Amazone Catros 2503 Special Operating Manual Download Page 64

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Cleaning, maintenance and repairs

11.5

Disc carrier fixture

Check the bolts for tightness.

Required tightening torque: 210 Nm.

11.6

Top and lower link pins

WARNING

Risk of contusions, catching, and knocks when the machine
unexpectedly releases from the tractor!

Check the upper and lower link pins for visible damage each time you
couple the machine. Replace upper and lower link pins if there are
clear signs of wear.

Catros BAG0160.4 02.19

Summary of Contents for Catros 2503 Special

Page 1: ... 4003 Special Catros 2503 Special Catros 3003 Special Catros 3503 Special Catros 4003 Special Mounted compact disc harrow MG5533 BAG0160 4 02 19 Printed in Germany Please read and follow this operating manual before putting the machine into operation Keep it in a safe place for future use en ...

Page 2: ...tion would not only harm himself but also make the mistake of blaming the machine for pos sible failures instead of himself In order to ensure success one should enter the mind of a thing make himself familiar with every part of the ma chine and get acquainted with how it s handled Only in this way could you be satisfied both with the machine and with yourself This goal is the purpose of this inst...

Page 3: ...DREYER GmbH Co KG Postfach 51 D 49202 Phone E mail Hasbergen 49 5405 501 0 amazone amazone de Spare part orders Spare parts lists are freely accessible in the spare parts portal at www amazone de Please send orders to your AMAZONE dealer Formalities of the operating manual Document number MG5533 Compilation date 02 19 Copyright AMAZONEN WERKE H DREYER GmbH Co KG 2019 All rights reserved Reprinting...

Page 4: ...machine into operation Only after careful reading will you be able to benefit from the full scope of your newly purchased machine Please ensure that all the machine operators have read this operating manual before they put the machine into operation Should you have any questions or problems please consult this op erating manual or contact your local service partner Regular maintenance and timely r...

Page 5: ...n is not observed 19 2 15 Safety conscious working 19 2 16 Safety information for users 20 2 16 1 General safety and accident prevention information 20 2 16 2 Hydraulic system 23 2 16 3 Electrical system 24 2 16 4 Cleaning maintenance and repairs 24 3 Loading and unloading 25 4 Product description 26 4 1 Overview of subassemblies 26 4 2 Safety and protection equipment 26 4 3 Supply lines between t...

Page 6: ...8 2 Working depth of the border elements 54 8 3 Scraper 55 8 4 Adjusting the intensity of the crushboard 55 8 5 Adjusting the working depth of the tractor wheel mark eradicators 56 9 Transportation 57 9 1 Conversion from operational to transport position 58 10 Use of the machine 59 10 1 Use on the field 60 10 2 Turning at headland 60 11 Cleaning maintenance and repairs 61 11 1 Cleaning 61 11 2 Ser...

Page 7: ...anual are always viewed in the direction of travel 1 3 Diagrams used Instructions for action and reactions Tasks to be carried out by the user are presented as numbered in structions Always keep to the order of the instructions The reaction to instructions is given by an arrow Example 1 Instruction for action 1 Reaction of the machine to instruction for action 1 2 Instruction for action 2 Lists Li...

Page 8: ...ng pictograms If you still have queries please contact the manufacturer Obligations of the user Before starting work anyone charged with working with on the ma chine is obliged To comply with the basic workplace safety instructions and acci dent prevention regulations To read and understand the section General safety information of this operating manual To read the section Warning symbols and othe...

Page 9: ...operator at the latest on the comple tion of the contract Guarantee and liability claims for damage to peo ple or goods will be excluded if they can be traced back to one or more of the following causes Improper use of the machine Improper installation commissioning operation and mainte nance of the machine Operation of the machine with defective safety equipment or improperly attached or non func...

Page 10: ...hysical injury WARNING Indicates a medium risk which could result in death or serious physical injury if not avoided If the instructions are not followed then this may result in death or serious physical injury CAUTION Indicates a low risk which could incur minor or medium level physical injury or damage to property if not avoided IMPORTANT Indicates an obligation to special behaviour or an activi...

