LEMKEN Karat 9 KA Operating Instructions Manual
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LEMKEN Karat 9 KA Operating Instructions Manual

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Operating Instructions
Cultivator
Karat 9 KA
- en -
Item no. 175_4385
06/07.21
LEMKEN GmbH & Co. KG
Weseler Straße 5, 46519 Alpen / Germany
Telephone +49 28 02 81 0, Fax +49 28 02 81 220
lemken@lemken.com, www.LEMKEN.com

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  • Page 1 Operating Instructions Cultivator Karat 9 KA - en - Item no. 175_4385 06/07.21 LEMKEN GmbH & Co. KG Weseler Straße 5, 46519 Alpen / Germany Telephone +49 28 02 81 0, Fax +49 28 02 81 220 lemken@lemken.com, www.LEMKEN.com...
  • Page 3 However, this brief instruction is not a substitute for thorough study of the operating instructions. These operating instructions will help to familiarise you with the LEMKEN GmbH & Co. KG device and the options available for using it.
  • Page 4 Remember that you should only use genuine LEMKEN spare parts. Reproduction parts have a negative influence on the function of the device, have a shorter ser- vice life and present risks and hazards that cannot be estimated by LEMKEN GmbH & Co. KG. They also increase the maintenance costs.

  • Page 5: Table Of Contents

    CONTENTS General information ....................11 Liability ......................... 11 Guarantee ........................11 Copyright ........................12 Optional accessories ....................12 Type plate ........................13 Symbols used in the Operating Instructions ............15 Hazard classes ......................15 Information........................15 Environmental protection ................... 15 Indication of passages ....................
  • Page 6 Applicable rules and regulations ................28 Operation on public highways ................... 28 3.9.1 Lighting system and identification ................28 3.9.2 Requirements of the tractor ..................28 3.9.3 Permissible transport speed ..................29 3.9.4 Permissible lateral inclination during transportation ........... 30 3.9.5 Check before departure .....................
  • Page 7 Preparation of the Tractor ..................44 Tyres ..........................44 Lift Rods ........................44 Check Chains or Sway Blocks of the Three Point Linkage ........44 Required voltage sources ..................44 Hydraulic equipment required ..................45 Brake system ....................... 46 6.6.1 Air brake system ......................46 6.6.2 Hydraulic brake system .....................
  • Page 8 Traction increase device .................... 65 Safety chain ......................... 65 Folding the lateral parts in and out ............... 67 Folding in ........................67 Folding out ........................69 10 Driving on public highways ................... 71 10.1 General information ....................71 10.2 Preparation for driving on public roads ..............71 10.3 Hydraulic transport lock .....................
  • Page 9 11.7 Automatic overload protection .................. 90 11.7.1 Tines ........................90 11.7.2 Concave discs ......................91 11.7.3 Edge discs ......................91 11.8 Mounting and dismantling the weed harrow ............. 92 11.9 Adjusting the weed harrow..................94 11.10 Rollers .......................... 96 11.10.1 General .......................
  • Page 10 13 Detaching ....................... 113 13.1 General information ....................113 13.2 Braking system ......................114 13.2.1 Compressed air brake ..................114 13.2.2 Hydraulic braking system ..................114 13.3 Uncoupling......................... 115 13.3.1 Machine with hydraulic drawbar ................115 13.3.2 Machine with traction increase device ..............116 14 Switching over to different share systems ............
  • Page 11 16.4 Maintenance intervals ....................130 16.4.1 After the initial start-up (at the latest after 2 hours) ..........130 16.4.2 Daily inspection ....................130 16.4.3 Weekly checks ..................... 131 16.4.4 Annual check ......................131 16.4.5 Lubrication chart ....................132 16.4.6 Overview of lubricating points................133 16.5 Draining the compressed air tank ................
  • Page 12 17 Technical data ....................... 150 18 Noise, Airborne Sound ..................153 19 Notes ........................153 Index ..........................154...

  • Page 13: General Information

    Co. KG, in particular Section IX, shall apply. Liability. In line with the dimensions cited in these conditions the LEMKEN GmbH & Co. KG shall not be held liable for any personal or material damage, when such damage is caused by one or more of the following reasons: ...

  • Page 14: Copyright

    Infringements will result in a claim for damages. Optional accessories LEMKEN implements may be equipped with various accessories. The operating instructions below describe both series components and optional accessories. Please note: These accessories will vary depending on the type of equipment.

  • Page 15: Type Plate

    General information Type plate The implement is marked with a type plate. The type plate is located at the front right of the implement. The operating instructions can apply to va- rious implement types implement equipment. In the operating instructions, contents are marked that are only valid for a certain im- plement type...
  • Page 16 General information 2 Type designation 3 Model year 4 Serial number 5 Year of manufacture 6 Vehicle class, subclass, speed index 7 EU type approval number 8 Vehicle identification number. The vehicle identification number is also engraved in the frame near the type plate. 9 Permitted gross weight [kg]* 10 Permissible drawbar load [kg] (axle 0) 11 Permissible axle load [kg] (axle 1)

  • Page 17: Symbols Used In The Operating Instructions

    Symbols used in the Operating Instructions SYMBOLS USED IN THE OPERATING INSTRUCTIONS Hazard classes The following symbols are used in the Operating Instructions for particularly im- portant information: DANGER Denotes an imminent hazard with high risk, which will result in death or severe physical injury, if not avoided.

  • Page 18: Indication Of Passages

    Symbols used in the Operating Instructions Indication of passages The following symbols are used for particular passages in the operating instruc- tions:  Indicates work steps  Indicates enumerations...

  • Page 19: Safety Measures And Precautions

    Safety measures and precautions SAFETY MEASURES AND PRECAUTIONS General safety instructions for the operator are specified in the chapter entitled «Safety measures and precautions». At the start of some main chapters the safety instructions, which refer to all work to be carried out in this chapter, are listed to- gether.

