Krone AM 203 S User manual

Original operating instructions
Disc Mower
AM 203 S
AM 243 S
AM 283 S
AM 323 S
(from serial no.: 829 190)
Order no.: 150 000 002 01 us
27.04.2015

Table of Contents
2
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Dear customer,
Dear customer,
You have now received the operating instructions for the KRONE
product which you have purchased.
These operating instructions contain important information for the
proper use and safe operation of the machine.
If these operating instructions should become wholly or partially
unusable, you can obtain replacement operating instructions for
your machine by stating the number given overleaf.
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Table of Contents
3
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1 Table of Contents
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1Table of Contents...................................................................................................................................3
2Foreword.................................................................................................................................................6
3Introduction.............................................................................................................................................7
3.1Purpose of Use...................................................................................................................................7
3.2Validity................................................................................................................................................7
3.2.1Contact........................................................................................................................................7
3.3Identification Plate..............................................................................................................................8
3.4Information Required for Questions and Orders................................................................................8
3.5Intended Use......................................................................................................................................9
3.6Service life of the machine.................................................................................................................9
3.7Technical data....................................................................................................................................9
4Safety.....................................................................................................................................................10
4.1Identifying Symbols in the Operating Instructions............................................................................10
4.2Identification of the hazard warnings................................................................................................10
4.2.1Personnel Qualification and Training........................................................................................11
4.2.2Dangers in Case of Non-compliance with the Safety Instructions............................................11
4.2.3Safety-conscious work practices...............................................................................................11
4.3Safety Instructions and Accident Prevention Regulations ...............................................................12
4.4Attached devices..............................................................................................................................13
4.5PTO operation..................................................................................................................................14
4.6Hydraulic system..............................................................................................................................15
4.7Maintenance.....................................................................................................................................15
4.8Unauthorised Conversion/Modification and Spare Parts Production...............................................16
4.9Inadmissible Modes of Operation.....................................................................................................16
4.10Working in the vicinity of power transmission lines..........................................................................16
4.11Introduction.......................................................................................................................................17
4.12Position of the Adhesive Safety Stickers on the Machine................................................................18
4.13Position of the General Information Labels on the Machine............................................................20
4.13.1Re-Ordering the Adhesive Safety and Information Labels .......................................................21
4.13.2Affixing the Adhesive Safety and Information Labels ...............................................................21
4.13.3Contact for KRONE NORTHAMERICA ....................................................................................21
5Commissioning.....................................................................................................................................23
5.1First installation ................................................................................................................................23
5.2Special Safety Instructions...............................................................................................................23
5.3Mounting onto the Tractor................................................................................................................24
5.3.1Clutching points.........................................................................................................................24
5.3.2Attaching the Three-Point Block ...............................................................................................26
5.4PTO shaft.........................................................................................................................................27
5.4.1Length adjustment.....................................................................................................................27
5.5Adjustment Piece for Lifting Cylinder and Compensation Spring....................................................28
6Start-up..................................................................................................................................................29
6.1Mounting onto the Tractor................................................................................................................29
6.2Hydraulics.........................................................................................................................................30
6.2.1Special Safety Instructions........................................................................................................30
6.2.2Connecting the hydraulic lines..................................................................................................30
6.3PTO shaft.........................................................................................................................................31

Table of Contents
4
6.4Install the PTO shaft.........................................................................................................................31
6.5Fastening the Compensation Spring................................................................................................32
7Driving and Transport..........................................................................................................................33
7.1Switching from working position to transport position......................................................................33
7.2Lighting.............................................................................................................................................34
8Operation...............................................................................................................................................35
8.1From transport into working position................................................................................................35
8.2Before mowing .................................................................................................................................36
8.2.1Folding down the Safety Device ...............................................................................................36
8.3Using the Machine for Work.............................................................................................................37
8.4Headland Position............................................................................................................................37