Page 11: ...on equipment Before each commissioning of the machine all the safety and protec tion equipment must be properly attached and fully functional Check all the safety and protection equipment regularly Faulty safety equipment Faulty or disassembled safety and protection equipment can lead to dangerous situations 2 5 Informal safety measures As well as all the safety information in this operating manua...

Page 12: ... who have been instructed in their assigned tasks and in the possible risks in the case of improper behaviour have been trained if necessary and have been in formed about the necessary protective equipment and measures 3 People with specialist technical training shall be considered as a specialist Due to their specialist training and their knowledge of the appropriate regulations they can evaluate...

Page 13: ...hat bolted connections are firmly secured and tight en if necessary When the maintenance work is completed check the function of the safety devices 2 10 Constructive changes You may make no changes expansions or modifications to the ma chine without the authorisation of AMAZONEN WERKE This is also valid when welding support parts Any expansion or modification work shall require the written approva...

Page 14: ...ties there is no guarantee that they have been designed and manufactured in such a way as to meet the requirements placed on them AMAZONEN WERKE accepts no liability for damage arising from the use of unapproved spare parts wear parts or auxiliary materials 2 11 Cleaning and disposal Handle and dispose of any materials used carefully in particular When carrying out work on lubrication systems and ...

Page 15: ...s Warning pictograms The following diagrams show the arrangement of the warning picto grams on the machine Always keep all the warning pictograms of the machine clean and in a legible state Replace illegible warning pictograms You can obtain the warning pictograms from your dealer using the order number e g MD075 Catros BAG0160 4 02 19 15 ...

Page 16: ...e danger Warning pictograms explanation The column Order number and explanation provides an explanation of the neighbouring warning pictogram The description of the warning pictograms is always the same and specifies in the following order 1 A description of the danger For example danger of cutting 2 The consequence of nonobservance of the danger protection instructions For example causes serious ...

Page 17: ...e and or climb the running machine This ban also applies to machines with treads or platforms Ensure that no one rides with the machine MD095 Read and understand the operating manual safe ty information before starting up the machine MD096 Danger of infection to the whole body from liquids escaping at a high pressure hydraulic fluid This danger will cause serious injuries over the whole body if hy...

Page 18: ...er area be tween the tractor and the machine MD100 This symbol indicates lashing points for fastening slinging gear when loading the machine MD102 Danger from unintentional machine starting and rolling during intervention in the ma chine e g installation adjusting trouble shooting cleaning maintaining and repair ing This danger will cause serious injuries anywhere on the body or death Secure the t...

Page 19: ... Failure of important machine functions Failure of prescribed methods of maintenance and repair Danger to people through mechanical and chemical impacts Risk to environment through leakage of hydraulic fluid 2 15 Safety conscious working Besides the safety information in this operating manual the national general workplace safety and accident prevention regulations are binding Comply with the acci...

Page 20: ...tics of the tractor and the connected machine Connecting and disconnecting the machine Only connect and transport the machine with tractors suitable for the task When connecting machines to the tractor three point hydraulic system the attachment categories of the tractor and the ma chine must always be the same Connect the machine to the prescribed equipment in accordance with the specifications W...

Page 21: ...tand all the equip ment and actuation elements of the machine and their function There is no time for this when the machine is already in opera tion Do not wear loose fitting clothing Loose clothing increases the risk over being caught by drive shafts Only start up the machine when all the safety equipment has been attached and is in the safety position Comply with the maximum load of the connecte...

Page 22: ...oaded vehicle combination tractor plus connected machine Check the brake power before moving off When turning corners with the machine connected take the broad load and balance weight of the machine into account Before moving off ensure sufficient side locking of the tractor lower links when the machine is fixed to the three point hydrau lic system or lower links of the tractor Before moving off m...

Page 23: ...n key Have the hydraulic hose line checked at least once a year by a specialist for proper functioning Replace the hydraulic hose line if it is damaged or worn Only use AMAZONE original hydraulic hose lines The hydraulic hose lines should not be used for longer than six years including any storage time of maximum two years Even with proper storage and approved use hoses and hose connec tions are s...

