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Operating Manual AMAZONE Catros 3001 Catros 3001 Catros 3501 Catros 3501 Catros 4001 Catros 4001 Catros 4002-2 Catros 4002-2 Catros 5002-2 Catros 5002-2 Catros 6002-2 Catros 6002-2 Compact Disc Cultivator Please read and follow this operating manual before putting MG3578 the machine into operation.
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Reading the instruction Manual and following it should seem to be in- convenient and superfluous as it is not enough to hear from others and to realize that a machine is good, to buy it and to believe that now everything should work by itself.
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+49 5405 501-0 E-mail: 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: MG3578 Compilation date: 02.17 ...
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Dear Reader We update our operating manuals regularly. Your suggestions for improvement help us to create ever more user-friendly manuals. AMAZONEN-WERKE H. DREYER GmbH & Co. KG Postfach 51 D-49202 Hasbergen Phone: +49 5405 501-0 E-mail: amazone@amazone.de Catros BAG0053.14 10.17...
User information User information ..................7 Purpose of the document ......................7 Locations in the operating manual ................... 7 Diagrams used ......................... 7 General safety instructions ................. 8 Obligations and liability ......................8 Representation of safety symbols ..................10 Organisational measures ....................... 11 Safety and protection equipment ...................
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User information GreenDrill catch crop sowing unit ..................49 5.10 Central lubrication (optional) ....................50 Commissioning ..................52 Checking the suitability of the tractor ..................53 6.1.1 Calculating the actual values for the total tractor weight, tractor axle loads and load capacities, as well as the minimum ballast ................
User information User information The "User information" section supplies information on using the op- erating manual. Purpose of the document This operating manual • Describes the operation and maintenance of the machine. • Provides important information on safe and efficient handling of the machine.
General safety instructions General safety instructions This section contains important information on safe operation of the machine. Obligations and liability Comply with the instructions in the operating manual Knowledge of the basic safety information and safety regulations is a basic requirement for safe handling and fault-free machine operation. Obligations of the operator The operator is obliged only to let those people work with/on the ma- chine who...
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General safety instructions Risks in handling the machine The machine has been constructed to the state-of-the art and the recognised rules of safety. However, there may be risks and re- strictions which occur when operating the machine • For the health and safety of the user or third persons, •...
General safety instructions Representation of safety symbols Safety instructions are indicated by the triangular safety symbol and the highlighted signal word. The signal word (DANGER, WARNING, CAUTION) describes the gravity of the risk and has the following sig- nificance: DANGER Indicates an immediate high risk, which will result in death or serious physical injury (loss of body parts or long term damage) if not avoided.
General safety instructions Organisational measures The operator must provide the necessary personal protective equip- ment, such as: • Protective glasses • Protective shoes • Protective suit • Skin protection, etc. The operation manual • Must always be kept at the place at which the machine is oper- ated.
General safety instructions User training Only those people who have been trained and instructed may work with/on the machine. The operator must clearly specify the responsi- bilities of the people charged with operation, maintenance and repair work. People being trained may only work with/on the machine under the supervision of an experienced person.
General safety instructions Safety measures in normal operation Only operate the machine if all the safety and protection equipment is fully functional. Check the machine at least once a day for visible damage and check the function of the safety and protection equipment. Dangers from residual energy Note that there may be residual mechanical, hydraulic, pneumatic and electrical/electronic energy at the machine.
Immediately replace any machine parts which are not in a perfect state. Use only genuine AMAZONE spare and wear parts or the parts cleared by AMAZONEN-WERKE so that the operating permit retains its validity in accordance with national and international regulations. If...
General safety instructions 2.13 Warning pictograms and other signs on the machine 2.13.1 Positioning of warning pictograms and other labels The following diagrams show the arrangement of the warning picto- grams on the machine. Fig. 1 Fig. 2 Catros BAG0053.14 10.17...
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General safety instructions Warning pictograms Fig. 3 Fig. 4 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).