8.5Detaching the machine ....................................................................................................................38
9Settings .................................................................................................................................................41
9.1Adjusting the cutting height..............................................................................................................41
9.2Adjusting the Compensation Springs...............................................................................................42
9.3Setting of the pole protection mechanism........................................................................................43
9.4Default Setting of the Tractor's Lower Suspension Arms ................................................................44
9.5Adjustable throttles...........................................................................................................................44
10Maintenance..........................................................................................................................................45
10.1Special Safety Instructions...............................................................................................................45
10.1.1Test run.....................................................................................................................................45
10.2Spare Parts ......................................................................................................................................45
10.3Tightening torques............................................................................................................................46
10.3.1Metric Thread Screws with Control Thread ..............................................................................46
10.3.2Metric Thread Screws with Fine Thread...................................................................................47
10.3.3Metric Thread Screws with Countersunk Head and Hexagonal Socket...................................47
10.3.4Deviating Torque.......................................................................................................................48
10.4Filling Quantities and Lubrication Designations for Gearboxes.......................................................49
10.4.1Oil Level Check and Oil Change Intervals (Gearboxes)...........................................................49
10.5Main gearbox....................................................................................................................................50
10.6Gearbox on the carrying bar ............................................................................................................51
10.7Oil level check and oil change on the cutter bar..............................................................................52
10.7.1Oil change.................................................................................................................................52
10.7.2Checking the oil level................................................................................................................52
10.8Guard Cloths....................................................................................................................................53
10.9Maintenance of pole protection........................................................................................................54
10.10Checking the Cutter Blades and Blade Holder ................................................................................55
10.10.1Cutter Blades ............................................................................................................................56
10.10.2Blade Screw Connection...........................................................................................................57
10.10.3Blade Quick-Fit Device .............................................................................................................57
10.11Blade Changing on Cutting Discs ....................................................................................................58
10.12Special Tool......................................................................................................................................58
10.12.1Blade Screw Connection...........................................................................................................59
10.12.2Blade Quick-Fit Device .............................................................................................................60
10.13Replacing the Linings.......................................................................................................................61
11Maintenance – lubrication chart .........................................................................................................62
11.1Special Safety Instructions...............................................................................................................62
11.2PTO shaft.........................................................................................................................................62

Table of Contents
5
11.3Lubrication Chart..............................................................................................................................63
12Placing in Storage................................................................................................................................64
13Before the Start of the New Season ...................................................................................................65
13.1Special Safety Instructions...............................................................................................................65
13.2Test run............................................................................................................................................65
13.3Friction Clutch ..................................................................................................................................67
13.4Walterscheid Overload Coupling......................................................................................................67
14Special equipment................................................................................................................................68
14.1Special Safety Instructions...............................................................................................................68
14.2Adjusting Skids.................................................................................................................................68
15Disposal of the machine......................................................................................................................69
15.1Disposal of the machine...................................................................................................................69
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Foreword
6
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2 Foreword
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Dear Customer!
By purchasing the disc mower, you have acquired a quality product made by KRONE.
We are grateful for the confidence you have invested in us in buying this machine.
To be able to use the disc mower optimally, please read these operating instructions thoroughly
before you start using the machine.
The contents of this manual are laid out in such a way that you should be able to perform any
task by following the instructions step by step. It contains extensive notes and information about
maintenance, how to use the machine safely, secure working methods, special precautionary
measures and available accessories. This information and these instructions are essential,
important and useful for the operational safety, reliability and durability of the disc mower.
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Note
In the operating instructions which follow, the disc mower will also be referred to as the
"machine".
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Please note:
The operating instructions are part of your machine.
Only operate this machine after you have been trained to do so and according to these
instructions.
It is essential to observe the safety instructions!
It is also necessary to observe the relevant accident prevention regulations and other generally
recognised regulations concerning safety, occupational health and road traffic.
All information, illustrations and technical data in these operating instructions correspond to the
latest state at the time of publication.
We reserve the right to make design changes at any time and without notification of reasons.
Should you for any reason not be able to use these operating instructions either wholly or
partially, you can receive a replacement set of operating instructions for your machine by
quoting the number supplied overleaf.
We hope that you will be satisfied with your KRONE machine.