Page 24: ...e on board power supply the user must check whether the installation might cause faults on the vehicle electronics or other com ponents ο Ensure that the retrofitted electrical and electronic compo nents comply with the EMC directive 2004 108 EEC in the appropriate version and carry the CE label 2 16 4 Cleaning maintenance and repairs Only carry out cleaning maintenance and repair work on the mach...

Page 25: ...fting crane CAUTION When loading the machine using a lifting crane use the marked lash ing points for lifting belts CAUTION The minimum tensile strength of each lifting belt must be 1000 kg The machine has 4 lashing points for lifting belts Catros BAG0160 4 02 19 25 ...

Page 26: ...e machine This helps you to understand the machine better 4 1 Overview of subassemblies 1 Three point attachment 2 1 disc row 3 2 disc row 4 Trailing roller in various versions 5 Setting the working depth 4 2 Safety and protection equipment Transport safety bar for the rear harrow during road transport 4 3 Supply lines between the tractor and the machine Electric cable for lighting 26 Catros BAG01...

Page 27: ...t and is operated by an additional person Slopes can be travelled Along the contours Direction of travel to left 15 Direction of travel to right 15 Along the gradient Up the slope 15 Down the slope 15 The intended use also includes Compliance with all the instructions in this operating manual Execution of inspection and maintenance work Exclusive use of AMAZONE original spare parts Other uses to t...

Page 28: ...on reasons Here the special safety regulations of the appropriate section shall be valid No one may stand in the machine danger area as long as the tractor engine is running with a connected PTO shaft hydraulic system as long as the tractor and machine are not protected against unintentional start up and running The operating person may only move the machine or switch or drive the tools from the t...

Page 29: ...nsport width mm 3000 3000 3500 4500 Transport height mm 1500 1500 1500 1500 Total length mm 2400 2400 2400 2400 with front rack 3020 3020 3020 3020 Working width mm 2500 3000 3500 4000 Anzahl der Scheiben 20 24 28 32 Disc diameter mm Catros 460 Catros 510 Thickness of the discs mm Catros 4 Catros 5 Disc spacing mm 250 Einstellung des Scheibenver satzes mecanical Working depth mm Catros 30 120 Catr...

Page 30: ...h Matrix profile KWM650 530 610 700 790 Angle profile roller WW580 kg 300 360 410 470 U profile roller UW580 kg 310 370 420 480 Double U profile roller DUW580 kg 440 520 590 660 Disc roller DW600 kg 555 650 745 840 Rear harrow kg 70 73 79 85 Spring blade system 142 kg 103 118 132 150 Spring clearer system 167 kg 81 94 108 121 Front rack kg 200 Crushboard kg 144 163 199 221 Tractor wheel mark eradi...

Page 31: ... pump power At least 15 l min at 150 bar Implement hydraulic fluid HLP68 DIN 51524 The implement hydraulic fluid is suitable for the combined hydraulic fluid circuits of all standard tractor brands Control units Depending on equipment see page 33 Three point attachment The tractor s lower links must have lower link hooks The tractor s upper links must have upper link hooks 4 10 Noise production da...

Page 32: ... cultivator is suitable for shallow stubble cultivation directly after threshing seed bed preparation in spring for maize or sugar beet incorporation of catch crops e g yellow mustard The Catros is attached to the tractor with a three point attachment The two row disc arrangement ensures soil cultivation and rotavation The trailing roller serves to re consolidate the soil 32 Catros BAG0160 4 02 19...

Page 33: ...of activa tion depending on the hydraulic function Latched for a permanent oil circulation Tentative activate until the action is executed Float position free oil flow in the control unit Marking Function Tractor control unit green working depth Optional increase double acting decrease Beige Crushboard Intensity Enlarging Double act ing reducing WARNING Danger of infection from escaping hydraulic ...