  • Page 20: Safety Features Of The Device

    Safety measures and precautions Safety features of the device To protect the operator and the device, the device is equipped with special safety features in accordance with country specific requirements.  Always keep all safety devices in working order. Warning panel at rear and front, illuminated Hydraulic transportation lock of side sections and rollers Side protective devices...

  • Page 21: Safety And Warning Signs

    Safety measures and precautions Rear parking support Wedges Safety and warning signs 3.4.1 General information The implement features all equipment which ensures safe operation. If hazardous areas could not be completely secured with respect to operational safety, warning signs are affixed which indicate these resi- dual risks.

  • Page 22: Warning Sticker Positions

    Safety measures and precautions 3.4.2 Warning sticker positions 3.4.3 Meaning of warning signs  Please familiarise yourself with the meaning of the warning signs. The following explanations provide detailed information. Please read and observe the operating in- structions and safety instructions before starting up the implement for the first time.
  • Page 23 Safety measures and precautions Before carrying out maintenance or repair work, switch off the engine and remove key. Do not remain in the operating and swivel area of the implement. Danger of crushing. Keep out of the folding area of the device. When the three-point power lift is activated, stay outside of the lifting range of the three- point suspension.
  • Page 24 Safety measures and precautions Hydraulic accumulator contains gas and oil under pressure. For removal and repair instructions in technical manual must be followed. Before uncoupling or parking the imple- ment, secure it with wheel chocks. Lock the lifting device  Lock the lifting device before travelling on public roads.

  • Page 25: Meaning Of Other Symbols

    Safety measures and precautions 3.4.4 Meaning of other symbols. Traction increase device Before detaching the machine and dis- connecting the hydraulic hoses:  Close the shut-off valve. After attaching the machine and connec- ting the hydraulic hoses:  Open the shut-off valve. Connection overview of hydraulic ho- P1 / T1 Folding P2 / T2 Chassis...

  • Page 26: Special Safety Instructions

    Safety measures and precautions Special safety instructions Risk of injury due to non-observance of the currently valid occupational safety guidelines If the currently valid occupational safety guidelines are bypassed WARNING or safety equipment is rendered unusable when handling the de- vice, there is a risk of injury.

  • Page 27: Danger Areas

    Safety measures and precautions Risk of injury when freeing casualties When rescuing people trapped or injured by the device, there is a risk of additional serious injury to the casualty if the hydraulic con- nections were not connected according to their colour coding as described in the section entitled "Required hydraulic equipment".

  • Page 28: Danger Areas When Folding And Unfolding

    Safety measures and precautions 3.6.2 Danger areas when folding and unfolding Risk of impact and crushing from moving implement compo- nents There is a risk of impact or crush injuries from moving implement components. The danger area includes the area extending across the entire width of the implement (a).

  • Page 29: Residual Risks

    Safety measures and precautions Residual risks Residual risks are particular hazards which occur when handling the device and which cannot be eliminated despite a design in accordance with safety require- ments. Residual risks are not usually obvious and may be the source of a potential injury or health hazard.

  • Page 30: Hazard During Operation

    Safety measures and precautions 3.7.3 Hazard during operation During operation there is a risk of injury, particularly to the face, from ejected stones and lumps of earth. Applicable rules and regulations The applicable rules which must be observed during operation of the device are listed below: ...

  • Page 31: Permissible Transport Speed

    Compressed air 710/35-22.5 ** 620/40-22.5 ** 550/45-22.5 hydraulic 620/40-22.5 ** 710/35-22.5 ** * in France 25 km/h. ** only Karat 9 KA 700 Further, observe the applicable country-specific road traffic regulations as well as the country and machine-specific registration documents.

  • Page 32: Permissible Lateral Inclination During Transportation

    Safety measures and precautions 3.9.4 Permissible lateral inclination during transportation Overturning of implement CAUTION If the maximum permissible lateral inclination is exceeded, the im- plement or the tractor will overturn.  Never exceed the maximum permissible lateral inclination.  When on slopes and slopes in a contour line, drive at reduced and suitable speed.

  • Page 33: Correct Behaviour In Road Traffic

    Safety measures and precautions 3.9.6 Correct behaviour in road traffic  When driving on public highways, observe the relevant statutory national regu- lations. Driving behaviour, steering and braking performance are influenced by ballast weights.  Ensure that the tractor has adequate steering and braking performance. ...

  • Page 34: Safe Use Of The Implement

    Safety measures and precautions 3.11 Safe use of the implement 3.11.1 General  Before starting work, familiarise yourself with all the equipment and controls and how they work.  Do not operate the implement unless all the safety guards are in place and cor- rectly positioned.

  • Page 35: Personnel Selection And Qualifications

    Safety measures and precautions 3.11.2 Personnel selection and qualifications  The tractor driver must have the appropriate driving licence.  All work on the implement must be carried out by properly trained and instructed personnel. The personnel must not be under the influence of drugs, alcohol or medication.

  • Page 36: Handing Over The Implement

    Handing over the Implement HANDING OVER THE IMPLEMENT  As soon as the implement is delivered, ensure that it corresponds with the order package.  Also check the type and completeness of any supplied accessories. When the device is handed over, your dealer will explain how it works. ...

  • Page 37: Design And Function

    Design and function DESIGN AND FUNCTION Overview Karat 9 KA with traction increase device Karat 9 KA with hydraulic drawbar Headstock Concave discs Hydraulic ram of the hydraulic Outer discs drawbar Fixing points for side shield (not Hydraulic ram for the traction increase de-...

  • Page 38: Function

    Design and function Function 5.2.1 Three-point tower The three-point tower with top link pin and drawbar comply optionally with catego- ry 3 or 4N in accordance with ISO 730. The drawbar L3/Z3 complies with category 3. The drawbar L3/Z4 complies with category 4N. Drawbar K 700 is a special category for tractors that are equipped with this cate- gory.

