Zetor CRYSTAL 160 User Manual

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150

160

Tractor is Zetor. Since 1946.

OPERATOR´S MANUAL

CRYSTAL

1/2015

Table of Contents

Default Chapter4
- Table of Contents4
Location of Serial Numbers12
Safety Instructions for Users14
- General Safety Regulations14
- Proper Clothing14
- Starting the Engine15
- Driving Operation15
- Transportation of Persons, Operation15
- Fire Prevention Principles16
- Preventive Daily Maintenance17
- Front Passenger´s Seat Notification18
- Protection of Cab against Aerosols18
- The Level of External Noise of Tractor19
- The Level of Internal Sound of Tractor19
- The Level of Vibrations on Driver´s Seat19
- Tractors Equipped with Front End Loader20
- Zetor Tractors Used for Work in the Woods21
- Principles for Operating Tractors Equipped with Front End Loader21
Preventive Daily Maintenance22
- Fuel System Leaks22
- Engine Oil Level22
- Cooling System22
- Liquid Brakes23
- Trailer Air Brakes23
- Trailer Hydraulic Brakes23
- Hydrostatic Steering23
- Air Cleaner24
- Cab Filtration24
- Hitches24
- After Work with Front Implements and in Case of Cooler Clogging24
- Tyres and Wheels25
- Short Functional Test25
Acquaintance with the Tractor26
- Safety Cabin26
- Opening the Door from the Outside26
- Opening the Door from the Inside26
- Rear Window27
- Side Window27
- Hinged Lid27
- Adjustable Screen and Cover of the Swing Lid27
- Shelf28
- Rear View Mirrors28
- Internal Lighting28
- Aggregation Opening29
- Driver´s Seat29
- Driver's Seat Sears30
- Passenger´s Seat30
- Control Panel on the Right Column of the Cabin31
- Control Panel on the Right Rear Mudguard31
- Panel of the Instrument Panel31
- Lights Switch32
- Lights Switch between the Grill and the Cabin32
- Switch of Warning Lights32
- Direction Lights, Lower Beam Head Lights, Head Lights and Horn Switches33
- Switch Box33
- Switch Box Key in the Position (0)33
- Switch Box Key in the Position (I)34
- Switch Box Key in the Position (II)34
- Tilting and Protrusion of Steering Wheel34
- Manual Throttle34
- Reversing Lever35
- Gear Shifting Lever35
- Gear Shifting Scheme35
- Pedals35
- Road and Reduced Speeds Shifting Lever36
- PTO Revolutions Preselection Lever36
- Manual Brake Lever and Coupling for Semi-Trailer Control Lever36
- Battery Disconnector37
- Heating Control Panel, * Air-Condition37
- Heating Valve Control (A)37
- Switch Air-Condition (C)38
- Air Circulation in Cabin Control (D)38
- Proper Function of the Heating and Air-Condition System38
- Fast Heating of the Cabin Area39
- Fast Cooling of the Space of the Cabin39
- Operation of Heating or Air-Condition with Tractor´s Work39
- Immediately after Cooling the Cabin39
- Air-Condition and Heating Registers (A)40
- Front Windshield (B) Defrosting40
- Air Filter with Active Carbon41
- Wiper and Washer of the Front Window41
- Front Wiper Speed Switch41
- Rear Window Wiper42
- Windshield Washer Tank42
- Washer Nozzle42
- Fuel Tank43
- Fuel Tank Drain Plug43
- Urea Tank43
Dashboard44
- Instrument Panel - Signal Lamps44
- Instrument Panel - Instruments45
- Instrument Panel - Buttons45
- Display Description46
- Change of the Look of Display46
- Display - Change of Display46
- Display - Resetting Data50
- Display - Manual Brake51
- Display - Indicator of Service Inspection Intervals51
- Exceeding the Service Interval51
- Zeroing (Reset) of the Indicator of Service Inspection Intervals52
- Error Signalling52
- Display - Error Messages53
- Description of the Display of Error Messages53
- Symbols of Tractor Nodes54
- Display - Service Menu54
- Service Menu54
- Display - History of Defects55
- Display - Setting Language Mutation55
- Display - Machined Area56
- Machined Area Menu56
- Machined Area Width56
- Setting of the User-Defined Width of Aggregation57
- Machined Area Record57
- Display - Setting and Calibration58
- Travel Speed Calibration59
- Setting of Steering Sensors of the Front Axle60
- Setting of Time61
- Instrument Panel - Warning61
- Replenish Fuel61
- Add Urea62
