 Drawbar 11 Jack 06 Hose support GNCRPE 230 28 to 40 disc blades 01 01 03 0...

Page 30: ...blades 4 Components 01 Frame 07 Wheel 02 Front frame 08 Hydraulic cylinder 03 Rear frame 09 Front disc gang 04 Stabilizer bar 10 Rear disc gang 05 Drawbar 11 Jack 06 Hoses 12 Hose support 01 01 03 03...

Page 31: ...ox end wrench B is used to tighten the nuts on the traction set The box end wrench C is used to tighten the nuts of the bearing bolts The L type socket wrench D is used to tighten the nuts that fasten...

Page 32: ...nd spacer spools GNCRP Assembly of bearings and spacer spools 32 disc blades 32 disc blades 08 DM bearings 08 DM bearings 20 spacer spools 20 spacer spools 08 shims 08 shims 36 disc blades 36 disc bla...

Page 33: ...er spools 40 disc blades 40 disc blades 12 DM bearings 12 DM bearings 24 spacer spools 24 spacer spools 08 shims 08 shims 44 disc blades 44 disc blades 12 DM bearings 12 DM bearings 28 spacer spools 2...

Page 34: ...cer spools 48 disc blades 48 disc blades 12 DM bearings 12 DM bearings 32 spacer spools 32 spacer spools 08 shims 08 shims 52 disc blades 52 disc blades 12 DM bearings 12 DM bearings 36 space spools 3...

Page 35: ...er spools 56 disc blades 56 disc blades 12 DM bearings 12 DM bearings 40 spacer spools 40 spacer spools 04 shims 04 shims Bearing Bearing Spacer spool Spacer spool Shims Shims 56 disc blades 56 disc b...

Page 36: ...er spools 60 disc blades 60 disc blades 16 DM bearings 16 DM bearings 40 spacer spools 40 spacer spools 08 shims 08 shims Bearing Bearing Spacer spool Spacer spool Shims Shims 60 disc blades 60 disc b...

Page 37: ...y of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 64 disc blades 64 disc blades 12 DMO bearings 12 DMO bearings 48 spacer spools 48 spacer spools 68 disc blades 68 disc blades...

Page 38: ...spacer spools 36 disc blades 36 disc blades 08 DM bearings 08 DM bearings 24 spacer spools 24 spacer spools 08 shims 08 shims GNCRPE Bearing Bearing Spacer spool Spacer spool Shims Shims 72 disc blade...

Page 39: ...er spools Bearing Bearing Spacer spool Spacer spool Shims Shims 40 disc blades 40 disc blades 12 DM bearings 12 DM bearings 24 spacer spools 24 spacer spools 08 shims 08 shims 44 disc blades 44 disc b...

Page 40: ...er spools 48 disc blades 48 disc blades 12 DM bearings 12 DM bearings 32 spacer spools 32 spacer spools 08 shims 08 shims 52 disc blades 52 disc blades 12 DM bearings 12 DM bearings 36 spacer spools 3...

Page 41: ...er spools Bearing Bearing Spacer spool Spacer spool Shims Shims 56 disc blades 56 disc blades 12 DM bearings 12 DM bearings 40 spacer spools 40 spacer spools 04 shims 04 shims 60 disc blades 60 disc b...

Page 42: ...embly of bearings and spacer spools 28 disc blades 28 disc blades 08 DM bearings 08 DM bearings 16 spacer spools 16 spacer spools Bearing Bearing Spacer spool Spacer spool 32 disc blades 32 disc blade...

Page 43: ...embly of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 36 disc blades 36 disc blades 12 DM bearings 12 DM bearings 20 spacer spools 20 spacer spools 40 disc blades 40 disc blade...

Page 44: ...embly of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 44 disc blades 44 disc blades 12 DM bearings 12 DM bearings 28 spacer spools 28 spacer spools 48 disc blades 48 disc blade...

Page 45: ...embly of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 52 disc blades 52 disc blades 12 DM bearings 12 DM bearings 36 spacer spools 36 spacer spools 56 disc blades 56 disc blade...