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General safety instructions Warning pictograms - structure Warning pictograms indicate dangers on the machine and warn against residual dangers. At these points, there are permanent or unexpected dangers. A warning pictogram consists of two fields: Field 1 is a pictogram describing the danger, surrounded by triangular safety symbol.
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General safety instructions Order number and explanation Warning pictograms MD078 Risk of contusions for fingers or hands through accessible moving machine parts! This danger causes extremely serious injuries with the loss of body parts such as fingers or hands. Never reach into the danger area when the trac- tor engine is running with PTO shaft / hydraulic system connected.
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General safety instructions MD084 Risk of contusions over the whole body from machine parts moving down from above! This danger will cause serious injuries anywhere on the body or death. It is forbidden to stand in the swivel area of mov- ing machine parts.
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General safety instructions 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 hydraulic fluid escaping at high pressure passes through the skin and into the body.
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General safety instructions 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 tractor and the machine against unintentional start-up and rolling before any intervention in the machine.
General safety instructions 2.14 Dangers if the safety information is not observed Nonobservance of the safety information • Can pose both a danger to people and also to the environment and machine. • Can lead to the loss of all warranty claims. Seen individually, non-compliance with the safety information could pose the following risks: •...
General safety instructions 2.16 Safety information for users WARNING Risk of being crushed, cut, caught, drawn in or struck due to insufficient traffic and operational safety! Before starting up the machine and the tractor, always check their traffic and operational safety. 2.16.1 General safety and accident prevention information •...
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General safety instructions • When coupling and uncoupling machines, move the support equipment (if available) to the appropriate position (stability). • When actuating the support equipment, there is a danger of inju- ry from contusion and cutting points! • Be particularly careful when coupling the machine to the tractor or uncoupling it from the tractor! There are contusion and cutting points in the area of the coupling point between the tractor and the machine.
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General safety instructions Machine transportation • When using public highways, national road traffic regulations must be observed. • Before moving off, check: ο the correct connection of the supply lines ο the lighting system for damage, function and cleanliness ο the brake and hydraulic system for visible damage ο...
• 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...
• Spare parts must meet at least the specified technical require- ments of AMAZONEN-WERKE! This is ensured through the use of AMAZONE original spare parts. Catros BAG0053.14 10.17...
Loading and unloading Loading and unloading Loading using a lifting 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! Fig.
Read this section when actually at the machine. This helps you to understand the machine better. The machine is composed of the following main components: • Rigid frame (Catros 3001, 3501 and 4001) • Hydraulically foldable frame (Catros 4002-2, 5002-2, 6002-2)) •...
Product description Fig. 7 Catros -2: (1) Foldable boom, right (2) Foldable boom, left (3) Hydraulic cylinder for folding the booms (4) Hydraulic cylinder for depth adjustment Safety and protection equipment Catros -2: (1) Stop valve to prevent activating an uninten- tional unfolding action from the tractor via the cable winch.
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 those specified above are forbidden and shall be con- sidered as improper. For any damage resulting from improper use: •...
Product description Danger area and danger points The danger area is the area around the machine in which people can be caught: • By work movements made by the machine and its tools • By materials or foreign objects ejected by the machine •...
Product description Rating plate and CE marking The following diagrams show the location of the rating plate and CE marking. The rating plate shows: • Vehicle- / machine ID no.: • Type • Basic weight kg • Permissible system pressure (bar) •...
Product description Necessary tractor equipment For the machine to be operated as intended, the tractor must fulfil the following requirements: Tractor engine power Catros 3001 from 66 kW (90 PS) Catros 3001 from 77 kW (105 PS) Catros 3501 from 77 kW (105 PS)
Structure and function Structure and function The following section provides information on the machine structure and the functions of the individual components. Function Fig. 12 The Catros compact disc cultivator is suitable for • shallow stubble cultivation directly after threshing •...
Structure and function Hydraulic system connections • All hydraulic hose lines are equipped with grips. Coloured markings with a code number or code letter have been applied to the gripping sections in order to assign the respective hydraulic function to the pressure line of a tractor control unit! Films are stuck on the implement for the markings that illustrate the respective hydraulic function.