Maschinenfabrik Bernard Krone GmbH
Spelle
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Introduction
7
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3 Introduction
These operating instructions contain fundamental instructions. These must be observed in
operation and maintenance. For this reason, these operating instructions must be read by
operating personnel before commissioning and use, and must be available for easy reference.
Follow both the general safety instructions contained in the section on safety and the specific
safety instructions contained in the other sections.
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3.1 Purpose of Use
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The disc mower is used for cutting crops growing on the ground.
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3.2 Validity
These operating instructions apply to disc mowers of series:
AM 203 S; AM 243 S; AM 283 S and AM 323 S
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3.2.1 Contact
Pos: 8.6 /BA/Adr essen/Adresse Maschinenf abrik KRONE Spelle @ 0\mod_1 195568531083_78.d ocx @ 734 @ @ 1
Maschinenfabrik Bernard Krone GmbH
Heinrich-Krone-Strasse 10
D-48480 Spelle (Germany)
Telephone: + 49 (0) 59 77/935-0 (Head Office)
Fax.: + 49 (0) 59 77/935-339 (Head Office)
Fax.: + 49 (0) 59 77/935-239 (Spare parts - domestic)
Fax.: + 49 (0) 59 77/935-359 (Spare parts - export)
Email: [email protected]
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Introduction
8
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3.3 Identification Plate
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Maschinenfabrik Bernard Krone GmbH
Heinrich-Krone-Straße 10, D 48480 Spelle
Jahr
Année Masch. Nr No. de série
Type Made in
W.-Germany
AMS-1-038
Fig. 1
The machine data are rendered on the type plate (1). It is attached to the carrying bar.
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3.4 Information Required for Questions and Orders
Year
Mach. No.
Type
Note
The entire identification plate represents a legal document and should not be altered or
rendered illegible!
When asking questions concerning the machine or ordering spare parts, be sure to provide type
designation, machine number and the year of manufacture of the relevant machine: To ensure
that these data are always available, we recommend that you enter them in the fields above.
Note
Authentic KRONE spare parts and accessories authorised by the manufacturer help to ensure
safety. The use of spare parts, accessories or additional equipment not manufactured, tested or
approved by KRONE will exclude any liability for consequential damage.
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Introduction
9
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3.5 Intended Use
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The disc mower is built exclusively for customary use in agricultural work (intended use).
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Any use of the machine for other purposes is deemed not to be in accordance with intended
use. The manufacturer shall not be liable for any resulting damage; the user alone shall bear
the risk.
Operation in accordance with intended use also includes observing the operating, maintenance
and service instructions specified by the manufacturer.
Unauthorised modifications to the machine may affect the properties of the machine or disrupt
proper operation. For this reason, unauthorised modifications shall exclude any liability of the
manufacturer for consequential damage.
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3.6 Service life of the machine
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– The service life of this machine strongly depends on proper use and maintenance as well as
the operating conditions.
– Permanent operational readiness as well as long service life of the machine can be
achieved by observing the instructions and notes of these operating instructions.
– After each season of use, the machine must be checked thoroughly for wear and other
damage.
– Damaged and worn parts must be replaced before placing the machine into service again.
– After the machine has been used for five years, carry out full technical inspection of the
machine. According to the results of this inspection, a decision concerning the possibility of
reuse of the machine should be taken.
– Theoretically, the service life of this machine is unlimited as all worn or damaged parts can
be replaced.
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3.7 Technical data
All information, illustrations and technical data in these operating instructions correspond to the
latest state at the time of publication. We reserve the right to make design changes at any time
and without notification of reasons.
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wa Type AM 203 S AM 243 S AM 283S AM 323 S
Working width [mm] 2000 2400 2800 3200
Transport width [mm] Tractor width
Number of mowing discs 3 4 5 6/4
Number of mowing drums 2 2 2 2/4
Acreage [ha/h] 2.5 3 3.5 4
Power consumption [kW/HP] 27/37 32/43 38/52 44/60
PTO speed [rpm] 540
Hydraulic connections
required 1 x EW*
Service weight [kg] approx.
