Amazone Catros 4002-2TS Operating Manual Download

Page: 101 / 116

Cleaning, maintenance and repairs

12.4.1

Hydraulic brakes

Check of the hydraulic brake

•

Check all brake hoses for wear

•

check all screw unions for seal tightness

•

renew any worn or damaged parts.

Venting the brake system (workshop work)

After each brake repair, for which the system has
been opened, bleed the brake system, because
air may have entered the pressure hoses.

1. Slightly loosen the vent valve.

2. Actuate the tractor brake.

3. Close the vent valve as soon as oil es-

capes.

→

Collect the escaping oil.

4. Perform a brake check.

Fig. 71

Catros BAG0155.4 05.19

101

Summary of Contents for Catros 4002-2TS

Page 1: ...ros 5002 2TS Catros 6002 2TS Catros 6002 2TS Trailed compact disc cultivator with swivelling running gear MG5422 BAG0155 4 05 19 Printed in Germany Please read and follow this operating manual before...

Page 2: ...ion 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...

Page 3: ...REYER 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 Pleas...

Page 4: ...achine 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 m...

Page 5: ...nformation for users 23 2 16 1 General safety and accident prevention information 23 2 16 2 Hydraulic system 26 2 16 3 Electrical system 27 2 16 4 Attached machines 27 2 16 5 Cleaning maintenance and...

Page 6: ...0 6 1 3 Machines without their own brake system 73 6 2 Securing the tractor machine against unintentional start up and rolling 74 7 Coupling and uncoupling the machine 75 7 1 Coupling the machine 75 7...

Page 7: ...device 107 12 13 Hydraulic cylinder for foldable booms 108 12 14 Hydraulic system 109 12 14 1 Labelling hydraulic hose lines 110 12 14 2 Maintenance intervals 110 12 14 3 Inspection criteria for hydr...

Page 8: ...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 o...

Page 9: ...g 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...

Page 10: ...perator 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 cause...

Page 11: ...ysical 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 physic...

Page 12: ...n 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 Fau...

Page 13: ...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 equip...

Page 14: ...at 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 exp...

Page 15: ...ies 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...

Page 16: ...s The following diagrams show the arrangement of the warning picto grams on the machine Fig 1 Fig 2 Fig 3 Always keep all the warning pictograms of the machine clean and in a legible state Replace ill...

Page 17: ...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 sam...

Page 18: ...when riding on the machine This danger will cause serious injuries anywhere on the body or death It is forbidden to ride on the machine and or climb the running machine This ban also applies to machi...

Page 19: ...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...

Page 20: ...p and rolling before any intervention in the machine Depending on the type of intervention read and understand the information in the rele vant sections of the operating manual MD 114 This pictogram i...

Page 21: ...etween tractor and attached machine This danger can cause extremely serious and potentially fatal injuries Do not remain in the danger area between tractor and machine while the tractor engine is runn...

Page 22: ...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...

Page 23: ...istics 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 trac...

Page 24: ...stand 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...

Page 25: ...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 ac...

Page 26: ...e 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 Th...

Page 27: ...followed In the case of retrofitting of electrical units and or compo nents on the machine with a connection to the on board power supply the user must check whether the installation might cause faul...

Page 28: ...ry If the machine or parts of the machine are raised secure them against unintentional lowering before cleaning maintaining or repairing the machine When replacing work tools with blades use suitable...

Page 29: ...nuts to 270 Nm Fig 4 See page 105 Loading using a lifting crane WARNING Risk of crushing due to accidental falling of a machine attached to a load carrier during loading and unloading Only attach you...

Page 30: ...nto the low loader The low loader must have the necessary ground clearance Lower the disc rows onto the low loader by slightly raising the chassis Fig 6 Loading onto truck platform Machine is folded o...

Page 31: ...e tractor fulfils the power re quirements Compressed air brake system You may only move off with the machine connected if the pres sure gauge on the tractor shows 5 0 bar If the machine is to be loade...

Page 32: ...d controls Read this section when actually at the machine This helps you to understand the machine better 4 1 Overview of subassemblies Fig 8 1 Drawbar with tensioned crosspiece drawbar eye or ball br...

Page 33: ...9 1 Hose cabinet 2 Drawbar hydraulically actuated for coupling procedure 3 Brake valve 4 Compressed air reservoir 5 Jack for hydraulic drawbar 6 Wheel chocks in transport position 7 Parking brake Cat...

Page 34: ...to prevent activating an unintentional unfolding action from the tractor via the cable winch Stop valve in position A hydraulic unfolding locked Stop valve in position B hydraulic unfolding unlocked t...

Page 35: ...ortation equipment Fig 11 1 Warning signs square 2 Rear lights brake lights turn indicators 3 Red reflectors Fig 12 1 2 warning signs square 2 2 limiting lights turn indicators One additional warning...

