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Related Manuals for LEMKEN Karat 9
Summary of Contents for LEMKEN Karat 9
- Page 1 Operating Instructions Cultivators Karat 9 and 9U - EN - Item no. 175_4449 2/04.10 LEMKEN GmbH & Co. KG Weseler Straße 5, D-46519 Alpen / PO Box 11 60, D-46515 Alpen Telephone (0 28 02) 81-0, Fax (0 28 02) 81-220...
- 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.
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Page 5: Table Of Contents
Contents CONTENTS Contents ........................... 3 General information ....................8 Liability........................... 8 Guarantee........................8 Copyright ........................9 Optional accessories ....................9 Symbols used in the Operating Instructions............10 Hazard classes ......................10 Information........................10 Environmental protection ................... 10 Indication of passages....................11 Safety measures and precautions................. - Page 6 Contents Operation on public highways ................... 21 3.9.1 Lighting system and identification ................21 3.9.2 Requirements of the tractor..................21 3.9.3 Axle loads......................... 22 3.9.4 Check before departure ................... 23 3.9.5 Correct behaviour in road traffic ................23 3.10 Obligation of the operator ..................24 3.11 Operating the device safely..................
- Page 7 Contents 6.7.1 Transport........................36 6.7.2 Work assignment ..................... 36 6.7.3 Coupling and uncoupling..................36 Coupling and uncoupling..................37 Coupling........................37 Uncoupling........................41 Draw rail ........................42 7.3.1 Mounting position ..................... 42 7.3.2 Changing the mounting position................43 Top link ........................44 7.4.1 Mounting position .....................
- Page 8 Contents 9.8.1 General information....................58 9.8.2 Blade rollers ......................59 Pressure load on rollers ..................... 61 10 Switching over to different share systems............63 10.1 Share tips, guide plates and wing shares ..............63 10.2 Tine with integrated share foot .................. 64 10.3 Tine with quick-change system .................
- Page 9 Contents 12.6 Tyres and air pressure ....................78 13 Identification plate ....................79 14 Noise, Airborne Sound ................... 80 15 Notes ........................80 Index ..........................81 EU Declaration of Conformity ..................82 TechnischeDokumentation...
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Page 10: General Information
inadequate monitoring of parts which are subject to wear, maintenance work not carried out properly or in good time, the use of other than original spare parts of LEMKEN GmbH & Co. KG, Catastrophic events caused by external factors or force majeure. -
Page 11: Copyright
Infringements will result in a claim for damages. Optional accessories LEMKEN products feature a number of optional accessories. All accessories are described in these operating instructions. Please note: These accessories will vary depending on the type of equipment. -
Page 12: 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 13: 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 enumerations and work steps Indicates instructions for action and information in safety instructions TechnischeDokumentation... -
Page 14: 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 15: Safety Equipment On The Device
Safety measures and precautions Safety equipment on the device To protect the user and the device, the device features special safety equipment. Always keep all safety equipment in working order. Warning sign with light... -
Page 16: Safety And Warning Signs
Safety measures and precautions Safety and warning signs 3.4.1 General information The device features all equipment which ensures safe operation. If hazardous ar- eas could not be completely secured with respect to operational safety, warning signs are affixed which indicate these residual risks. Damaged, lost or illegible warning signs must be replaced immediately. - Page 17 Safety measures and precautions ATTENTION: Do not remain in the operating and swivel area of the device! ATTENTION: Danger of crushing!
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Page 18: Position Of The Safety And Warning Signs
Safety measures and precautions 3.4.3 Position of the safety and warning signs 390 0506 390 0510 390 0510 390 0506 390 0555 390 0509... -
Page 19: 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 20 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".