Page 34: ...lic plug s into the hydraulic sockets until the hydraulic plug s is are felt to lock Check the coupling points of the hydraulic hose lines for a cor rect tight seat 1 Swivel the actuation lever on the control valve on the tractor to float position neutral position 2 Clean the hydraulic connectors of the hydraulic hose lines be fore you couple the hydraulic hose lines to the tractor 3 Connect the h...

Page 35: ...ontact ball bearing with slide seal and oil filling and is maintenance free The following are adjustableThe working intensi ty of the discs over the working depth of the disc cultivator can be adjusted The depth is adjusted ο mechanically by means of spacer ele ments ο hydraulically via tractor control unit green The elastic rubber sprung suspension of the individual discs enables adaptation to so...

Page 36: ...ng in the edge area is performed using the border elements The border elements can be folded to reduce the transport width not for Catros 2503 1 Side disc 2 Depth adjustment 3 Pin for locking the transport and working position 36 Catros BAG0160 4 02 19 ...

Page 37: ...des very good crumbling Cage roller ο SW520 ο SW600 The cage roller can be used where lighter reconsolidation of the soil is required Disposes of a very good self propulsion Wedge ring roller KW580 with adjustable scraper Very well suited for medium soils Wedge ring roller KWM 650 with Matrix profile and adjustable scraper Very well suited for light medium and heavy soils Tooth packer roller PW 60...

Page 38: ...ell suited for light and medium soils Resistant to clogging and good load bearing capacity Angle profile roller WW580 Very well suited for light medium and heavy soils Provides very good crumbling Unsuitable for stony soils Disc Roller DW600 Very well suited for light medium and heavy soils Resistant to clogging and good load bearing capacity 38 Catros BAG0160 4 02 19 ...

Page 39: ... link pins with locking linch pins 2 positions for coupling the top link Depending on the installation of the bolted lower link pin a spread of Category 2 or 3 is reached 5 7 Front rack The front rack enables mounting of the crush board or the tractor wheel mark eradicator Catros BAG0160 4 02 19 39 ...

Page 40: ...l The working intensity can be adjusted mechani cally or hydraulically 5 9 Tractor wheel mark eradicator The tractor wheel mark eradicators loosen the compacted soil behind the tractor wheels The working depth of the tractor wheel mark eradicators can be adjusted 40 Catros BAG0160 4 02 19 ...

Page 41: ...o that the harrow is resting and can swing freely to the rear 2 Position of the positioning pin to lock the exact following harrow during road transport 3 Install the road safety bar for road transport 4 Depending on the harrow system adjust the harrow height so that it is free of play Make the same adjustments on all of the setting points Raise and peg the harrow to take it out of operation Attac...

Page 42: ...Structure and function Harrow system 12 284 Hi For rollers TW520 380 DUW580 Spring blade system 167 For roller UW580 Spring clearer system142 For roller WW580 42 Catros BAG0160 4 02 19 ...

Page 43: ...cultivation with the Catros disc cultivator 1 GreenDrill 2 Foldable ascent 3 Bolt with linch pin for securing the foldable ascent See also the GreenDrill operating manual Fold the access ladder in the transport position before driving and secure it in the transport position using bolt and lynch pin Use the step of the ladder as handle Catros BAG0160 4 02 19 43 ...

Page 44: ...r the task The tractor and machine must meet the national road traffic regulations The operator and the user shall be responsible for compliance with the statutory road traffic regulations WARNING Risk of contusions cutting catching drawing in and knocks in the area of hydraulically or electrically actuated components Do not block the operator controls on the tractor which are used for hydraulic a...

Page 45: ...ubjected to at least 20 of the empty weight of the tractor The tractor must achieve the brake delay specified by the tractor manufacturer even with the machine connected 6 1 1 Calculating the actual values for the total tractor weight tractor axle loads and load capacities as well as the minimum ballast The approved total tractor weight specified in the vehicle documenta tion must be greater than ...

Page 46: ...ht or measure ment a1 m Distance from the centre of the front axle to the centre of the lower link connection See tractor operating manual or measure ment a2 m Distance between the centre of the lower link connection point and the centre of gravi ty of the front machine mount or front weight centre of gravity distance See technical data of front machine mount ing or front weight or measurement b m...