  • Page 39: Hydraulic Cylinder For Traction Servo Unit

    Design and function 5.2.3 Hydraulic cylinder for traction servo unit The hydraulic cylinder transfers weight from the implement to the tractor. This in- creases tractor traction, reduces slip and improves fuel consumption. 5.2.4 Support wheels The support wheels are mounted outside on the frame. They prevent the outer tines from working at too great a depth.

  • Page 40: Side Shields

    Design and function 5.2.10 Side shields The side shields restrict the soil flow at the sides and are protected from overloa- ding by springs. 5.2.11 Rollers The rollers ensure reconsolidation and additional crumbling of the soil. During op- eration on the field they bear the weight of the implement if the implement has been lowered for work and they ensure exact depth guiding.

  • Page 41: Compressed Air Braking System

    Design and function The traction increase device transfers the supporting forces to the back axle of the tractor. The supporting forces acting on the support wheels are maintained at a low level. A sensor in the rear section of the trailer detects whether the machine is in the operating position or lifted out.
  • Page 42 Design and function Spring operated brake cylinder Brake lever Guiding screw Holder for guiding screw Brake rod...
  • Page 43 Design and function Function description Parking brake The parking brake is not ready to use until the guiding screw (9) has been removed, inserted in the holder (10) and secured. The parking valve (3) operates the parking brake. To engage the parking brake: ...

  • Page 44: Hydraulic Brake System

    Design and function Brake cylinder If the operating pressure of the air brake system falls below 3.0 bar, the springs on the brake cylinder lock the brake. The bra- ke rod (11) moves out slightly and locks the brake using the brake lever (8). If the brake lever (8) moves by more than 40 mm, the brake must be adjusted.
  • Page 45 Design and function Functional specification The service brake operates hydraulically. The parking brake operates mechanically. The handbrake lever operates the brake through a Bowden cable (7) . To tighten the parking brake (8):  Pull the handbrake lever forward. To release the parking brake (8): ...

  • Page 46: Preparation Of The Tractor

    Preparation of the Tractor PREPARATION OF THE TRACTOR Tyres The pressure - especially in the rear tractor tyres - must be equal. In heavy condi- tions it may be necessary to add wheel weights and/or water ballast. (See manu- facturer’s instructions). Lift Rods Adjust lift rods to equal length.

  • Page 47: Hydraulic Equipment Required

    Preparation of the Tractor Hydraulic equipment required The machine is supplied as standard with separate hydraulic connections for each consumer. The protecting caps for the hydraulic connections are colour-coded and the hydraulic connections themselves are alphanumerically coded. For operation of the specific hydraulic equipment listed below, the tractor must be equipped with the following control units: Control unit Tractor/machine...

  • Page 48: Brake System

    Preparation of the Tractor Brake system Danger through incompatibility of braking systems The braking system of the tractor and implement must be compat- ible and fully functional. If there is no conformity or if a malfunction exists, sufficient braking deceleration will not be possible. This DANGER means that the tractor and implement may be damaged.

  • Page 49: Without Brake System

    Preparation of the Tractor 6.6.3 Without brake system For implements without brake systems, running axles or brake axles without actua- tion devices are used. Safety chain According to national regulations, a safety chain (1) may be required for implements without a brake system. The safety chain is only intended as a safety component.
  • Page 50 Preparation of the Tractor The following drawbars (1) have been ap- proved for this implement: Category As per ISO 730-1 As per ISO 730-1 K700  Make sure that the tractor's three-point linkage category and the drawbar's cat- egory match. If there is no conformity: ...

  • Page 51: Upper Link Pin

    Preparation of the Tractor Upper link pin Danger to life if three-point linkage category is too small If a drawbar or a top link pin is used with a category that is too small, these components may be overloaded and break. This me- ans that the implement: DANGER ...

  • Page 52: Work Assignment

    Preparation of the Tractor 6.9.2 Work assignment  For use on the land, switch the hydraulic system of the three-point linkage of the tractor to "position control". Refer to the operating instructions from the tractor manufacturer. 6.9.3 Coupling and uncoupling Lowering or raising the three-point linkage CAUTION If the three-point linkage moves uncontrollably due to an incorrect...

  • Page 53: Preparations On Implement

    Preparations on implement PREPARATIONS ON IMPLEMENT Final assembly For transportation-specific reasons, the implement is not always delivered in a ful- ly-assembled condition. Use the implement only when the implement has been fully assembled and a functional check has been performed. Spring brake cylinders Risk of accident due to deactivated brakes DANGER...
  • Page 54 Preparations on implement  Loosen the nut (2) until the guiding screw (1) is no longer under spring force and is free.  Turn the guiding screw (1) 90° and re- move it from the brake cylinder (3).  Cover the aperture in the brake cylinder with the protective cap (4).

  • Page 55: Traction Servo Unit

    Preparations on implement Traction servo unit Swivelling three-point tower If the shut-off valve (3) is opened when the implement is disman- CAUTION tled, the three-point tower swivels to the rear. This means that people can be knocked over and injured by the three-point tower. Furthermore, the implement can no longer be attached without additional conversion work.
  • Page 56 Preparations on implement The traction servo unit and its hydraulic cylinder (1), piston accumulator (2), and shut-off valves (3) and (4) load the tractor's rear axle during work, thus significantly boosting the traction of the tractor. The oil pressure in the traction servo unit's hydrau- lic system is shown on the pressure gauge (5).

  • Page 57: Contourtrack

    Preparations on implement ContourTrack ContourTrack can operate with load-sensing systems with load feedback as well as with constant flow hydraulic assemblies.  Prior to initial use: Adapt ContourTrack to the hydraulic assembly of the tractor.  When changing the tractor: Check and adapt the adjustments, if necessary. Control valve: 1 –...