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Page 21: Hazardous Areas
Safety measures and precautions Hazardous areas Moving hazardous area WARNING The hazardous area of the device moves during operation of the device! During operation of the device there must be nobody in front of the actual hazardous area, as the hazardous area moves with the device! 3.6.1 Hazardous areas during operation of the device Residual risks... -
Page 22: Hazard Caused By Mechanical Systems
Safety measures and precautions 3.7.1 Hazard caused by mechanical systems There is a risk of accidents due to crushing, cutting and striking body parts on abruptly moving machine parts, on moving machine parts caused by stored mechanical energy in elastic parts, such as springs, ... -
Page 23: Operation On Public Highways
Safety measures and precautions Operation on public highways 3.9.1 Lighting system and identification A proper lighting system, identification and equipment must be on the device if it is to be transported on public roads. Further information can be requested from the appropriate authorities. -
Page 24: Axle Loads
Safety measures and precautions 3.9.3 Axle loads The mounting of devices on the front and rear three-point linkage must not cause the permitted gross weight, the permitted axle lo- ads and the tyre load capacities of the tractor to be exceeded. The front axle of the tractor must always be loaded with at least 20% of the tractor net weight. -
Page 25: Check Before Departure
Safety measures and precautions 3.9.4 Check before departure Before driving with the implement raised, lock the control lever, otherwise it may drop and the implement may be unintentionally lowered. Attach and check the transport equipment such as the lighting system, warning signs and protective devices! The actuating cables for the quick-release couplings of the tractor must hang loose and must not actuate themselves in any position! -
Page 26: Obligation Of The Operator
Safety measures and precautions 3.10 Obligation of the operator Before switching on the device, read the operating instructions. Follow the safety instructions! Wear appropriate protective clothing when carrying out any work on the device. Protective clothing must be tight-fitting! ... -
Page 27: Operating The Device Safely
Safety measures and precautions 3.11 Operating the device safely 3.11.1 General information Before starting work, familiarise yourself with all equipment and actuating ele- ments as well as their functions! Do not operate the device until all protective devices have been attached and are in the safety position! ... -
Page 28: Personnel Selection And Qualifications
Safety measures and precautions 3.11.2 Personnel selection and qualifications The driver of the tractor must have the appropriate driving licence! Any work on the device may be carried out by trained and instructed personnel only. Personnel must not be on drugs, intoxicated or taking medication! ... -
Page 29: Handing Over The Device
Handing over the device HANDING OVER THE DEVICE As soon as the device 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 30: Design And Function
Design and function DESIGN AND FUNCTION Overview 1 Three-point tower 2 Frame 3 Tines 4 Working depth adjustment for tines 5 Automatic overload safety device for tines 6 Hollow discs (serrated) 7 Edge discs 8 Roller (blade roller MSW 600) -
Page 31: Function
Design and function Function 5.2.1 Three-point headstock The three-point headstock with top link pin and draw bar complies with ISO 730. The draw bar L3/Z3 complies with category 3. The draw bar L2/Z3 complies with category 3N. The implement with a 3 m working width is fitted with a choice of category 2 or 3 top link pin and the implement with a 3,5 m / 4 m working width is fitted exclusively with a category 3 top link pin. -
Page 32: Tines
Design and function Tines Either tines with a permanently integrated share foot or tines with quick-change system can be used. a) Tines with permanently integrated share foot On this tine the different share tips, guide plates and wing shares can be screwed on and off independently of each other. -
Page 33: Hollow Discs
Design and function Hollow discs The hollow discs protected by shear bolts are serrated and level the soil behind the tines. They level the ridges which are thrown up by the tines on the back row. The hollow discs are also available with an automatic overload safety device. Edge discs The depth and pitch angle of the edge discs, protected by shear bolts, can be ad- justed. -
Page 34: 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 35: Required Hydraulic Equipment
Preparation of the Tractor Required hydraulic equipment The implement is supplied as standard with separate hydraulic connections for each consumer. The protective caps for the hydraulic connections are colour- coded and the hydraulic connections themselves are alphanumerically coded. For operation of the individual hydraulic devices listed below, the tractor must be equipped with the following double-acting control units: Tractor/Implement Single acting... -
Page 36: Three-Point Linkage
Preparation of the Tractor Three-point linkage For this implement, the only draw rails (1) and top link pins (2) approved are those listed in the table below and corresponding to the category of the three-point linkage on the tractor. If they do not match, then either the tractor's three-point linkage or the device's draw rail (1) and the top link pin (2) must be replaced with a suitable,... - Page 37 Preparation of the Tractor Tractor output Cat. Pintle diameter of draw Length draw rail rail (mm) (shoulder distance) (mm) 80 - 185 109 - 251 36,6 80 - 185 109 - 251 36,6 150 - 350 204 - 476 50,8 150 - 350 204 - 476 50,8...
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Page 38: Hydraulic System
Preparation of the Tractor Hydraulic system 6.7.1 Transport Lowering the three-point linkage CAUTION The device may be damaged if the three-point linkage of the trac- tor is lowered due to an incorrect setting or operation. For transport always switch the hydraulic system of the tractor to "position control". -
Page 39: Coupling And Uncoupling
Coupling and uncoupling COUPLING AND UNCOUPLING Coupling When coupling the implement, switch the hydraulic system of the tractor to po- sition control. Drive the tractor backwards towards the device until the tractor is in front of the device and the catch hooks of the lower links (2) can be coupled with the draw rail (3). - Page 40 Coupling and uncoupling Secure the top link pin (7) with the lynch pin. Attach the lighting system with warning signs (8) if the drive to the field is via public highways. Risk of injury when coupling the device WARNING There is a risk of body parts being crushed between the tractor and device...
- Page 41 Coupling and uncoupling Risk of accident from spurting hydraulic fluid Hydraulic fluid which escapes under high pressure may penetrate your skin and cause severe injuries. If injuries occur, call a doctor immediately Before connecting the hydraulic hoses to the tractor hydraulics, WARNING check that the hydraulics are depressurised on the tractor and device.
- Page 42 Coupling and uncoupling Danger to life due to unsecured connection between lower link and draw rail If the connection between lower link and draw rail is not secured, the pintle of the draw rail may slip out. DANGER As a result, the device may fall down at the side and injure or kill people in the immediate vicinity.