Page 36: ...ion 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...

Page 37: ...hall 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 agai...

Page 38: ...ta Catros Catros Disc diameter 460 mm 510 mm Working depth 30 mm 120 mm 60 mm 150 mm Catros 4002 2TS 5002 2TS 6002 2TS Working width 4000 mm 5000 mm 6000 mm Transport width 3000 mm 3000 mm 3000 mm Tra...

Page 39: ...kg 1060 kg 1220 kg Tandem roller TW 520 380 700 kg 820 kg 960 kg Tooth packer roller PW 600 700 kg 840 kg 1020 kg U profile roller UW 580 520 kg 620 kg 740 kg Double U profile roller DUW 580 740 kg 8...

Page 40: ...or the combined hydraulic fluid circuits of all standard tractor brands Control units Depending on equipment see page 47 Service brake system Dual circuit service brake sys tem 1 hose coupling red for...

Page 41: ...e cultivation directly after threshing seed bed preparation in spring for maize or sugar beet incorporation of catch crops e g yellow mustard The two row disc arrangement ensures soil cultivation and...

Page 42: ...the two disc rows is ad justed via the offset slide Fig 22 2 to working depth and speed Adjustment is made with the AMAZONE eccentric pins The working intensity of the discs over the working depth of...

Page 43: ...Damage on the roller It is forbidden to turn on the roller Cage roller SW520 SW600 The cage roller can be used where lighter reconsolidation of the soil is required Disposes of a very good self propul...

Page 44: ...able cutting bar as an option Raising the knife holder with increased organic matter content reduces the risk of blocking Very well suited for medium and heavy soils Unsuitable for stony soils Disc ro...

Page 45: ...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 t...

Page 46: ...profile roller DUW580 Fig 22 Spring mounted clearing system 167 For roller U profile roller UW580 Fig 23 Spring blade system 142 For roller Angle profile roller WW580 Fig 24 Clearer system WW 142 HI...

Page 47: ...that illustrate the respective hydraulic function The tractor control unit must be used in different types of activa tion depending on the hydraulic function Latched for a permanent oil circulation Te...

Page 48: ...s with biological oils Observe the maximum approved hydraulic fluid pressure of 210 bar Only couple clean hydraulic connectors Push the hydraulic plug s into the hydraulic sockets until the hydraulic...

Page 49: ...r tank is not refilled The ma chine must therefore be parked only with wheel chocks The brakes are released immediately with a full compressed air tank when the supply line red is connected to the tra...

Page 50: ...st be filled If the com pressed air tank is empty the parking brake cannot be disengaged using the control elements 1 Release valve with actuator button If the actuator button is pressed in to the sto...

Page 51: ...ng of the supply line red The operating brake of the machine moves out of the brake position immediately the red hose coupling has been coupled 1 Open the tractor coupling head caps 2 Remove brake lin...

Page 52: ...o this order as otherwise the service brake system will trip and may set the unbraked machine moving When the machine is uncoupled or pulled away from the trailer air is vented from the trailer brake...

Page 53: ...aulic couplings 1 Remove the protective caps 2 If necessary clean the hydraulic connector and hydraulic socket 3 Connect the hydraulic socket on the ma chine face with the hydraulic connector on the t...

Page 54: ...accumulator of the emergency brake is being charged DANGER Risk of accident through brake malfunction After withdrawing the safety splint e g when activating the emergen cy brake it is essential to i...

Page 55: ...perates the spindle and bowden cable 1 Parking brake 2 Wheel chocks A Apply the tractor parking brake B Release parking brake Fig 29 Correct the setting of the parking brake if the spindle s tension i...

Page 56: ...this machine Mounting onto another Catros disc cultivator is not permitted Running gear swivelled up implement in working position with out vibration compensation Fig 30 Running gear swivelled up impl...

Page 57: ...sk of accidents if the connection between machine and tractor separates Always use ball sleeves with sockets and integrated linch pins Hydraulic drawbar Hydraulic drawbar for coupling with implements...

Page 58: ...ch pin With machine uncoupled Jack fixed in lowered position with pin and se cured with linch pin Fig 35 Moveable jack 1 Handle 2 Bolt with linch pin During operation or transport Jack fixed in raised...

Page 59: ...ctor lower link in float position The support wheels must not be used for cornering If necessary lift the machine slightly via the tractor lower link Machines with hydraulic depth adjustment can be ad...

Page 60: ...machine thus relieving the front spacer elements 4 Swivel in and secure the spacer elements again Reduce working depth 1 Actuate tractor control unit yellow Lower the machine thus relieving the front...

Page 61: ...e swing compensation when required 1 Open the stop tap Position B 2 Actuate tractor control unit yellow Raise the running gear slightly from the ground 3 Switch tractor control unit yellow to the floa...