Page 46: ...embly of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 60 disc blades 60 disc blades 12 DM bearings 12 DM bearings 44 spacer spools 44 spacer spools 64 disc blades 64 disc blade...

Page 47: ...embly of bearings and spacer spools Bearing Bearing Spacer spool Spacer spool 68 disc blades 68 disc blades 16 DM bearings 16 DM bearings 44 spacer spools 44 spacer spools 72 disc blades 72 disc blade...

Page 48: ...5 Use the wrenches from the set of wrenches page and tighten the gangs a Place one of the wrenches on the outer side of the gangs locked side and support it on the soil as shown on the next page b Us...

Page 49: ...Ft lbs 1 1 4 1840 1 1 2 2670 1 5 8 2890 1 3 4 3020 2 3150 2 1 8 3300 2 1 2 3500 2 3 4 3750 3 4000 NOTE The axle B threads must be cleaned and greased before their assembly Check the torque table page...

Page 50: ...es page and tighten the gangs a Place one of the wrenches on the inner side of the gangs locked side and support it on the soil as shown on the next page b Use the other wrench on the outer side and t...

Page 51: ...1 1 4 1840 1 1 2 2670 1 5 8 2890 1 3 4 3020 2 3150 2 1 8 3300 2 1 2 3500 2 3 4 3750 3 4000 NOTE The axle B threads must be cleaned and greased before their assembly Check the torque table page on the...

Page 52: ...ugh the bearing hanger hole D On the upper part place a square washer B nut and counternut C C B E D A For the equipment models that have bearing scrapers 1 On the other bearing hanger D hole place a...

Page 53: ...rs 1 On the other bearing hanger D hole place a bolt A and square washer passing them through the bearing housing F and through the bearing hanger hole E on the upper part place the scraper G and fast...

Page 54: ...ounternut C 2 Note the scrapers fixation position and assemble them with their end facing the disc blades concavity 3 Repeat this operation on the other bearings NOTE The scrapers feature an adjustmen...

Page 55: ...nd nut 3 Assemble the scraper B and the shim D using bolts E which are placed underneath the fixation plate on the upper part place flat and spring washers and nuts 5 Assembly Scraper Scraper option 1...

Page 56: ...frame A using bolts B washers and nuts C 2 Note that the bolts B are placed from the bottom to the top GNCRP 40 to 60 disc blades GNCRP 40 to 60 disc blades GNCRPE 36 to 60 disc blades GNCRPE 36 to 6...

Page 57: ...he frame A using bolts B square washer D washers and nuts C 2 Note that the bolts B are placed from the bottom to the top GNCRPE 230 28 to 72 disc blades GNCRPE 230 28 to 72 disc blades 1 Fasten the f...

Page 58: ...inder ports to their correct position 1 Loosen up the pin B and cotter pin letting the cylinder barrel free NOTE When assembling the cylinder the ports A must be facing up and the cylinder rod must be...

Page 59: ...n the wheel axle D using a junction axle and cotter pin E GNCRP 32 and 36 disc blades GNCRP 32 and 36 disc blades GNCRPE 230 28 to 40 disc blades GNCRPE 230 28 to 40 disc blades A A B B E E D D C C 1...

Page 60: ...in E GNCRP 40 to 72 disc blades GNCRP 40 to 72 disc blades GNCRPE 36 to 60 disc blades GNCRPE 36 to 60 disc blades GNCRPE 230 44 to 72 disc blades GNCRPE 230 44 to 72 disc blades A A B B E E D D C C N...

Page 61: ...ng bolts D washers nuts and counternuts on the frame B 2 Assemble the bearing C on the bearing complement A using bolts E washers nuts and counternuts E E D D B B A A C C D D C C A A B B Tires assembl...

Page 62: ...lated to the frame The wheel support axle B must have no clearance on the bearing 5 Assembly F F GNCRP 32 and 36 disc blades GNCRP 64 to 72 disc blades GNCRPE 36 to 60 disc blades GNCRPE 230 28 to 72...

Page 63: ...ng bolts E and nuts Observe that all nuts must be on the upper part of the drawbar 3 Fasten the universal joint F in the center of the hitch bar using the supports G bolts H spring washers and nuts 5...