- High Temperature of the Cooling Liquid62
- Low Level of the Cooling Liquid62
- High Temperature of the Engine Oil63
- High Air Temperature in the Engine Air Intake System63
- Water in the Coarse Filter of Fuel64
- High Oil Temperature in the Gearbox64
- Full Pushing Filter of the Gearbox Distributor65
- Full Pushing Filter of the Hydraulics65
System of Additional Treatment of Exhaust Gases66
- System of Additional Treatment of Exhaust Gases (SCR)66
- Conditions for System SCR Operation66
- Urea (Aqueous Urea Solution aus 32)66
- Principles for Safe Handling of Urea66
- Limitation of the Engine Power and Engine Revolutions67
- Indication of Amount of Urea in the Tank67
- Long-Term Shutdown of Tractor67
- Repairs and Maintenance of the System of Additional Treatment of Exhaust Gases67
Driving Operation68
- Before You Start68
- If You Do Not Succeed in Starting the Engine68
- Non-Permitted Starting68
- Starting the Engine of the Tractor69
- Blocking of the Start69
- Immediately after Start69
- Engine Heating70
- Error Signalling70
- Indication of the Limitation of the Engine Power and Engine Revolutions70
- Signalling Errors in the System of Additional Treatment of Exhaust Gases71
- Gear Shifting71
- Reversing Lever71
- Reversing Lever Position Signalization72
- Shifting Road and Reduced Speeds72
- Road and Reducing Speeds Lever Position Signalization72
- Driver´s Seat - Safety Switch72
- The Principles of Appropriate Use of Tractors73
- The Description of the System of Travel Clutches73
- The Way of Controlling the Travel Clutch by73
- The Differences in Ways of Controlling the Travel Clutch by73
- Interrupted Sound Signal74
- Dead Start of the Tractor74
- Dead Start of Tractor in Regular Operation - Automatic Dead Start Function74
- Dead Start by Means of Automatic Dead Start Function74
- Dead Start of Tractor in Regular Operation - Clutch Pedal74
- Dead Start - Using the Clutch Pedal75
- Change the Direction of Drive75
- Change the Direction of Drive by Means of Reversing Lever75
- Change the Direction of Drive - Using the Clutch Pedal76
- Gear Shifting76
- Gear Shifting - Using the Clutch Pedal76
- Gear Shifting - Using the Clutch Control Button on the Head of Gear Shifting Lever76
- Blocking the Automatic Dead Start Function76
- Three-Gear Torque Multiplier76
- Signalization of Multiplier Function77
- Increasing, Decreasing the Travel Speed by Two Gears77
- Multiplier Preselection Switch77
- Multiplier Pre-Selection Signalization77
- Automatic Multiplier Shifting78
- Front Drive Axle Control79
- Driving with Engaged Front Axle Drive79
- Manual Front Drive Axle Control79
- Automatic Front Drive Axle Control80
- Axle Lock Control of Rear and Front Axle80
- Automatic Axle Lock Control of Rear and Front Axle81
- Suspension Front Drive Axle81
- Front Drive Axle Suspension Mode Setting82
- Height Adjustment of the Front Part of the Tractor82
- Manual Brake - Signalization83
- Driving down the Slope83
- Foot Brakes84
- Warning Signalization of Air Pressured Drop84
- One-Hose and Two-Hose Brakes84
- One-Hose Brakes84
- Two-Hose Brakes85
- Hydraulic Brakes of Trailers85
- Connecting and Disconnecting Quick Couplings of Trailer Hydraulic Brakes85
- Stopping the Tractor - Manual Brake86
- Stopping the Engine86
- Leaving the Tractor86
- Warning Signalization of Hydrostatic Steering Failure86
- Limiting Travel Speed87
Running in the Tractor88
- General Principles of New Tractor Run-In in First 100 Hours of Operation88
- In First 10 Hours of Operation88
- From 100 Hours of Operation88
Transportation90
- CBM Stage Quick-Adjusting Hitch90
- Height Adjustment and Disassembly of the CBM Stage Hitch90
- Automatic Mouth of the CBM Stage Hitch90
- Modular System of Hitches for Trailers and Semi-Trailers91
- Swinging Draw-Bar Console Module91
- Swinging Draw-Bar Console with a Fixed Pin Module91
- Console with a Ø 80 Ball Module92
- Hitch for a Single-Axle CBM Semi-Trailer92
Drive of Agricultural Machinery96
- Work with PTO Shaft96
- Controlling the Front and Rear PTO Shaft96