Page 62: ...ake it possible to optimise the penetration of the discs into the soil One set of additional weights corresponds to 4 times 25 kg Install max 2 x 3 sets Mounting the additional weights 1 Mount the hol...

Page 63: ...ascent Fig 43 See also the GreenDrill operating manual Fold the access ladder to the transport position before driving Use the step of the ladder as handle 5 16 Safety chain for machines without brake...

Page 64: ...Structure and function 5 17 Immobiliser for lower link hitch Immobiliser for attaching the tensioned cross piece 1 Immobiliser on the drawbar when not in use Fig 45 64 Catros BAG0155 4 05 19...

Page 65: ...e 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...

Page 66: ...bjected 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 va...

Page 67: ...f tractor and front ma chine mounting or front weight 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...

Page 68: ...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 th...

Page 69: ...r 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...

Page 70: ...ermissible support capability for the supported weight ac tually present that the axle loads and weights of the tractor altered by the drawbar load are within the approved limits If necessary weigh th...

Page 71: ...24347 Lower hitch Towing hooks hitch hooks ISO 6489 19 Drawbar eye Centre bore 50 mm Eyelet 30 mm ISO 5692 1 Swivel drawbar eye compatible only with form Y hole 50 mm ISO 5692 3 Drawbar eye Centre bo...

Page 72: ...ar of the implement Coupling device of the tractor The actual DC value calculated for the combination must be less than or equal to the DC values specified The permissible DC values of the implement c...

Page 73: ...own brake system WARNING Risk of contusions cuts dragging catching or knocks from insufficient tractor brake power The tractor must achieve the brake delay specified by the tractor manufacturer even w...

Page 74: ...tor engine is running with the PTO shaft hydraulic system connected if the ignition key is in the tractor and the tractor engine can be started unintentionally with the PTO shaft hydraulic system conn...

Page 75: ...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 mac...

Page 76: ...the pivot points on the three point frame attachment to secure them against unintentional release WARNING Risk of energy supply failure between the tractor and the ma chine through damaged power lines...

Page 77: ...ctuate tractor control unit yellow4 Position the ball bracket hydraulically on the tractor ball coupling and lock it 7 Actuate the yellow4 tractor control unit Lift the implement using the drawbar con...

Page 78: ...nintention ally 2 Lower the jack 3 Apply the parking brake 4 Use the wheel chocks 5 Disconnect the supply lines 6 Set the implement down on the jack 7 Unlock and uncouple the lower link hooks from the...

Page 79: ...unintentional start up and rolling before making adjustments to the machine See Page 74 8 1 Mechanical working depth adjustment The working depth of the discs is set by adjusting the spindle length U...

Page 80: ...irection 3 Use the hand lever Fig 38 1 to lengthen or shorten the spindle 4 Secure using the clip pin Fig 38 3 Fig 49 8 2 Hydraulic working depth adjustment optional Actuate tractor control unit green...

Page 81: ...nintentional starting and unintentional rolling away 3 Release clip pins Fig 40 1 4 Insert eccentric pins Fig 40 2 into the desired insertion hole 5 Secure the clip pin Fig 51 CAUTION Crushing hazard...

Page 82: ...isible and follows the 1st disc row Adjust 1st disc row to left Fig 53 Fig 54 Fig 55 8 4 Working depth of the outside discs The raised outside discs at the front right and rear left must be adjusted U...

Page 83: ...ntentional rolling away 2 Release the screw Fig 46 1 below the scraper 3 Adjust the scraper in the slotted hole 4 Retighten the screw Fig 57 Wedge ring rollers Do not adjust the distance between strip...

Page 84: ...s cutting catching drawing in and knocks when making interventions in the machine through unintentional machine movements On folding machines check that the transport locks are locked correctly Secure...

Page 85: ...running ma chine 9 1 Conversion from operational to transport position WARNING Instruct persons away from the swivel range of the running gear before folding this up or down Instruct people to leave t...

Page 86: ...width of 3 m is not exceeded 3 Actuate tractor control unit blue Fold in machine wings completely 4 Deactivating the vibration compensation Close the stop tap Observe the sequence described otherwise...

Page 87: ...e 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 t...

Page 88: ...sion arm out or in Only when the machine is fully raised do the soil cultivating tools have sufficient ground clearance and are thus protected against damage Implement in working position without vibr...

Page 89: ...n 10 3 Driving on the headlands Depending on the roller turning is performed on the roller or on the running gear wheels Single roller Turn on the roller Double roller Turn on the running gear wheels...

Page 90: ...machine danger area Different working depths across the working width Synchronise the hydraulic cylinders For a uniform working depth across the entire implement width the corresponding hydraulic cyl...