Page 64: ...ing axles C flat washers castle nuts and cotter pins GNCRP 64 to 72 disc blades GNCRPE 230 28 to 72 disc blades H H J J I I D D E E F F G G 2 Assemble the spring rod D on the drawbar E U using a pin F...

Page 65: ...sten the extensor B to the wheel arm D using a pin F clamp and cotter pin 3 Fasten the stabilizer bar B to the drawbar support C using a pin E clamp and cotter pin F F E E A A B B D D C C 1 Couple the...

Page 66: ...ilizer bar assembly 5 Assembly 1 Fasten the support B to the wheel arm D with a junction axle G and cotter pin 2 Fasten one of the ends of the stabilizer bar A to the drawbar support C using a junctio...

Page 67: ...n to search for high pressure hydraulic leaks GNCRP 32 to 60 disc blades GNCRPE 36 to 60 disc blades GNCRP 32 36 disc blades GNCRP 32 36 disc blades Item Item Quantity Quantity Description Description...

Page 68: ...ORTANT Hydraulic circuit 5 Assembly GNCRPE 230 28 and 40 disc blades Item Item Quantity Quantity Description Description 01 01 3 8 X 7500 TM TM hose Return Return 02 01 3 8 X 7500 TM TM hose Pressure...

Page 69: ...e soil When finishing to assemble the hydraulic hoses carry out a general inspection to check if all hose ports are tightened and if they are properly installed IMPORTANT Hydraulic circuit 5 Assembly...

Page 70: ...fitting 08 04 O ring 09 02 Male quick coupler 1 2 NPT with cap GNCRPE 230 44 72 disc blades GNCRPE 230 44 72 disc blades Item Item Quantity Quantity Description Description 01 01 3 8 X 7500 TR TM hos...

Page 71: ...r are the most used ways to increase the soil traction and give greater stability to the tractor Check if the tractor is in its full condition before using it The drawbar is used to get a better power...

Page 72: ...es inflation page in the maintenance section 6 Lubricate all grease fittings appropriately see the lubrication page in the maintenance section Hitching to the tractor hydraulic connection 1 Approach t...

Page 73: ...equipment for the job the tractor equipment must be leveled related to the soil Besides that the tractor must be hitched to the equipment hitch to avoid unnecessary efforts during the set up GNCRPE 23...

Page 74: ...ower the hitch to align it with the tractor drawbar 3 Hitch the drawbar E to the tractor drawbar using a pin F Use the bushing G on the hitch and a pin F that matches with it Note that the tractor dra...

Page 75: ...the tractor model However the hitch and the hoop must pass through the chain links as shown on the illustration below Never hitch the hook without passing it through the chain When towing the equipmen...

Page 76: ...spindle above the nut and locknut Such adjustment must be kept both in transportation and at work Lower the disk harrow so that the disc gangs rest on the ground Adjust the spindle nuts only until the...

Page 77: ...sed the safety locks must be fixed on the disk harrow on their appropriate place Keep the tractor drawbar fixed during working and transportation Never remove the hoses without lowering the disk harro...

Page 78: ...ndition and use safety glasses foot protection earplugs muffs protective gloves and any other required PPE Do not carry out any adjustment while the equipment is working ATTENTION RISK OF ACCIDENT IMP...

Page 79: ...disk harrow cutting width Whenever possible the tractor should pass far from the last furrow The displacement is done by changing the position of the drawbar on the hitch bar Normal position centrali...

Page 80: ...point change the stabilizer bar C fixation to the hole E to let it as short as possible Then change the points as necessary C C E E IMPORTANT When adjusting the lateral displacement it is also necess...

Page 81: ...of furrows or untilled strips 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 Harrowing in squares Harrowing...

Page 82: ...also avoids the undesirable formation of large furrows in the local maneuvers As previously mentioned this disk harrow provides several working angles to operate properly in all types of soil However...

Page 83: ...ressure as stated on the maintenance section tires inflation page 7 Speed is relative to the tractor gear and can only be determined by local conditions We adopted an average 7 to 12 km h which is not...