  • Page 58: Attachment

    Attachment ATTACHMENT Risk of injury when attaching the implement There is a risk of crushing body parts between the tractor and im- plement. The headstock is connected to the drawbar by a ball joint and the hydraulic ram for the traction increase device. It may WARNING swivel during implement attachment.
  • Page 59 Attachment Risk of injury due to unsecured top link pin If the top link pin is not secured, it may slip out or go astray. CAUTION As a result:  the implement may drop to the ground or be damaged, ...

  • Page 60: Implement With Three-Point Connection

    Attachment Implement with three-point connection  When attaching the implement, switch the hydraulic system for the tractor’s three-point linkage to position control.  Reverse the tractor up to the implement so that it is lined up immediately in front of the implement and the lower links (2) can be connected to the cross shaft (3).
  • Page 61 Attachment tor in accordance with the table in the “Hydraulic equipment required” section.  Connect the electrical cables to the trac- tor in accordance with the table in the “Power sources required” section.  Connect the braking system hoses. (See the “Air brake system”...
  • Page 62 Attachment  If the implement will be transported on public roads, the prescribed lighting equipment and warning signs must be installed and the safety guards must be in place. See the “Safety guards” sec- tion.  Raise the implement by a few centi- metres using the lower links (2).

  • Page 63: Implement With Hydraulic Drawbar

    Attachment Implement with hydraulic drawbar Risk of accidents if drawbar is unsuitable or too weak If the drawbar used is too weak, it may break and the implement may break away. This may cause death or injury to other people and road users.
  • Page 64 Attachment On implements with a traction loop:  Reverse the tractor further back until the traction loop can be coupled with the drawbar.  Now insert the pin through the drawbar and the traction loop.  Secure the pin. On implements with a ball coupling: ...
  • Page 65 Attachment On implements with an air brake system:  Release the parking brake by pressing the red button (8) on the park valve in- wards.  Raise the front and rear of the imple- ment completely.  Lock the tractor spool valves. ...

  • Page 66: Air Brake System

    Attachment Air brake system  Connect the hoses for the air brake sys- tem to the tractor.  Release the parking brake by pressing the red button (13) on the park valve. Hydraulic braking system  First connect the hydraulic hose for the braking system to the tractor.

  • Page 67: Traction Increase Device

    Attachment Traction increase device Implement with traction increase device You must open the shut-off valve (12) after attaching the implement.  Lift the locking knob (16) and move the lever. Safety chain Depending on national regulations, attach the safety chain to the tractor.
  • Page 68 Attachment  Push the pin (1) inwards.  Push the lock (2) away from the hook (3). The lock may also be placed cross- wise.  Attach the safety chain (4) to a suffi- ciently robust attachment point on the tractor.

  • Page 69: Folding The Lateral Parts In And Out

    Folding the lateral parts in and out FOLDING THE LATERAL PARTS IN AND OUT Folding in Risk of accident due to the lateral parts folding in incorrectly Incorrect folding in of the lateral parts will result in accidents if:  Persons are located in the swivelling and folding range of the la- teral parts.
  • Page 70 Folding the lateral parts in and out The lateral parts (1) of the machine must be folded in prior to transport.  Before folding in the lateral parts (1), ful- ly lift the machine at the front and rear. By actuating the control unit into the fold-in position (1st pressure position), the lateral parts of the cultivator frame and the roller are folded in via the folding cylinders (2) as...

  • Page 71: Folding Out

    Folding the lateral parts in and out Folding out Risk of accident due to the lateral parts folding out incor- rectly Incorrectly folding out of the lateral parts will result in accidents if:  people are in the hazardous area of the lateral parts or ...
  • Page 72 Folding the lateral parts in and out  Before folding out the lateral parts (1), fully lift the machine at the front and rear.  Unlock the control unit of the tractor for the folding cylinders (2).  Then switch the control unit into the fold- in position (1st pressure position) and then swiftly into the fold-out position (2nd pressure position).

  • Page 73: Driving On Public Highways

    Driving on public highways DRIVING ON PUBLIC HIGHWAYS 10.1 General information A proper lighting system, identification and equipment must be on the implement, if it is to be transported on public roads. The country-specific valid laws and regu- lations pertaining to driving on public roads must be observed. 10.2 Preparation for driving on public roads Before commencing a journey on public roads, the following components and sa-...

  • Page 74: Protective Equipment

    Driving on public highways 10.5 Protective equipment WARNING Risk of injury Other road users could be injured by the tines.  Before driving on public roads, always mount the protective equipment. Before driving on public highways, cover the tines of the side sections with the pro- tective devices (1).

  • Page 75: Lighting System

    Driving on public highways 10.6 Lighting system The lighting system must be supplied with power. 10.7 Transport dimensions Danger due to machine being raised too high WARNING The height of the retracted machine may be too high. This means there is an increased danger under bridges, driveways and high- voltage lines ...
  • Page 76 Driving on public highways a "steep" share position on public roads.

  • Page 77: Operation

    Operation OPERATION  Read and follow the information in the section entitled "Safety and protection measures". CAUTION  The implement may only be used, maintained and repaired by people who are familiar with it and who are aware of the ha- zards involved.

  • Page 78: Working Depth Of The Tines

    Operation 11.1 Working depth of the tines 11.1.1 General information The working depth of the machine is guided at the rear via the roller. The lower links or the hydraulic drawbar generally guide the depth at the front of the machine. The support wheels (2) located at the front of the frame ensure constant depth control at the front of the machine.
  • Page 79 Operation The respective set working depth can be read off on the scale (6). A graduation mark on the scale (6) corresponds to an approx. 3 cm change in working depth. The support wheels (2) are automatically adjusted to the set working depth. Also see section "Support wheels".

