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Operating Manual AMAZONE Catros 4001-2TS Catros 4001-2TS Catros 5001-2TS Catros 5001-2TS Catros 6001-2TS Catros 6001-2TS Compact Disc Cultivator Please read and follow this operating manual before putting MG3661 the machine into operation. BAG0081.10 09.14 Printed in Germany Keep it in a safe place for...
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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 501-234 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: MG3661 Compilation date: 09.14 ...
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We update our operating manuals regularly. Your suggestions for improvement help us to create ever more user-friendly manuals. Send us your suggestions by fax. AMAZONEN-WERKE H. DREYER GmbH & Co. KG Postfach 51 D-49202 Hasbergen Phone: +49 5405 501-0 Fax: +49 5405 501-234 E-mail: amazone@amazone.de Catros BAG0081.10 09.14...
Table of Contents User information ..................8 Purpose of the document ......................8 Locations in the operating manual ................... 8 Diagrams used ......................... 8 General safety instructions ................. 9 Obligations and liability ......................9 Representation of safety symbols ..................11 Organisational measures .......................
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Table of Contents Support wheels (Option) ....................... 47 Swing compensation ......................49 5.10 Additional weights ......................... 50 5.11 GreenDrill catch crop sowing unit ..................51 5.12 Safety chain for machines without brake systems ..............51 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 Always keep all the warning pictograms of the machine clean and in a legible state.
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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 MD087 Laceration or amputation hazard. Will cause severe injury to toes or feet. Keep a safe distance from the machine while the tractor engine is running with connected PTO shaft. MD094 Danger from electric shock or burns due to unintentional contact with electric transmis- sion lines or from approaching high-voltage transmission lines without authorisation.
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General safety instructions 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.
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General safety instructions MD199 The maximum operating pressure of the hydrau- lic system is 210 bar. MD201 The torque for the bolt connection is 325 Nm. MD217 Hazard resulting from the machine folded in and coupled tipping over. This danger can cause extremely serious and potentially fatal injuries.
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...
General safety instructions 2.16.3 Electrical system • When working on the electrical system, always disconnect the battery (negative terminal). • Only use the prescribed fuses. If fuses are used with too high a rating, the electrical system will be destroyed – danger of fire. •...
• 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 BAG0081.10 09.14...
Loading and unloading Loading and unloading After unloading: Move the wheels from transport position to operating position. 1. Fold out the machine. 2. Raise the chassis slightly to that the wheels are clear of the ground. 3. Rotate both wheels and tighten the wheel nuts to 325 Nm.
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Loading and unloading Loading on a low-loader: • Machine is folded in, the chassis is lowered. • Lower the machine in longitudinal direction onto 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.
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Loading and unloading Loading and unloading with a tractor WARNING There is a risk of an accident when the tractor is unsuitable and the machine brake system is not connected to the tractor or is filled. • Correctly couple the machine to the tractor, before loading the machine onto a transport vehicle or unloading it from a transport vehicle.
Product description Product description This section: • Provides a comprehensive overview of the machine structure. • Provides the names of the individual modules and controls. Read this section when actually at the machine. This helps you to understand the machine better. Overview of subassemblies Fig.
Product description Safety and protection equipment (1) Stop valve to prevent activating an unintentional unfolding action from the tractor via the cable winch. ο Stop valve in position A – hydraulic unfolding locked. ο Stop valve in position B – hydraulic unfolding unlocked through activation of 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 By tools rising or falling unintentionally •...
For the machine to be operated as intended, the tractor must fulfil the following requirements: Tractor engine power from 91 kW (125 PS) from 102 kW (140 PS) Catros 4001-2TS Catros 4001-2TS from 110 kW (150 PS) from 120 kW (165 PS) Catros 5001-2TS...
Structure and function Structure and function The following section provides information on the machine structure and the functions of the individual components. Function Fig. 13 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.
Structure and function Chassis The running gear and draw bar are a component of the entire ma- chine and must only be used as a part of this machine. Mounting onto another Catros disc cultivator is not permitted. • chassis raised, machine in working position. Fig.
• The offsetting of the two disc rows is ad- justed via the offset slide (Fig. 17/2) 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.
Structure and function Wedge ring tyre roller The wedge ring roller takes over the depth control of the concave discs. (1) Cage roller with 520 mm diameter (2) Tandem roller The tandem roller consists of ο the front spiral tube roller, ο...
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Structure and function Fig. 20 (1) Knife holder raised (2) Knife holder lowered (3) Adjustment screw with lock nut → After adjusting, lock the bolts with a lock nut! (1) Fastening bolts of the knife holder. (2) Stop bolt for the blade The fastening bolts of the knife holder shear in event of overload.
Structure and function Tensioned crosspiece Fig. 23 The machine is coupled to the tractor using the tensioned crosspiece with Category III lower link pins. WARNING Risk of accidents if the connection between machine and tractor separates! Always use ball sleeves with sockets and integral linch pins. Stand Fig.
Structure and function Support wheels (Option) The support wheels are designed for a load that has the mass of the machine so that the lower links of the tractor can be moved in the float posi- tion. The front supporting wheels guide the machine reliably at the set working depth.
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Structure and function Increase working depth: 1. Actuate tractor control unit yellow. → Raise the machine, thus relieving the rear spacer elements. 2. Swivel out the rear spacer elements (starting with both stop washers (Fig. 26/4) on both booms). 3. Actuate tractor control unit yellow. →...