Page 84: ...e closer to each other 19 Relieve the control valve pressure before disconnecting the quick couplers and when doing any verification in the hydraulic cylinders 20 The tractor drawbar must remain fixed...

Page 85: ...th works in constant lubrication but it is still necessary to give them the following attention 1 In a flat place check the oil level of each bearing before using the disk harrow for the first time an...

Page 86: ...h 32 to 60 and GNCRPE model with 36 to 60 disc blades is 130 ml The oil volume on the DM bearings of the GNCRPE 230 model with 28 to 72 disc blades is 190 ml Lubrication 8 Maintenance NOTE Duromark st...

Page 87: ...85 GNCRP GNCRPE GNCRPE 230 Rev 03 Aug 22 NOTE Lubricate the points shown above and all grease fittings as well Lubricate every 24 hours of service 8 Maintenance Lubrication points...

Page 88: ...ment as well as a higher cost for repairing it because when the bearing breaks during work more parts of the set gets damaged 1 Check the retainer A position to allow that the excess of grease gets ou...

Page 89: ...as well as a higher cost for repairing it because when the bearing breaks during work more parts of the set gets damaged 1 Check the retainer A position to allow that the excess of grease gets out and...

Page 90: ...wear The bearing must be replaced in a preventive way to avoid breaking it and the unavailability of the equipment as well as a higher cost for repairing it because when the bearing breaks during wor...

Page 91: ...nder Make sure you have the correct tools for the job You may require the following tools Proper seal kit Screwdriver and rubber cable Pliers and wrenches Ports Ports Disassembly 1 Remove the end cap...

Page 92: ...nstall 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 seal...

Page 93: ...ness on the barrel or other problems consequently leading to internal leakages lack of power gripping damages to the cylinder rods etc Do not attempt any makeshift repairs to the hydraulic lines fitti...

Page 94: ...or being positioned far on the right Position the tractor in a way that the front disc on the left pass on the edge of the furrow Incorrect adjustment of the disc gangs laterally Move the rear disc ga...

Page 95: ...rol valve using the relief valve with the aid of a pressure gauge Normal pressure 180 kgf cm2 Hoses leaking with fixed terminals Insufficient tightening Retighten carefully Lack of sealing material on...

Page 96: ...erly tightened To assure a great performance and avoid wear and rupture these bolts must be tightened every so often Check wear occurence on all moving parts Replace any part if necessary Replace the...

Page 97: ...losion Welding can compromise the structure of the wheel or distort it When filling the tires make sure the hose is long enough for you to stand Also do this process in a safety cage 6 50 x 16 tires 6...

Page 98: ...X Where R Hourly income L Disk harrow working width meters V Average speed of the tractor meters per hour E Efficiency 0 90 X Hectare value 10 000 m2 Example with a GNCRP 32 disc blades R L 3 1 m V 7...

Page 99: ...48 4 70 2 96 26 65 52 5 10 3 21 28 92 56 5 50 3 47 31 19 60 5 90 3 72 33 45 64 6 20 3 91 35 19 68 6 58 4 15 37 35 72 6 92 4 36 39 24 Model Model Number of Number of disc blades disc blades Cutting wi...

Page 100: ...Example An area of 50 hectares to be worked with a GNCRP that has 32 disc blades hourly income 1 95 hectares So 50 25 64 1 95 Approximately will be spent 25 twenty five hours to work in an area of 50...

Page 101: ...336 455 616 3 4 10 167 226 5 269 5 365 4 380 5 516 0 M 18 x 1 5 96 5 130 854 257 348 49 378 512 568 3 4 16 186 252 2 300 406 8 424 5 575 6 M 20 x 2 5 121 5 164 754 323 5 438 67 475 644 1 7 8 9 169 5...

Page 102: ...ar without the safety devices removed to allow a better view and detailed instructions Never operate the equipment without these safety devices ATTENTION MARCHESAN IMPLEMENTOS E M QUINAS AGR COLAS TAT...

Page 103: ...trabajo 11 No efectuar regulajes con el equipo en funcionamiento 12 No permitir que ni os jueguen sobre o pr ximo de los equipos en operaci n durante el transporte o almacenado 13 La velocidad de ope...

Page 104: ...www marchesan com br...

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