420 approx. 460 approx. 500 approx. 550
*) EW= Single-action control unit
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Safety
10
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4 Safety
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4.1 Identifying Symbols in the Operating Instructions
The safety instructions contained in this manual which could result in personal injury if not
followed are identified by the general danger sign:
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4.2 Identification of the hazard warnings
Danger!
DANGER! - Type and source of the hazard!
Effect: Danger to life or serious injuries.
• Measures for hazard prevention
Warning !
WARNING! - Type and source of the hazard!
Effect: Injuries, serious material damage.
• Measures for hazard prevention
Caution!
CAUTION! - Type and source of the hazard!
Effect: Property damage
• Measures for risk prevention.
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General function instructions are indicated as follows:
Note!
Note - Type and source of the note
Effect: Economic advantage of the machine
• Actions to be taken
Instructions which are attached to the machine need to be followed and kept fully legible.
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Safety
11
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4.2.1 Personnel Qualification and Training
The machine may be used, maintained and repaired only by persons who are familiar with it
and have been instructed about the dangers connected with it. The operator must define areas
of responsibility and monitoring of personnel. Should personnel lack the required knowledge,
they must receive the required training and instruction. The operator must ensure that the
contents of these operating instructions have been fully understood by personnel.
Repair work not described in these operating instructions should only be performed by
authorised service centres.
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4.2.2 Dangers in Case of Non-compliance with the Safety Instructions
Failure to follow the safety instructions could result in personal injury and environmental
hazards as well as damage to the machine. If the safety instructions are not respected, this
could result in the forfeiture of any claims for damages.
Failure to follow the safety instructions could result, for example, in the following hazards:
• Endangering of persons due to not protected working areas.
• Breakdown of important machine functions
• Failure of prescribed methods for repair and maintenance
• Endangering of persons due to mechanical and chemical effects
• Damage to the environment due to leaking hydraulic oil
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4.2.3 Safety-conscious work practices
Always observe the safety instructions set out in these operating instructions, all existing
accident prevention rules and any internal work, operating and safety rules issued by the
operator.
The safety and accident prevention regulations of the responsible professional associations are
binding.
The safety instructions provided by the vehicle manufacturer should also be observed.
Observe the applicable traffic laws when using public roads.
Be prepared for emergencies. Keep the fire extinguisher and first aid box within reach. Keep
emergency numbers for doctors and fire brigade close to the telephone.
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Safety
12
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4.3 Safety Instructions and Accident Prevention Regulations
1 Please follow all generally applicable safety and accident prevention regulations in addition
to the safety instructions contained in these operating instructions!
2 The attached warning and safety signs provide important information for safe operation. Pay
attention to these for your own safety!
3 When using public roads, make sure to observe the applicable traffic regulations!
4 Make sure that you are familiar with all equipment and controls as well as with their
functions before you begin working with the machine. It is too late to learn this when you are
using the machine for work!
5 The user should wear close fitting clothes. Avoid wearing loose or baggy clothing.
6 Keep the machine clean to prevent the danger of fire!
7 Before starting or moving the machine, make certain that nobody is in the vicinity of the
machine! (Watch for children!) Make sure that you have a clear view!
8 Carrying passengers during operation and transport on the working implement is not
permitted.
9 Couple implements correctly! Attach and secure implements to specified devices only!
10 When attaching or detaching implements, place the supporting devices in the correct
positions!
11 Use extreme caution when attaching or detaching implements onto or from the tractor!
12 Always attach ballast weights properly to the fixing points provided!
13 Observe permitted axle loads, gross weight and transport dimensions!
14 Check and attach transport equipment, such as lighting, warning devices and protective
equipment!
15 Actuating mechanisms (cables, chains, linkages etc.) for remote controlled devices must be
positioned in such a way that no movements are unintentionally triggered in any transport or
working positions.
16 Ensure that implements are in the prescribed condition for on-road travel and lock them in
place in accordance with the manufacturer's instructions!