Structure and function Swing compensation The swing compensation reduces the pitching motion and jumping of the machine when in operation. Switch on the swing compensation when required: 1. Open the stop tap (Position B). 2. Actuate tractor control unit yellow. →...
Structure and function 5.10 Additional weights Fig. 29 (Optional) The Catros can be equipped with additional weights (Fig. 29/1). 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.
Structure and function 5.11 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) Locking pin for securing the foldable ascent See also the GreenDrill operating manual.
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] Front weight (if available) See front weight in technical data, or weigh [kg] Maximum drawbar load...
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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 6.1.2 Requirements for tractor operation with attached machines WARNING Risk of breakage during operation of components through unap- proved combinations of connecting equipment! • Ensure: ο that the connection fittings on the tractor possess sufficient permissible support capability for the supported weight ac- tually present.
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. •...
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Coupling and uncoupling the machine 6. Perform a visual inspection to ensure that the lower link hooks are correctly locked before reversing the tractor. 7. Raise the stand into the transport position. 8. Remove the wheel chocks. Country-specific regulation for machines without brake systems: 9.
Coupling and uncoupling the machine Uncoupling the machine WARNING Risk of contusions, cutting, catching, drawing in and knocks through insufficient stability and possible tilting of the uncou- pled machine! Park the empty machine on a horizontal space with a hard surface. When uncoupling the machine, there must always be enough space in front of the machine, so that you can align the tractor with the ma- chine if necessary.
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 Both rollers must be aligned flush with one another! Adjusting the spindle using the ratchet 1. Remove the clip pin (Fig. 36/3). 2. Engage the turning lever (Fig. 36/2) in the required direction. 3. Use the hand lever (Fig. 36/1) to lengthen or shorten the spindle.
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. 38). 1. Move the machine back a little.
Adjustments 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 Fig. 40 • Fig. 40: Correct setting of disc rows. • Fig. 41: Adjust 1st disc row to right and check again.
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. 44/1) 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...
Transportation WARNING Danger of breaking during operation, insufficient stability and insufficient tractor steering and braking power on improper use of the tractor! These risks pose serious injuries or death. Comply with the maximum load of the connected machine and the approved axle and support loads of the tractor.
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Transportation 1. Actuate tractor control unit yellow. → Lower chassis completely to transport position. 2. Raise tractor lower links. 3. Actuate tractor control unit blue. → Fold in machine wings completely. 4. Remove tarpaulins from parking position on the chassis. 5.
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...
Use of the machine 10.1 Conversion from transport to operational position WARNING • Instruct people to leave the swivel area of machine's exten- sion arm before you fold the machine's extension arm out or in. • Instruct persons away from the swivel range of the running gear before folding this up or down! •...
Use of the machine 10.2 Use on the field The device must be adjusted at the lower link of the tractor so that the frame is parallel to the soil surface longitudinally and transversely during the work procedure! Machine with support wheels, see page 47. 10.3 Turning at headland When turning through a curve at the headland, the disc rows must be...
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 11.2.1 Lubricants For lubrication work, use a lithium saponified multipurpose grease with EP additives: Company Lubricant name ARAL Aralub HL2 FINA Marson L2 ESSO Beacon 2 SHELL Retinax A 11.2.2 Lubrication point overview Fig. 49 Lubrication point Interval [h] Quantity Roller frame mounting Chassis hydraulic cylinder...
Cleaning, maintenance and repairs 11.3 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 See page Servicing work Component...
Cleaning, maintenance and repairs 11.5 Slide bearings of offset slide (Workshop work) Replace slide bearing at approx. 4 mm clearance. To replace the slide bearings (Fig. 54/1), 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 11.8 Roller WARNING Inspect the roller bearings for free movement at regular inter- vals! Risk of accidents due to defective bearings! 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 11.11 Tyres/wheels Check chassis wheels regularly for damage and firm seating on the wheel rim. • Required tyre pressure. Running gear wheels and support wheels: 3,0 bar • Required tightening torque for wheel nuts or bolts: 325 Nm •...
Cleaning, maintenance and repairs 11.11.2 Mounting tyres (workshop work) • Remove any outbreaks of corrosion from the wheel rim seating surfaces before fitting a new/another tyre. Corrosion can cause damage to the wheel rims when the vehicle is in operation. •...
Cleaning, maintenance and repairs 11.13 Hydraulic cylinder for foldable booms Check that the cylinder eye is firmly attached to the hydraulic cylinder Required tightening torque for lock nut on hydraulic cylinder for folda- ble booms: 300 Nm Check the screw connections on the hydraulic cylinders (Fig.
• 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 11.14.1 Labelling hydraulic hose lines The assembly labelling provides the follow- ing information: Fig. 63/... (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).
11.14.4 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...
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Cleaning, maintenance and repairs Hydraulics – Set working depth (green) Catros BAG0081.10 09.14...
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Cleaning, maintenance and repairs 11.17 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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Postfach 51 Phone: +49 5405 501-0 D-49202 Hasbergen-Gaste Fax: +49 5405 501-234 Germany e-mail: amazone@amazone.de http:// www.amazone.de Plants: D-27794 Hude • D-04249 Leipzig • F-57602 Forbach Branches in England and France Manufacturers of mineral fertiliser spreaders, field sprayers, sowing machines,...
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