Page 91: ...e cleaner steam jet or liposoluble agents Observe the statutory requirement for the handling and removal of cleaning agents Cleaning with a high pressure cleaner steam jet Always observe the following...

Page 92: ...Marson L2 ESSO Beacon 2 SHELL Retinax A 12 2 2 Lubrication point overview Fig 53 Lubrication point Interval h Quantity 1 Tensioned crosspiece 50 3 2 Upper lower coupling points 50 3 3 Chassis hydrauli...

Page 93: ...tem Inspection for defects Check leak tightness 109 X Roller Check bolts of clamping brack ets 104 Axle Check axle bolts 104 Wheels Wheel nut check 105 Daily Component Servicing work see page Speciali...

Page 94: ...Hydraulic cylinder folding Check that the cylinder eye is firm ly attached to the hydraulic cylin der 107 Every year 1000 operating hours Component Servicing work See page Workshop work Brake system...

Page 95: ...ed for welding torch cutting and drill ing work in the vicinity of brake lines Always carry out a braking test after any adjusting or repair work on the braking system General visual inspection WARNIN...

Page 96: ...st be removed Checking the play on wheel hub bearings To check the play on wheel hub bearings raise the axle until the wheels turn freely Release the brake Place a lever between the tyre and the groun...

Page 97: ...4 Adjusting the linkage adjuster Move the linkage adjuster by hand in the pres sure direction If the free travel of the long stroke diaphragm cylinder pressure rod is max 35 mm the wheel brake must be...

Page 98: ...point grease Fig 66 Draining the air reservoir 1 Run the tractor engine approx 3 mins until the compressed air tank has filled 2 Switch off the tractor engine apply the handbrake and remove the ignit...

Page 99: ...2 by a few turns 3 Lift the plate 3 over the rubber seal 4 and turn to the side The unit is under spring tension 4 Remove the rubber seal Fig 68 5 Clean and grease the sealing surfaces O ring and fil...

Page 100: ...tes 6 Seal any leaking areas or replace leaking valves 2 Check pressure in the air reservoir 1 Connect a pressure gauge to the test connection on the air res ervoir Set value 6 0 to 8 1 0 2 bar 3 Chec...

Page 101: ...damaged parts Venting the brake system workshop work After each brake repair for which the system has been opened bleed the brake system because air may have entered the pressure hoses 1 Slightly loo...

Page 102: ...nal lowering 1 Release the four screws securing the disc 2 Remove the disc 3 Secure the new disc with four screws Fig 72 Fig 73 Fig 74 CAUTION When removing spring suspended elements disc segments rem...

Page 103: ...unit has two slide bearings 1 Release the screw union Fig 66 2 of the shifting shaft Fig 66 3 2 Drive the shifting shaft out of the bearing 3 Remove the circlips from the slide bearing 4 Replace the...

Page 104: ...t of the bolts 1 Check the bolts 1 for tightness Check the roller bearing 2 for ease of movement Fig 77 12 9 Disc carrier fixture Check the bolts for tightness Fig 78 12 10 Axle 1 Axle bolts with clam...

Page 105: ...ficient skills and proper assembly tools Use the jack only at the jacking points indicated 12 11 1 Tyre pressures The required tyre pressure is dependent on tyre size tyre load rating speed of travel...

Page 106: ...wheel rim seating surfaces before fitting a new another tyre Corrosion can cause damage to the wheel rims when the vehicle is in operation When fitting new tyres always use new valves for tubeless tyr...

Page 107: ...ightening torque Lower link trav erse Cat 3 34 5 mm Cat 4 48 0 mm Cat 5 56 0 mm M20 8 8 8 410 Nm Ball coupling K80 LI009 82 mm M16 10 9 8 300 Nm K80 LI040 82 mm M20 10 9 8 560 Nm K80 LI015 82 mm M20 1...

Page 108: ...equired tightening torque for lock nut on hydraulic cylinder for folda ble booms 300 Nm Check the screw connections on the hydraulic cylinders Fig 72 1 Check the screw connec tions on the hydraulic cy...

Page 109: ...ydraulic 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 speciali...

Page 110: ...aged hydraulic hose lines immediately 12 14 3 Inspection criteria for hydraulic hose lines For your own safety comply with the following inspection criteria Replace hydraulic hose lines on determining...

Page 111: ...uences 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 usin...

Page 112: ...Cleaning maintenance and repairs 12 16 Hydraulics diagram 1 Chassis hydraulics yellow 2 Folding hydraulics blue Fig 84 112 Catros BAG0155 4 05 19...

Page 113: ...Cleaning maintenance and repairs Hydraulics Set working depth green Fig 85 Hydraulics Drawbar Fig 86 Catros BAG0155 4 05 19 113...

Page 114: ...5 485 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...

Page 115: ...Cleaning maintenance and repairs Catros BAG0155 4 05 19 115...

Page 116: ......

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