- Rear PTO Shaft Revolutions Preselection Lever96
- Standard and Economical Independent Revolutions of Rear PTO Shaft97
- Dependent and Independent Rear PTO Shaft Revolutions97
- Facilitating Connection of Joint Shaft of an Aggregated Machine to the Tractor98
- Selection Switch of Rear PTO Clutch Revolutions (P.T.O.)98
- Replaceable End Points of Rear PTO Shaft99
- Rear PTO Switch99
- Engaging Rear PTO Shaft - Independent Revolutions100
- Engagement of Rear PTO Shaft - Dependent Revolutions100
- Automatic Disengagement of PTO Clutch101
- Setting Automatic Disengagement of PTO Shaft Clutch - Display Description101
- Automatic Disengagement of PTO Shaft Clutch - Return to Basic Setting101
- Setting Automatic Disengagement of PTO Shaft Clutch102
- Work with Automatic Disengagement of PTO Shaft Clutch103
- Front PTO Shaft103
- Front PTO Shaft Control104
- Maximum Transferred Output104
- Drive of Machines with Greater Inertia Masses105
Hydraulic System106
- Hydraulic Pump106
- Control Elements Placement106
- Outer Hydraulic Circuit106
- Connecting and Disconnecting Quick-Couplers107
- Quick-Couplings with Drip Collection107
- Hydraulic Distributor of the Outer Hydraulic Circuit107
- Description of the Functions of Individual Positions of Control Levers of the Hydraulic Distributor108
- Rear Outlets of the Outer Hydraulic Circuit108
- Front Outlets of the Outer Hydraulic Circuit109
- Connecting Machines and Implements to the Outer Hydraulic Circuit109
Electro-Hydraulic System110
- Control Element Functions110
- Equipment 'OFF110
- Blocking Cancellation111
- Quick Sinking111
- Transport of Implements112
- Stop Position112
- Vibration Compensator (Damper)112
- Limitation of the Upper Position of the Three-Point Hitch113
- Lowering Speed113
- Free Position113
- Setting the Control of Three-Point Hitch113
- Manual Setting of Control of Three-Point Hitch114
- Automatic Control of Three-Point Hitch114
- Using the Rear Control115
- External Control Buttons of the Electro-Hydraulic System115
- Indication of EHR-B Errors115
- Description of Signals of EHR-B Electro-Hydraulic System Errors116
- Description of Minor Errors of the EHR-B Electro-Hydraulic System117
Hitches118
- Rear Three-Point Hitch118
- Safety Principles of Working with the Three-Point Hitch118
- Height Adjustment of the Lifting Draw-Bars119
- Fixed and Free Position of the Lower Hydraulic Draw-Bars119
- Limiting Draw-Bars119
- Automatic Limiting Draw-Bars120
- Lower Draw-Bars with CBM Hooks120
- Securing the Lower Draw-Bars with CBM Hooks120
- Upper Draw-Bar121
- Front Three-Point Hitch121
- Adjusting the Lowering Rate of the Front Three-Point Hitch121
- Controlling Front Three-Point Hitch121
- Hydraulic Lock of the Front Three-Point Hitch122
- Working and Transport Position of the Front Three-Point Hitch122
- Driving with Agricultural Machines Attached to the Front Three-Point Hitch122
Wheel Track Change124
- Front Wheels Track of Front Drive Axle in Tractors Equipped with Non-Removable Discs124
- Toe-In of the Wheels of the Front Driving Axle124
- Adjustment of Toe-In of the Wheels of the Front Driving Axle125
- Rear Wheels Wheel Track126
Ballast Weights128
- Rear Wheel Weights128
- Bottom Weights128
- Front Weights128
- Weight of the Front Three-Point Hitch129
- Valve for Filling Tyre Tubes with Liquid129
- Procedure of Draining Liquid from the Tyres130
- Antifreeze Solution for Tyre Filling130
Electric Installation132
- Basic Service Information132
- Accumulator Battery132
- Battery Disconnector133
- Accumulator Battery Maintenance133
- Alternator134
- Alternator Maintenance134
- Electric Installation Overload134
- Fuse Panel135
- Checking the Adjustment of the Front Grill Headlights137
- Adjusting the Front Grill Headlights137
- Checking the Adjustment of the Cab Roof Headlights138
- List of Lamps139
Tractor Maintenance140
- Steps Performed Daily before the Start of Work140
- Steps Performed Every 50 Hours of Work140
- Steps Performed Every 100 Hours of Work140
- Steps Performed Every 500 Hours of Work140