Structure and function 5.2.1 Coupling the hydraulic hose lines WARNING Risk of being crushed, cut, caught, drawn in or struck due to faulty hydraulic functions when the hydraulic hose lines are connected incorrectly! When coupling the hydraulic hose lines, observe the coloured mark- ings on the hydraulic plugs.
• The offsetting of the two disc rows is ad- justed via the offset slide (Fig. 13/2) to working depth and speed. Adjustment is made with the AMAZONE eccentric pins. • The working intensity of the discs over the working depth of the disc cultivator can be adjusted.
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Structure and function Catros 3001 / 3501: To achieve the transport width, the disc rows must be locked in the transport position.. They are locked and unlocked via a release cord from the tractor cabin. The disc rows are locked when the locking pawls (Fig.
Structure and function Roller The roller takes over the depth control of the tools. • Tandem roller TW520/380 The tandem roller consists of ο the front spiral tube roller installed in the top group of holes. ο the rod roller installed in the bottom group of holes.
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Structure and function • U-profile roller UW580 → Very well suited for light soils. → Resistant to clogging and good load- bearing capacity. • Double U-profile roller DUW580 → Very well suited for light and medium soils. → Resistant to clogging and good load- bearing capacity.
Structure and function Adaptor frame, Category IV and V (optional) The Adaptor frame is designed so that it meets the requirements and dimensions of 3-point at- tachment of Category 4 or 5. Install adaptor frame on the machine side on Category 3.
Structure and function Rear harrow (optional) The rear harrow is used to crumble and level the soil. The working intensity can be adjusted by insert- ing the pins into different holes. Secure the pin with a linch pin. (1) Positioning pin for adjusting the working intensity.
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Structure and function Harrow system 12-284 Hi For rollers: TW520/380, DUW580 Fig. 24 Spring blade system 142 For roller: WW580 Fig. 25 Spring-mounted clearing system 167 For roller: UW580 Fig. 26 Catros BAG0053.14 10.17...
Under dry and extremely hard conditions, the additional weights make it possible to optimise the penetration of the discs into the soil. • One set of additional weights corresponds to 4 times 25 kg. Catros 3001, 3501 and 4001: → Install max. 2 sets. Catros 4002-2, 5002-2, 6002-2: →...
Structure and function GreenDrill catch crop sowing unit The GreenDrill catch crop sowing unit enables the sowing of fine seeds and catch crops during soil 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.
Structure and function 5.10 Central lubrication (optional) Only for Catros Pro The implement is lubricated electrically with a central pump. (1) Tank (2) Connection for filling with cartridge/return line (3) Rotary knob for time interval with sealing (4) Grease nipple for filling the tank Fig.
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Structure and function Lubrication recommendation • When applying slurry: Initial use: Pause time 2 hours Later: Pause time 2-4 hours • No slurry: Lubricate once a day Connection (1) red (+) (2) brown (-) The direction of rotation of the pump must match with the arrow on the hopper.
Commissioning Commissioning This section contains information • on operating your machine for the first time. • on checking how you may connect the machine to your tractor. • Before operating the machine for the first time the operator must have read and understood the operating manual. •...
Commissioning Checking the suitability of the tractor WARNING Danger of breaking during operation, insufficient stability and insufficient tractor steering and braking power on improper use of the tractor! • Check the suitability of your tractor before you attach or hook up the machine.
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Commissioning 6.1.1.1 Data required for the calculation Fig. 33 [kg] Empty tractor weight See tractor operating manual or vehicle [kg] Front axle load of the empty tractor documentation [kg] Rear axle load of the empty tractor [kg] Total weight of rear-mounted machine or See technical data for machine or rear bal- rear ballast last...
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Commissioning 6.1.1.2 Calculation of the required minimum ballasting at the front G of the tractor for V min assurance of the steering capability • − • • • Enter the numeric value for the calculated minimum ballast G V min required on the front side of the tractor, in the table (Section 6.1.1.7).