  • Page 80: Setting The Working Width On Implements With Contourtrack

    Operation 11.1.3 Setting the working width on implements with ContourTrack The working depth is set using the hydraulic working depth adjustment system on the implement. Note the following:  Set the tractor hydraulics to position con- trol.  Adjust the lower links. Align the soil wor- king implement so that it is parallel to the ground when the implement is moving.
  • Page 81 Operation ground. If this is not the case:  Lengthen or shorten the spindles (3) so that the support wheels make slight con- tact with the ground. The support wheels are protected against overload by means of a hydraulic accumulator in the hydraulic system. If overload occurs, the side sections retract a little.

  • Page 82: Basic Setting

    Operation 11.2.2 Basic setting The support wheels are set to their basic setting at the factory. If necessary, the basic setting can be adjusted as follows.  Set the turnbuckles (3) to a shorter set- ting.  Insert the implement. ...

  • Page 83: Calibrating Working Depth

    Operation 11.2.3 Calibrating working depth If the depth guidance of the support wheels (2) has changed, e.g. as a result of oil leakage in the cylinders, the working depth must be recalibrated.  To do so, completely lift out the imple- ment at the front and rear, if possible at the headland.

  • Page 84: Basic Setting Of The Touch Wheels For Contourtrack

    Operation 11.2.4 Basic setting of the touch wheels for ContourTrack  Fold out the rollers and the working sec- tions.  Retract the trailer (working position).  Disconnect the power supply of the sys- tem.  Remove the 3-pole plug at the vehicle interface.
  • Page 85 Operation WARNING Risk of injury due to removed shear bolt If the shear bolt is removed, the tines can pivot freely. This can lead to crushing of the fingers around the tine carrier.  Mount the removed shear bolts without delay. The hollow discs (1) are adjusted with the pins (2) as follows: ...
  • Page 86 Operation The hollow disc carrier is permanently mounted on the roller carrier. Once the control rods have been set to the correct length there is no need to make any further adjustments. The roller carrier rotates automatically if the roller depth changes.

  • Page 87: Working Depth Of The Edge Discs

    Operation 11.4 Working depth of the edge discs Loss of components DANGER If the guide pins are not secured, they can fall out due to vibra- tions in operation. This can result in components being lost during operation and transportation and can cause accidents or damage to the device and the tractor.

  • Page 88: Adjusting The Side Shields

    Operation 11.5 Adjusting the side shields Risk of injury from worn side shields WARNING Worn and abraded side shields may have sharp edges which can cause cut injuries to the hands.  Take care when handling worn and abraded side shields. ...

  • Page 89: Share Position

    Operation 11.6 Share position WARNING Risk of injury due to removed shear bolt When the shear bolt has been removed, the tine can swivel freely. This may result in crushed fingers in the area of the tine pocket.  Mount the removed shear bolts promptly. The share position or the pitch angle of the tines can be altered.
  • Page 90 Operation The share position is altered by inserting the shear bolt (2) in a different position. Flat share position  Insert shear bolt through the bore (4) of the tine pocket (3) and the bore (5) of the tine (1). Steep share position ...
  • Page 91 Operation Make the same settings for all tines.  Raise the implement several centi- metres.  Secure the device against sinking.  Loosen and remove nut from the shear bolt (2).  Press out the shear bolt (2) using a sui- table tool.

  • Page 92: Automatic Overload Protection

    Operation 11.7 Automatic overload protection 11.7.1 Tines Risk of fatal injury due to high spring energy If a tine, concave disc or boundary disc has tripped and has not DANGER yet returned to its working position, it may suddenly spring back into its working position with great force and at high speed.

  • Page 93: Concave Discs

    Operation 11.7.2 Concave discs Risk of fatal injury due to high spring energy If a tine, concave disc or boundary disc has tripped and has not DANGER yet returned to its working position, it may suddenly spring back into its working position with great force and at high speed. This may cause serious or fatal injury to anybody who is within the swivel range.

  • Page 94: Mounting And Dismantling The Weed Harrow

    Operation The edge discs (5) with overload safety device feature a compression spring (4) which is highly pretensioned. If an obstruc- tion in the soil is struck, the edge disc moves backwards and upwards and is au- tomatically reset to the working position after running over the obstruction.
  • Page 95 Operation Mounting the weed harrow The weed harrow (1) must always be mounted on a trailing roller. Brackets (2) and U-bolts (3) are available for mounting. There is one harrow segment for each trai- ling roller segment. Example image  Position both U-bolts (3) on the support- ing frame (5) of the roller.

  • Page 96: Adjusting The Weed Harrow

    Operation 11.9 Adjusting the weed harrow Adjusting the angle  Turn the screw (1) with the spanner Clockwise = flat angle Anticlockwise = steep angle  The yoke (2) moves up or down with the harrow tube. The angle of the harrow changes.
  • Page 97 Operation  Swivel the holder (3) to the required height. Example image To fix the holder in the swivelled in positi-  Insert the pin (2) into the matching not- ches above and below the holder. Example image  Secure the pin with a linch pin (1). ...

  • Page 98: 11.10 Rollers

    The implement can be fitted with different types of roller. The rollers control the working depth of the implement. The degree of reconsolidation or crumbling is de- termined by the type of roller used. Karat 9 KA Roller type Karat 9 KUA...

  • Page 99: Knife Rollers

    Operation 11.10.2 Knife rollers Adjusting the knife roller Blade working depth On both sides of the roller:  Take any loads off the upper bolt (4). o Turn the screw (3) clockwise to do so.  Release the upper bolt (4). ...
  • Page 100 Operation the support plate (1). o The knives operate more ag- gressively if the deflection trav- el is short. Large deflection travel (for very light or rocky soils):  Insert the lower bolt (5) into the lower holes in the adjustment plate (2). ...

  • Page 101: Pressure Load On Packer Profile Roller And Packer Double Roller

    Operation Blade position There are two mounting positions for the blades (11) on the knife bar (8):  Front position (9) (standard)  Rear position (10) (after wear) After wear:  Reposition the blades (11) towards the rear (10). 11.10.3 Pressure load on packer profile roller and packer double roller The pressure load on the rollers can be adjusted by changing the position of both...