17 Never leave the driver's seat when the vehicle is moving!
18 Always drive at the correct speed for the prevailing driving conditions! Avoid sudden
changes in direction when travelling uphill or downhill or across a gradient!
19 Hitched implements and ballast weights affect the driving, steering and braking response of
the machine. Make sure that you are able to brake and steer the machine as required!
20 Take into account the extension radius and/or inertia of an implement when turning corners!
21 Start up implements only when all safety devices have been attached and set in the
required position!
22 Keep safety equipment in good condition. Replace missing or damaged parts.
23 Keep clear of the working range of the machine at all times!
24 Do not stand within the turning and swivel range of the implement!
25 Never operate the hydraulic folding frames if anyone is inside the swivel range!
26 Parts operated by external power (e.g. hydraulically) can cause crushing and shearing
injuries!
27 Before leaving the tractor, lower the implement onto the ground, apply the parking brake,
switch off the engine and remove the ignition key!

Safety
13
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4.4 Attached devices
1 Use extreme caution when attaching or detaching implements onto or from the tractor!
2 Couple the respective application devices to the appropriate couplings (e.g. three-point
suspension) only and secure them in a way (transport, use) that excludes inadvertent lifting
or lowering of the device.
3 When using three-point linkage, the attachment categories of the tractor and the device
(e.g. PTO speed, hydraulic system) must be coordinated!
4 When using the outside controls for the three-point linkage, do not step between the tractor
and the device (risk of injury)!
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Safety
14
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4.5 PTO operation
1Use only PTO shafts specified by the manufacturer!
2The guard tube and guard cone of the PTO shaft and the PTO guard must be attached and
in good working condition (on the implement side, too)!
3Make sure that the required tube covers are in place for PTO shafts in transport and
working position!
4Before installing or detaching PTO shafts, disengage the PTO, switch off the engine and
remove the ignition key!
5When using PTO shafts with an overload safety or free-running coupling which are not
shielded by the guard on the tractor, mount the overload safety or free-running coupling on
the implement side!
6Always make sure that the PTO shaft is properly installed and secured!
7Attach chains to prevent the PTO shaft guard from rotating with the shaft!
8Before switching on the PTO, make sure that the selected PTO speed of the tractor
matches the permissible implement speed!
9Before switching on the PTO shaft make sure that no person is in the danger zone of the
device!
10Never switch on the PTO if the engine is switched off!
11No one should be in the vicinity of the rotating PTO or PTO shaft when the PTO is in use.
12Always switch off the PTO shaft when the angle is too large or the PTO shaft is not
required!
13 Caution! After disengaging the PTO danger due to the flywheel running on! Keep away from
the implement during this time. The machine may be worked on only if it is completely at
standstill and if the flywheel is secured by the parking brake.
14Cleaning, lubricating or adjusting PTO driven implements or the PTO shaft only with PTO
disengaged, engine switched off and ignition key withdrawn! Secure the fly-wheel with the
parking brake.
15Place the disconnected PTO shaft onto the support provided!
16After detaching the PTO shaft, attach the protective cover to the PTO end!
17If damage occurs, correct this immediately before using the implement!
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Note
The instructions of the manufacturer must be observed with regard to the PTO shaft. (separate
operating instructions)
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4.6 Hydraulic system
1The hydraulic system is pressurised!
2When connecting hydraulic cylinders and motors, make sure the hydraulic hoses are
connected as specified!
3When connecting the hydraulic hoses to the tractor hydraulics, make sure that the
hydraulics of both the tractor and the implement have been depressurized!
4In the case of hydraulic connections between tractor and machine, the coupling sleeves and
plugs should be marked to ensure a proper connection! If the connectors are interchanged,
the function will be reversed (e. g. raising/lowering) - Risk of accident!
5When searching for leaks, use suitable aids to avoid the risk of injury!
6Liquids escaping under high pressure (hydraulic oil) can penetrate the skin and cause
serious injury! Seek medical help immediately should injuries occur! Danger of infection!
7Before working on the hydraulic system, depressurise the system and switch off the engine!
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8 Check the hydraulic hose lines at regular intervals and replace them if damaged or worn!