Page 47: ...al in the table Section 6 1 1 7 6 1 1 4 Calculation of the actual total weight of the combined tractor and machine H L V tat F T G G Enter the numeric value for the calculated actual total weight and the approved total tractor weight specified in the tractor operating manual in the table Section 6 1 1 7 6 1 1 5 Calculation of the actual rear axle load of the tractor TH tat tat V tat tat H T G T En...

Page 48: ... steering and brake power It is forbidden to couple the machine to the tractor used as the basis for calculation if One of the actual calculated values is greater than the approved value There is no front weight if required attached to the tractor for the minimum front ballast GV min Ballast your tractor with weights at the front or rear if the tractor axle load is exceeded on only one axle Specia...

Page 49: ... is running with the PTO shaft hydraulic system connected ο if the ignition key is in the tractor and the tractor engine can be started unintentionally with the PTO shaft hydraulic system connected ο if the tractor and machine have not each been prevented from unintentionally rolling away by applying their parking brakes and or securing them with wheel chocks ο if moving parts are not blocked agai...

Page 50: ... operator controls for the tractor s three point hydrau lic system only from the intended workstation only if you are outside of the danger area between the tractor and the machine 7 1 Coupling the machine WARNING Danger of breaking during operation insufficient stability and insufficient tractor steering and braking power on improper use of the tractor You may only connect the machine to tractors...

Page 51: ... course of the power lines The power lines must give slightly without tension bending or rubbing on all movements of the connected machine may not scour other parts It is preferable to couple the implement with the smallest working depth In this way the implement is aligned horizontally 1 Fasten the ball sleeves over the top link pins and fasten the lower link pins in the pivot points of the three...

Page 52: ...surface with solid ground 2 Disconnect the machine from the tractor 2 1 Relieve the load from the top link 2 2 Unlock and uncouple the top link hooks from the tractor seat 2 3 Relieve the load from the lower link 2 4 Unlock and uncouple the lower link hooks from the tractor seat 2 5 Draw the tractor approximately 25 cm forwards The resulting free space between the tractor and the ma chine provides...

Page 53: ...49 8 1 Working depth adjustment 8 1 1 Setting the working depth The depth is adjusted by arranging the spacer element in front of or behind the stop washer on the setting rod 1 Spacer elements 2 Setting rod 3 Stop washer Increasing the working depth More spacer elements in front of the stop washer 1 Lower the coupled implement onto the ground unload the rear spacer elements 2 Secure the tractor ag...

Page 54: ... 1 2 Hydraulic working depth adjustment Actuate tractor control unit green The working depth is set hydraulically using the scale The scale provides orientation for the set working depth 8 2 Working depth of the border elements The raised border elements at the front right and rear left must be adjusted Use the bearing pin and hub as handle 1 Secure the tractor against unintentional starting and u...

Page 55: ... the screw Wedge ring rollers Do not adjust the distance between stripper and spacer ring to less than 10 mm to avoid excessive wear Tooth packer roller Adjust the distance between the scraper and shaft between 0 5 to 4 mm 8 4 Adjusting the intensity of the crushboard Hydraulic adjustment The intensity of the crushboard is hydraulically adjusted using the beige tractor control unit The display sho...

Page 56: ...higher intensity The display shows the set intensity 1 Crank 2 Linch pin 3 Read off edge 4 Scale 8 5 Adjusting the working depth of the tractor wheel mark eradicators 1 Secure the tractor against unintentional starting and unintentional rolling away 2 Pull out the rear pin 1 3 Raise or lower the tractor wheel mark erad icators manually to the desired working depth 4 Make the adjustment with the pi...

Page 57: ... pin against unintentional re lease WARNING Risk of contusions cuts dragging catching or knocks from tipping and insufficient stability Drive in such a way that you always have full control over the tractor with the attached machine 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 ...