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Commissioning 6.1.1.7 Table Actual value according to Approved value ac- Double approved calculation cording to tractor load capacity (two instruction manual tyres) Minimum ballast front / rear ≤ Total weight ≤ ≤ Front axle load ≤ ≤ Rear axle load •...
Commissioning Securing the tractor / machine against unintentional start-up and roll- WARNING Risk of contusions, cutting, catching, drawing in and knocks when making interventions in the machine through • unintentional lowering of the machine when it is raised with the tractor's three-point hydraulic system and unsecured. •...
Coupling and uncoupling the machine Coupling and uncoupling the machine When coupling and uncoupling machines, follow the instructions giv- en in the section "Safety instructions for the operator" page 23. WARNING Risk of contusions from unintentional starting and rolling of the tractor and machine when coupling or uncoupling the machine! Secure the tractor and machine against unintentional start-up and rolling away before entering the danger area between the tractor and...
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Coupling and uncoupling the machine WARNING Risk of contusions, cutting, catching, drawing in and knocks when the machine unexpectedly releases from the tractor! • Use the intended equipment to connect the tractor and the ma- chine in the proper way. •...
Coupling and uncoupling the machine 6. From the tractor seat, couple the upper link to the top attach- ment point of the three-point attachment frame using the top link hook. → The top link hook locks automatically. 7. Perform a visual inspection to ensure that the upper and lower link hooks are correctly locked before reversing the tractor.
Adjustments Adjustments WARNING Risk of contusions, cutting, catching, drawing in and knocks through • unintentional falling of the machine raised using the trac- tor's three-point hydraulic system. • unintentional falling of raised, unsecured machine parts. • unintentional start-up and rolling of the tractor-machine combination.
Adjustments 8.1.1 Mechanical working depth adjustment The depth is adjusted by turning the setting spin- dle (Fig. 36/1) using the hand lever (Fig. 36/2). Catros -2: Set the working depth to the same value at all adjustment units. Fig. 36 Adjusting spindle with ratchet 1.
Adjustments Offset of the disc rows The offset of the disc rows is adjusted as re- quired by means of an AMAZONE eccentric pin. 6 insertion holes are available for this purpose. (Fig. 39). 1. Move the machine back a little.
Adjustments Fine adjustment is carried out by rotating the eccentric pin (Fig. 41) from position 1 to position 1. Release the clip pin. 2. Turn the eccentric pin (position 1-4). 3. Secure the clip pin. Fig. 42 The work pattern must be checked by viewing the cultivation horizon behind the machine: (1) Cutting edge 1st disc row (2) Cutting edge 2nd disc row...
Adjustments Scraper Scrapers are adjusted at the factory. Adjust the setting to the working conditions as follows: 1. Secure the tractor against unintentional starting and unintentional rolling away. 2. Release the screw (Fig. 46/1) below the scraper. 3. Adjust the scraper in the slotted hole. 4.
Transportation Transportation • On transportation journeys, follow the instructions given in the section "Safety instructions for the operator", page 25. • Before moving off, check: ο that the supply lines are connected correctly. ο the lighting system for damage, function and cleanliness. ο...
It is forbidden to ride on the machine and/or climb the running ma- chine. Conversion from operational to transport position Catros 3001 and 3501 DANGER Risk of injury with overwidth transport. Push in and lock the outer border discs / border tines!
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Transportation Catros 4001 The transport position corresponds to the opera- tional position! No conversion is necessary! The machine is very wide! Pay attention to country-specific regu- lations for road transport! Catros-2 1. Raise the machine so that there is sufficient ground clearance to allow unobstructed folding in.
Use of the machine Use of the machine When using the machine, observe the information in the sections • "Warning signs and other labels on the machine", from page 17 • "Safety instructions for operators", from page 23 Observing this information is important for your safety. WARNING Danger of breaking during operation, insufficient stability and insufficient tractor steering and braking power on improper use...
Only when the machine is fully raised do the soil cultivating tools have sufficient ground clearance and are thus protected against damage. Catros 3001 and 3501 1. Lower the machine. 2. With the machine lowered, reverse a little on the field.