  • Page 102: 11.11 Contourtrack

    Operation Changing the link position  Lower the roller to the ground  Raise the implement to take the load off the bolts (3)  Remove the bolts (3)  Adjust the link (4) so that the holes line  Fit the bolts (3) ...

  • Page 103: Switch On

    Operation Activate the electrovalve on side "a":  Hydraulic ram retracts  Working section is lowered  Roller is lifted Activate the electrovalve on side "b":  Hydraulic ram extends  Working section is lifted  Roller is lowered Move hydraulic ram manually to the "neutral position"...

  • Page 104: 11.12 Turning At The Headland

    Operation 11.12 Turning at the headland DANGER Danger of damaging components If the machine is not fully lifted, there is a danger of damaging com- ponents when turning incorrectly at the headland. Before turning at the headland, the machine must be lifted fully before steering to avoid any damage to the machine.

  • Page 105: Use Without A Roller

    Use without a roller USE WITHOUT A ROLLER 12.1 General information  The machine may be used, maintained and repaired only by people who are familiar with it and who are aware of the ha- CAUTION zards involved.  Before carrying out any conversion, repair, maintenance and cleaning work or before rectifying any malfunctions, ensure that the drive has been switched off and the engine is at a standstill.

  • Page 106: Attaching The Pendulum Lock

    Use without a roller 12.2.2 Attaching the pendulum lock Machines with 5 m, 6 m and 7 m work- ing widths  Mount the turnbuckle (4) and the holder (2) with screws (3) to the outer fixing points of the beam (5). ...

  • Page 107: Attaching The Wheelmark Eradicators

    Use without a roller 12.2.4 Attaching the wheelmark eradicators The wheelmark eradicators are positioned directly behind the wheels of the trailer. Machines with 5 m, 6 m and 7 m work- ing widths  Mount the holder (11) for the wheelmark eradicator (12) on the beam (5).
  • Page 108 Use without a roller Machines with 4 m working width  Mount the holder (11) for the wheelmark eradicator (12) on the supporting tube (8).  Mount the wheelmark eradicator on the holder.  Adjust the working depth of the wheel- mark eradicator, see «Adjusting the wheelmark eradicators, page 108».

  • Page 109: Operation For Use Without A Roller

    Use without a roller 12.3 Operation for use without a roller 12.3.1 General information When used without a roller, the trailer assumes the role of the depth control of the roller. To do so, the depth control must be adjusted with clips on the hydraulic rams.

  • Page 110: Adjusting The Wheelmark Eradicators

    Use without a roller 12.3.3 Adjusting the wheelmark eradicators The machine can be equipped with the following wheelmark eradicators: Machines up to 31.12.2011  Wheelmark eradicators with narrow share (S4)  Wheelmark eradicators with flat share (VS33)  Wheelmark eradicators with duckfoot- share (G25) Machines since 01.01.2012 ...

  • Page 111: Swivelling In The Spiral Tines For Transportation

    Use without a roller 12.3.4 Swivelling in the spiral tines for transportation Only wheelmark eradicators with spiral tines  Remove the upper linch pin (13) from the upper pin (14).  Extract the upper pin from the holder (11) and the adjusting stalk (15). ...

  • Page 112: Changeover From Use Without A Roller To Use With A Roller

    Use without a roller 12.4 Changeover from use without a roller to use with a roller 12.4.1 Detaching the wheelmark eradicators  Remove the wheelmark eradicator (12) from the holder (11).  Undo the screw (17).  Remove the holder from the supporting tube (8) or the beam (5).

  • Page 113: Detaching The Pendulum Lock

    Use without a roller 12.4.3 Detaching the pendulum lock Machines with 5 m, 6 m and 7 m work- ing widths  Remove the linch pin of the fixing pin from the holder (6) of the lateral part (7).  Extract the fixing pin from the turnbuckle (4) and the holder.

  • Page 114: Attaching The Roller

    Use without a roller 12.4.5 Attaching the roller  Drive the machine as close as possible up to the roller.  Lower the machine until you can screw the roller units back onto the frame or the pendulum frame.  Mount the roller units using the screws (1).

  • Page 115: Detaching

    Detaching DETACHING Risk of injury when detaching the machine There is a risk of body parts being crushed between the tractor and the machine. The headstock is connected to the drawbar via a ball joint and the hydraulic ram of the traction increase device. WARNING The headstock may swivel when being detached.

  • Page 116: Braking System

    Detaching 13.2 Braking system 13.2.1 Compressed air brake  To activate the parking brake, extract the red button (13) on the park valve. 13.2.2 Hydraulic braking system  Applying the parking brake: To do so, pull the parking brake lever (18) to the front.

  • Page 117: Uncoupling

    Detaching 13.3 Uncoupling 13.3.1 Machine with hydraulic drawbar  Unlock and remove the pin (8) of the stand (9).  Swivel down the stand (9).  Secure the stand (9) with the pin (8).  Secure pin (8) with linch pin. ...

  • Page 118: Machine With Traction Increase Device

    Detaching  Disconnect the brake hoses.  Uncouple the hydraulic hoses and slide on the protecting caps.  Uncouple the machine from the tractor.  Drive the tractor away from the machine. 13.3.2 Machine with traction increase device  Unlock and remove the pin (8) of the stand (9).
  • Page 119 Detaching  Fix the top link (5) at the tractor. See the operating instructions of the tractor ma- nufacturer.  Fix the pivot bearing of the headstock with the top link pin (7).  Lower the lower link.  Close the shut-off valve (14) of the trai- ler.
  • Page 120 Detaching  Uncouple the lower link (2) from the cross shaft (3).  Switch the hydraulic system of the trac- tor to the float position. The hydraulic hoses are now pressureless.  Uncouple the hydraulic hoses and slide on the protecting caps. ...