The new hoses must fulfill the technical requirements set by the manufacturer of the
implement!
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4.7 Maintenance
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1Always make certain that the drive and the engine are switched off before doing any
repairs, maintenance or cleaning! - Remove the ignition key!
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2Regularly check that nuts and bolts are properly seated and tighten if necessary!
3When performing maintenance work with the machine raised, always secure it with suitable
supporting elements!
4Oils, greases and filters must be disposed of correctly!
5If protective devices and guards are subject to wear, check them regularly and replace them
in good time!
6Replacement parts must at least comply with the technical requirements set by the
manufacturer of the implements! This is guaranteed by original KRONE spare parts!
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7 When replacing working tools with cutting edges, use suitable tools and gloves!
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4.8 Unauthorised Conversion/Modification and Spare Parts Production
Conversions or modifications of the machine are permitted only with prior consultation with the
manufacturer. Original spare parts and accessories authorised by the manufacturer help to
ensure safety. Use of other parts may void liability for resulting damage.
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4.9 Inadmissible Modes of Operation
The operating safety of the delivered machine is guaranteed only when it is used as intended in
compliance with the introductory section "Intended use" of the operating instructions. The limit
values listed in the data charts should not be exceeded under any circumstances.
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4.10 Working in the vicinity of power transmission lines
1Always take great care when working under or in the vicinity of power transmission lines.
2Ensure that when in operation or being transported, the machine cannot exceed a total
height of approx. 4m.
3If there is any need to travel under overhead lines, the machine operator must request
information on the rated voltage and the minimum height of the overhead lines from the
overhead line operator.
4Always keep the safety distances according to the table.
Rated voltage
kV Safe distance from overhead lines m
To 1 1
Above 1 to 110 2
Above 101 to 220 3
Above 220 to 380 4
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4.11 Introduction
The disc mower is equipped with all safety devices (protective devices). However, it is not
possible to eliminate all potential hazards on this machine as this would impair its full functional
capability. Hazard warnings are attached to the machine in the relevant areas to warn against
any dangers. The safety instructions are provided in the form of so-called warning pictograms.
Important information on the position of these safety signs and what they mean is given below!
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WARNING!
Danger of injury on machine parts if danger zones have not been marked when warning
pictograms are missing, damaged or illegible.
Danger of injury due to dangerous parts and other residual risks as users or third parties enter
the danger area or reach into it as they are not aware of the danger.
• Immediately replace damaged or illegible labels.
• Following repair work, always attach appropriate adhesive safety labels to all the replaced,
modified or repaired components.
• Never clean areas carrying an adhesive safety label using a high-pressure cleaner.
Familiarise yourself with the statement of the warning pictograms. The adjacent text and
the selected location on the machine provide information on the special danger spots on
the machine.
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4.12 Position of the Adhesive Safety Stickers on the Machine
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2 58
7
43
61 6 9
Fig. 2
1)
CAUTION
Max. PTO speed
540 RPM939 462-0
Order No. 939 462 0 (1x)
2)
Order No. 942 020 2 (2x)
3)
Order No. 942 018 1 (1x)
4)
Order No. 942 050 0 (1x)

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19
5)
Order No. 942 019 1 (1x)
6)
Order No. 939 495 1 (2x)
7)
Order No. 942 228 0 (2x)
8)
Order No. 942 032 2 (1x)
9)
To avoid injury or death,
do not contact electric
lines.
Order No. 27 009 069 0 (1x)
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4.13 Position of the General Information Labels on the Machine
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51632
4
Fig. 3
1)
139 888-0 139 889-0
139-888 139-889
939 567-1 (1x)
2)
939 180 2 (1x)
3)
939 541 2 (1x) AM 203 S
939 542 2 (1x) AM 243 S
939 546 2 (1x) AM 283 S
939 545 2 (1x) AM 323 S
4)
942 132 0 (1x)
5)
15 mm
min. 3mm
942 009 2 (1x) with blade
screw connection
5)
18mm
12mm 939 548 0
939 548 0 (1x) with blade
screw connection