Use of the machine 10.2 Use on the field The compact disc cultivator should preferably be used in float position of the tractor three-point hydraulic system. The depth guidance is carried out by the roller. During use in the field, operation is limited to raising or positioning the device at the headland.
Faults Faults WARNING Risk of contusions, cutting, catching, drawing in and knocks through ο unintentional falling of the machine raised using the tractor's three-point hydraulic system. • unintentional falling of raised, unsecured machine parts. ο unintentional start-up and rolling of the tractor- machine combination.
Cleaning, maintenance and repairs Cleaning, maintenance and repairs WARNING Risk of contusions, cutting, catching, drawing in and knocks through • unintentional falling of the machine raised using the trac- tor's three-point hydraulic system. • unintentional falling of raised, unsecured machine parts. •...
Cleaning, maintenance and repairs Catros pro: Never aim the cleaning jet from the nozzle of the high pressure clean- er/steam jet directly on the neoprene cover! Fig. 55 12.2 Lubrication regulations Lubrication points on the machine are indicated with the foil (Fig. 55). Carefully clean the lubrication nipple and grease gun before lubrication so that no dirt is pressed into the bearings.
Cleaning, maintenance and repairs 12.2.2 Lubrication point overview Fig. 56 Lubrication point Interval [h] Quantity Centre section joint bearing, Catros -2: right and left Working depth above setting spindle or Working depth above hydraulic Catros pro: cylinder Catros -2: Hydraulic cylinder folding Fig.
Cleaning, maintenance and repairs 12.3 Service plan – overview • Carry out maintenance work when the first interval is reached. • The times, continuous services or maintenance intervals of any third party documentation shall have priority. After the first working run Servicing work Component See page...
Cleaning, maintenance and repairs 12.5 Slide bearings of offset slide (Workshop work) Replace slide bearing at approx. 4 mm clearance. To replace the slide bearings (Fig. 60/1), place the folded-out machine down so that the slide bearings are free from tension. The disc units must touch the ground, but must not support the weight of the machine! If necessary, support the disc units!
Cleaning, maintenance and repairs 12.7 Roller • Inspect the roller bearings for free move- ment at regular intervals! • Check the bolts for tightness. • Required tightening torque: 210 Nm. To connect the rollers correctly, the clamping bracket and its bolts must be installed according to Fig.
Cleaning, maintenance and repairs 12.10 Hydraulic cylinder for foldable booms Required tightening torque for lock nut on hydraulic cylinder for folda- ble booms: 300 Nm Check the screw connections on the hydrau- lic cylinders (Fig. 64/1) every 6 months: Fig. 65 Fig.
Cleaning, maintenance and repairs 12.11 Alignment of folding implements (workshop work) WARNING Danger of crushing due to unintentional movement of implement parts. Only dismount the hydraulic cylinder when it is in a powerless state. Aligning the boom parallel to the ground Adjust the length of the hydraulic cylinder such that both lateral frames are parallel to the ground when in working position on a level surface.
• 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...
Cleaning, maintenance and repairs 12.12.1 Labelling hydraulic hose lines The assembly labelling provides the follow- ing information: Fig. 69/... (1) Manufacturer's marking on the hydraulic hose line (A1HF) (2) Date of manufacture of hydraulic hose line (04 / 02 = year / month = February 2004) (3) Maximum approved operating pressure (210 BAR).
12.12.4 Installation and removal of hydraulic hose lines When installing and removing hydraulic hose lines, always observe the following information: • Only use AMAZONE original hydraulic hose lines. • Ensure cleanliness. • You must always install the hydraulic lines so that, in all states of operation: ο...
Cleaning, maintenance and repairs 12.15 Screw tightening torques 10.9 12.9 M 8x1 M 10 16 (17) M 10x1 M 12 18 (19) M 12x1,5 M 14 M 14x1,5 M 16 M 16x1,5 M 18 M 18x1,5 M 20 M 20x1,5 M 22 M 22x1,5 1050...
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