Page 58: ...der elements are positioned parallel to the disc gang In transport position the border elements are swivelled to be able to maintain the maximum authorised transport width Right border element swivelled into transport position Left border element swivelled into transport posi tion 1 Pull out the bolt 2 Both border elements can be folded into transport position can be unfolded into working position...

Page 59: ...ways have full control over the tractor with the attached machine In so doing take your personal abilities into account as well as the road traffic visibility and weather conditions the driving characteris tics of the driver and the connected machine WARNING Risk of being crushed cut caught drawn in or struck if the ma chine is unintentionally released from its attached or hitched position Each ti...

Page 60: ...e device at the headland The device must be adjusted at the lifting arm spindles and the top link of the tractor so that the frame is parallel to the soil surface longi tudinally and transversely during the work procedure 10 2 Turning at headland When turning through a curve at the headland the disc rows must be raised to prevent transverse stresses Use at the headland only when the direction of t...

Page 61: ... See page 49 11 1 Cleaning Cleaning with a high pressure cleaner steam jet Always observe the following points when using a high pressure cleaner steam jet for cleaning ο Do not clean any electrical components ο Do not clean any chromed components ο Never aim the cleaning jet of the cleaning nozzle of the high pressure cleaner steam jet directly at lubrication points bearings rating plates warning...

Page 62: ...n for defects Check leak tightness 64 X Roller Retighten bolts of clamping brackets Specified tightening torque 210 Nm 63 Weekly every 50 working hours Component Servicing work See page Specialist work shop Hydraulic hose lines Check 66 X Every 4 months 200 working hours Component Servicing work See page Specialist work shop Roller Retighten bolts of clamping brackets Specified tightening torque 2...

Page 63: ... CAUTION When removing spring suspended elements disc segments remem ber that the parts are under preten sion Use a suitable tool Use circlip pliers 78400609 For installation and removal addi tionally use longer screws as an auxiliary tool 1Fig 3 11 4 Roller Inspect the roller bearings for free movement at regular intervals Check the bolts for tightness Required tightening torque 210 Nm To connect...

Page 64: ...10 Nm 11 6 Top and lower link pins WARNING Risk of contusions catching and knocks when the machine unexpectedly releases from the tractor Check the upper and lower link pins for visible damage each time you couple the machine Replace upper and lower link pins if there are clear signs of wear 64 Catros BAG0160 4 02 19 ...

Page 65: ...hydraulic hose lines are connected correctly Regularly check all the hydraulic hose lines and couplings for damage and impurities Have the hydraulic hose line checked at least once a year by a specialist for proper functioning Replace the hydraulic hose line if it is damaged or worn Only use AMAZONE original hydraulic hose lines The hydraulic hose lines should not be used for longer than six years...

Page 66: ...ydraulic hose lines immediately 11 7 3 Inspection criteria for hydraulic hose lines For your own safety comply with the following inspection criteria Replace hydraulic hose lines on determining any of the follow ing during the inspection Damage to the outer layer up to the ply e g scouring points cuts cracks Brittleness of the outer layer crack formation of the hose materi al Deformations which do...

Page 67: ...the hose s own weight ο There is no possibility of jolting on short lengths ο Outer mechanical influences on the hydraulic hose lines are avoided Use appropriate arrangements and fixing to prevent any scouring of the hoses on components or on each other If necessary secure hydraulic hose lines using protective co vers Cover sharp edged components ο The approved bending radii may not be exceeded Wh...

Page 68: ...Cleaning maintenance and repairs 11 8 Hydraulics diagram depth adjustment 68 Catros BAG0160 4 02 19 ...

Page 69: ...05 485 M 18x1 5 325 460 550 M 20 30 410 580 690 M 20x1 5 460 640 770 M 22 32 550 780 930 M 22x1 5 610 860 1050 M 24 36 710 1000 1200 M 24x2 780 1100 1300 M 27 41 1050 1500 1800 M 27x2 1150 1600 1950 M 30 46 1450 2000 2400 M 30x2 1600 2250 2700 M M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 2 4 4 9 8 4 20 6 40 7 70 5 112 174 242 342 470 589 Coated screws have different tightening torques Note specia...

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