  • Page 121: Switching Over To Different Share Systems

    Switching over to different share systems SWITCHING OVER TO DIFFERENT SHARE SYSTEMS Danger presented by implement not secured against lowering DANGER If the raised implement is not secured to prevent it from lowering, people underneath may be injured or killed. A raised implement must be supported when people are carrying out maintenance or service work in its danger zone.

  • Page 122: Tines With Quick-Change System

    Switching over to different share systems - Observe the details in section "Tightening torques". 14.3 Tines with quick-change system Risk of accident due to falling and extending of components and implements Performing work under raised components/implements or next to WARNING swivelled-in components/implements is dangerous.

  • Page 123: Removing The Share Base

    Switching over to different share systems If the tine (1) features a quick-change sys- tem with exchangeable share base (2), the share base (2) can be removed together with the share system after the linch pin (3) has been removed and replaced by a share base (2) with a different share sys- tem.
  • Page 124 Switching over to different share systems  Remove the linch pin (3) by pulling it upwards.  Hold the share base (2) with both hands and swivel the share base (2) forwards to detach it from the tine (1).  Pull the share base (2) downwards and deposit it outside the implement.

  • Page 125: Attaching The Share Base

    Switching over to different share systems 14.3.2 Attaching the share base Risk of injury If the share foot is not held with both hands, it may fall down. As a result, your feet may be injured. CAUTION  The share foot must always be held with both hands. ...
  • Page 126 Switching over to different share systems The linch pin (3) holds the share base (2) in the detent position. The securing clip prevents the linch pin (3) from slipping out.  Fold the securing clip (5) downwards.

  • Page 127: Put The Implement Out Of Operation

    Put the implement out of operation PUT THE IMPLEMENT OUT OF OPERATION 15.1 Shutting down the implement in an emergency  In an emergency shut down the implement via the tractor.  Switch the tractor engine off.  Remove the ignition key. Damage caused by improper storage of the implement If incorrectly or improperly stored, the implement may be dam- CAUTION...

  • Page 128: Maintenance And Repairs

    Maintenance and repairs MAINTENANCE AND REPAIRS 16.1 Special safety instructions 16.1.1 General Risk of injury when carrying out maintenance and repair work There is always the risk of injury when carrying out maintenance and repair work. WARNING  Use suitable tools, suitable climbing aids, platforms and support elements.

  • Page 129: Immobilise The Implement For Maintenance And Repairs

    Maintenance and repairs 16.1.4 Immobilise the implement for maintenance and repairs Risk of accidents when tractor starts up Injuries may occur if the tractor starts moving during maintenance and repair work.  Switch off the tractor engine before carrying out any work on the WARNING implement.

  • Page 130: Working Under The Raised Device

    Maintenance and repairs 16.1.7 Working under the raised device Risk of accident due to lowering and extending of compo- nents and devices It is extremely dangerous to work under raised or next to retracted components and devices. WARNING  Always secure the tractor to prevent it from rolling away. ...

  • Page 131: Environmental Protection

    Maintenance and repairs Risk of accident due to tool slipping off If applying a large force, e.g. when loosening bolts, the tool may WARNING slip off. This may result in hand injuries on sharp-edged parts.  Avoid applying a large force by using suitable auxiliary equip- ment (e.g.

  • Page 132: Maintenance Intervals

    The hydraulic hos- es must be replaced at the latest 6 years after the date of manu- facture. Use hydraulic hoses authorised by LEMKEN only. Safety  Check that the safety equipment functions properly. See section equipment entitled "Safety equipment".

  • Page 133: Weekly Checks

    Maintenance and repairs 16.4.3 Weekly checks Check What needs to be done?  Wheel nuts Check that all the wheel nuts are tight.  If necessary, tighten the wheel nuts to the appropriate tightening torque.  Bolted connec- Tighten all the bolts and nuts on the implement to the appropriate tions tightening torque.

  • Page 134: Lubrication Chart

    Maintenance and repairs 16.4.5 Lubrication chart  For all lubrication work use the high-grade grease Olistamoly 2 or an equivalent high-grade grease only. Position Number of Every Every Every Before a After a win- (see Fig. lubrication winter break ter break points Operating hours...

  • Page 135: Overview Of Lubricating Points

    Maintenance and repairs 16.4.6 Overview of lubricating points a) Three-point tower/traction servo unit b) Cultivator frame flap hinges c) Hydraulic cylinder mounting bolts b) Roller frame flap hinges d) Roller self-aligning mounting c) Hydraulic cylinder mounting bolts...
  • Page 136 Maintenance and repairs e) Running gear swivelling axis h) Braking axle f) Running gear hydraulic cylinder i) Support wheel turnbuckles g) Depth guide joints g) Depth guide joints...

  • Page 137: Draining The Compressed Air Tank

    Maintenance and repairs 16.5 Draining the compressed air tank The condensation water must be drained out of the compressed air tank (2) regu- larly.  Pull or push the pin (1) on the drain valve sideways. The condensation water is forced out of the compressed air tank with the compres- sed air.

  • Page 138: Replacing Hollow Discs

    Maintenance and repairs 16.8 Replacing hollow discs Risk of injury from worn hollow discs and coulter discs Worn and abraded hollow discs and coulter discs may have sharp WARNING edges which can cause cut injuries to the hands.  Take care when handling worn and abraded hollow discs and coulter discs.

  • Page 139: Replacing The Side Shields

    Maintenance and repairs  Loosen the six self-locking nuts (2).  Unscrew the self-locking nuts completely and remove the hollow disc (1) from the bearing flange.  Clean the flange surface of the bearing flange.  Use new self-locking nuts for the flat- headed bolts and tighten them to 46 Nm.