- Steps Performed Outside the Interval of 500 Hours of Work140
- Filling and Filter Replacement141
- Used Operation Liquids and Filling - Quantities142
- ZETOR Service Fillings142
- Motor Oils142
- Specification of Oil for Tractor Transmission Devices142
- Specification of Oil for the Front Driving Axle142
- Other Recommended Service Fillings Tested on Zetor Tractors143
- Oil to Gear Systems of Tractors143
- Oil for the Front Driving Axle143
- Front PTO Oil143
- Hydraulic Brake Liquid for the Tractors144
- Liquid for the Cooling System of the Tractors144
- Fuel144
- Plastic Lubricant for the Tractor145
- Tractor Greasing Scheme145
- Solid Front Drive Axle145
- Suspension Front Drive Axle146
- Hitch for a Single-Axle Semi-Trailer146
- Front Three-Point Hitch146
- Three-Point Hitch147
- Hitch Mouth for a Trailer147
- Technical Maintenance of the Tractors after a General Overhaul of the Main Groups147
Maintenance Instructions148
- Opening the Hood148
- Checking the Oil Level in the Engine148
- Draining Oil from the Engine149
- Filling the Engine with Oil149
- Replacing Full-Continuous Motor Oil Filter150
- Fuel Filtering150
- Raw Fuel Filter Clearing151
- Cartridge Replacement in the Raw Fuel Filter151
- Cartridge Replacement in the Fine Fuel Filter152
- Fuel System Venting152
- Dry Air Cleaner Maintenance Instructions153
- Recovery of the Mainair Cleaner Element153
- Replacing the Safety Element of the Air Cleaner153
- Reassembly of the Air Cleaner Elements153
- Bleeding the Hydraulic Circuit of the Hydrostatic Steering154
- Replacing the Hydrostatic Steering Hoses154
- Replacing Coolant154
- Checking the Oil in Gearbox155
- Check and Replacement of Oil in Gear Box155
- Draining and Checking Holes155
- After Draining Oil155
- Replacement of the Transmission Oil Cleaner Element with Hydraulic Pump Suction Filter155
- Insertion Piece Replacement of the Oil Cleaner with Delivery Filter of the Gearbox Switchboard156
- Replacement of Filter Element of Urea Filter156
- Lubrication and Filling Points of the Front Driving Axle156
- Filling, Inspection and Drain Opening of Oil of the Front Wheel Reducers157
- Front PTO157
- Brake Fluid Replacement157
- Carbon Filter Installation Instructions157
- Cleaning the Heating Filters158
- Air Filter with Active Carbon158
- Air-Conditioning Maintenance158
- Draining Condensate from the Air Reservoir159
- Checking the Air Systems for Leaks159
- Working Pressure of Air Brakes159
- Maintenance and Treatment of Tyres160
- Tyres for Driving Wheels162
- Storing the Tractor162
Adjustment164
- Adjusting Valve Clearance164
- Flat Belt Drive Tension of Accessories164
- Adjusting the Play of the Brake Pedals164
- Bleeding the Brake System of the Tractor164
- Bleeding the Rear Brake System165
- Foot Brake Check165
- Foot Brake Adjustment166
- Parking Brake Adjustment166
- Adjustment of the Lifting Draw-Bars of the Hitch for a Single-Axle Semi-Trailer166
- Adjusting the Bowden Cable166
Main Technical Parameters168
- Main Tractor's Parameters (MM)168
- Technical Data of Engines168
- Permitted Maximum Load of Front Axle (Kg)169
- Permitted Maximum Load of Rear Axle (Kg)169
- Permitted Maximum Weight of Set 'Tractor + Mounted Machine' (Kg)169
- Manoeuvrability Condition169
- Front Tires Steerability170
- Change of the Load-Bearing Capacity of the Front Tyres (%)170
- Bearing Capacity of Rear Tires171
- Change of the Load Capacity of the Rear Tyres (%)171
- Permitted Combinations of Wheels for Tractors171
- Performance on Rear PTO Shaft171
- Lifting Force of the Three-Point Hitch172
- Tensile Force172
- Speed of Tractor with Engine Revolutions of 2 100 Rpm and Parameter of Rear Wheels (Km/H)173
- Independent Rear Pto Shaft Revolutions174
- Speed of the Zuidberg Front PTO175
- Clearance-Circle and Turning Circle Diameter175
Index176

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Zetor CRYSTAL 160 Specifications

General

Brand	Zetor
Model	CRYSTAL 160
Category	Tractor
Language	English

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