  • Page 140: 16.10 Calibrating The Hydraulic Drawbar

    Maintenance and repairs  Loosen the two self-locking nuts (2).  Unscrew the self-locking nuts completely and remove the side shield (1) from the stalk.  Use new self-locking nuts and tighten them to 80 Nm. 16.10 Calibrating the hydraulic drawbar After working or a malfunction due to leaks in the hydraulics of the drawbar or trailer, the hydraulic drawbar may need to be...

  • Page 141: 16.11 Tightening Torques

    Maintenance and repairs 16.11 Tightening torques 16.11.1 Wheel nuts Diameter / Tightening tor- thread [Nm] M12x1.5 M14x1.5 M18x1.5 M20x1.5 M22x1.5 16.11.2 Other bolt connections Diameter / Property class thread 8.8 [Nm] 10.9 [Nm] 12.9 [Nm] 13.6 16.3 M8 / M8x1 23.4 32.9 39.6...

  • Page 142: Points

    Maintenance and repairs 16.11.3 Points Position Screw Tightening tor- [Nm] (1) * M12-10.9/12.9 (2) * M12-10.9/12.9 M12-10 M12-10.9/12.9 M12x80-8.8 M12x8.8/12.9 * Observe the tightening sequence (1), (2) and then (1) again.

  • Page 143: 16.12 Checking Connections To The Tractor

    Maintenance and repairs 16.12 Checking connections to the tractor 16.12.1 Couplings Risk of accident due to spraying hydraulic fluid Fluid (hydraulic oil) escaping under high pressure can penetrate WARNING the skin and cause severe injuries. In case of injury, seek medical attention immediately.

  • Page 144: 16.13 Air Pressure Of Tyres

    Maintenance and repairs 16.13 Air pressure of tyres Danger due to incorrect air pressure WARNING Excessive air pressure in the tyres may cause the tyres to burst, whereas insufficient air pressure may cause overloading of the tyres. This will have a negative influence on accurate follow-on of the machine.

  • Page 145: Generating System Pressure

    Maintenance and repairs  Lift the implement far enough out to pre- vent the tines and the roller from touch- 160 mm ing the soil.  Switch the tractor's hydraulic system to position control.  Raise or lower the tractor's three-point linkage so that the piston rod (5) is ex- tended by exactly 145 mm (160 mm up to series from July 2010).
  • Page 146 Maintenance and repairs The system pressure may only be adjusted when the implement is connected to the tractor. Connection (1) is used for filling the traction servo unit's hydraulic system.  Place the three-point tower vertically so that the hydraulic cylinder is extended by 145 mm (up to series from July 2010: 160 mm).

  • Page 147: 16.15 Scrapers

    Maintenance and repairs Once the lever (4) has been dismantled, the shut-off valve (3) can be unlocked and locked again. To do so, the locking disc (5) has to be fitted accordingly to the square The shut-off valve has to be locked again after filling has been completed.

  • Page 148: Scrapers On Packer-Profile Roller

    Maintenance and repairs 16.15.2 Scrapers on packer-profile roller The rear scrapers (4) on the packer-profile rollers (5) have slots to allow adjustment.  Release the self-locking nuts (6).  Adjust the relevant scraper (4) on the roller (5) so that it has a clearance of be- tween 6 and 10 mm to the rings.
  • Page 149 Maintenance and repairs The front scrapers (7) on the packer-profile rollers have slots to allow adjustment.  Release the self-locking nuts (8).  Adjust each scraper (7) such that it can be mounted with a distance of 1 to 3 mm to the freely-rotating roller body (9).

  • Page 150: Scrapers On The Packer Double Roller

    Maintenance and repairs 16.15.3 Scrapers on the packer double roller The front scrapers (7) on packer double rollers also have slots for adjustment.  Loosen the self-locking nuts (8).  Set each scraper (7) so that it is installed at 1 to 3 mm from the freely rotating rol- ler body (9).

  • Page 151: Flex Ring Roller Scrapers

    Maintenance and repairs 16.15.4 Flex ring roller scrapers The scrapers (1) on the flex ring roller (2) must be replaced when worn down to a thickness of 5 mm so as to prevent the remaining piece from being lost and sub- sequent damage from being incurred.

  • Page 152: Technical Data

    Technical data TECHNICAL DATA Karat KA – standard drawbar (short) 400 U 500 U 600 U 700 U Length with double rollers 8780 8780 8780 8780 8780 8780 8780 8780 approx. [mm] ***** Length with sin- gle rollers ap- 8285 8585 8285 8285...
  • Page 153 Technical data Karat KA – long drawbar 400 U 500 U 600 U 700 U Length with double rollers 9240 9240 9240 9240 9240 9240 9330 9330 approx. [mm] ***** Length with sin- gle rollers ap- 8740 8740 8740 8740 8740 8740 8830...
  • Page 154 Technical data...

  • Page 155: Noise, Airborne Sound

    Noise, Airborne Sound NOISE, AIRBORNE SOUND The noise level of the implement does not exceed 70 dB (A) during work. NOTES As the version of equipment is depending from the order, the equipment of your implement and its description concerned may deviate in some cases. To ensure a continuously updating of the technical features, we reserve the right to modify the design, equipment and technique.

  • Page 156: Index

    Index INDEX "Air ........................142 "Check ........................ 30 "ContourTrack" ..............38, 44, 45, 55, 82, 100 "Folding ......................67, 69 "Folding" ......................45 "Hydraulic ......................45 "Lighting ......................44 "TECHNICAL ....................150 "Trailer" ....................... 45 "Transport ..................... 29, 73 "Tyres" ......................142 "Voltage.......................
  • Page 157 Index Repairs ......................126 Rollers ......................... 96 Scrapers ......................145 Scrapers ......................149 Share position ..................... 87 Shut-off valves ....................71 Spring brake cylinders ..................51 Support wheels ....................78 Sway Blocks ......................44 Traction increase device ..................71 Traction servo unit ....................53 Type plate ......................

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