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Page 43: Uncoupling
Coupling and uncoupling Uncoupling Lower the implement before uncoupling. To depressurise the hydraulic hoses, move the actuation levers for the control units to the "float position". Actuate the hydraulic system of the trac- tor until the top link pin (7) is relieved. ... -
Page 44: Draw Rail
Coupling and uncoupling Draw rail 7.3.1 Mounting position The draw rail (1) can be mounted on the device at two heights = draw point posi- tions. The picture shows the draw rail (1) in the upper mounting position = low draw point. -
Page 45: Changing The Mounting Position
Coupling and uncoupling 7.3.2 Changing the mounting position If a different mounting position of the draw rail (1) is required, the draw rail (1) must be removed as follows and placed in the new mounting position. The device must be deposited in the ex- tended position and detached from the tractor. -
Page 46: Top Link
Coupling and uncoupling Top link 7.4.1 Mounting position The top link (1) can be mounted in several positions on the three-point tower (2). A total of four mounting positions are pro- vided. Select a lower mounting position for the top link (1) ... -
Page 47: Changing The Mounting Position
Coupling and uncoupling 7.4.2 Changing the mounting position If the top link (1) is to be placed in a differ- ent mounting position, reposition the top link (1) as follows. To do this, extend and completely lower the device and switch the hydraulic system of the tractor to position control. -
Page 48: Safety Equipment
If fitted, swivel the edge discs backwards into the transport position. See “Edge discs” section. The Karat 9/350, 9/400, 9/350 U and 9/400 U are more than 3m wide. They may only be transported on public highways where this is permitted by law or a certifi-... -
Page 49: Adjustments
Adjustments ADJUSTMENTS Risk of accident when making adjustments When making any adjustments to the device, there are risks of crushing, cutting, clamping and striking your hands, feet and body on heavy and occasionally compressed and/or sharp-edged parts. Always park implement on the ground. DANGER ... -
Page 50: Working Depth Of Tines
Adjustments Working depth of tines 9.1.1 General information The working depth of the implement can be adjusted by approx. 5 to 30 cm. This is done using the guide pins (1). Raise the implement using the three- point hydraulics on the tractor. ... -
Page 51: Hydraulic Working Depth Adjustment
Adjustments 9.1.2 Hydraulic working depth adjustment In the hydraulic working depth adjustment the guide pins (1) are used to set the ma- ximum required working depth and the guide pins (9) are used to set the minimum required working depth. The hydraulic cylinders are used to set ei- ther the maximum or minimum working depth adjustment as required. -
Page 52: Support Wheels
Adjustments Support wheels The support wheels (1) are attached to the outside of the frame (2) at the front and improve the depth guide of the device. The support wheels must not be loaded with too much weight, otherwise the feed behaviour of the mounted devices will be nega- tively affected. - Page 53 Adjustments Risk of injury due to unsecured support wheel WARNING If pin and cam lever are removed simultaneously, the support wheel is no longer held in place and will slide down. This may re- sult in crushing and/or injury to feet. ...
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Page 54: Working Depth Of The Hollow Discs
Adjustments Working depth of the hollow discs The hollow discs (1) are adjusted with the pins (2) as follows: Release pin (2). Push up the disc carrier (3) slightly to unload the pin (2). Pull the pin (2) out. ... -
Page 55: Working Depth Of The Edge Discs
Adjustments Working depth of the edge discs The edge discs (1) are adjusted with the pins (2) as follows: Release pin (2). Push up the disc carrier (3) slightly to unload the pin (2). Pull the pin (2) out. ... -
Page 56: Share Position
Adjustments Share position The share position and the pitch angle of the tines (1) can be altered. A “flat” share position in conjunction with wing shares ensures a flat tillage horizon (share tip and wing shares work at almost the same depth) and reduces traction requirement, even in heavy soils. - Page 57 Adjustments WARNING Risk of injury from 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. Replace a removed shear bolt immediately. WARNING Risk of injury due to removed shear bolt If the shear bolt is removed, the tine can swing freely.
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Page 58: Automatic Overload Protection
Adjustments Automatic overload protection 9.7.1 Tine The tines (1) on the Karat 9 U feature an automatic overload safety device with compression springs (2) which are highly pretensioned. The overload protection is preset to a re- lease force of approx. 5500 N (550 kp) at the share point. -
Page 59: Edge Discs
Adjustments 9.7.3 Edge discs Danger to life due to high spring energy If the tine, the hollow disc or the edge disc is actuated and has still DANGER not been moved back into the working position, it can suddenly rebound into the working position with great force and at high speed. -
Page 60: Rollers
The rollers control the device at the working depth. Irrespective of the roller type used, the soil is more or less re-consolidated or more or less crumbled. Mounted devices Mounted devices Roller type Karat 9 U Karat 9 U Tube bar roller RSW 400 RSW 540... -
Page 61: Blade Rollers
Adjustments 9.8.2 Blade rollers Working depth of blades The working depth of the blades (6) is ad- justed using the guide pins (3) as follows: Turn the spindles clockwise to the stop until the guide pins (3) have been re- lieved of load. - Page 62 Adjustments Movement of blades Upward movement of the blades (6) is lim- ited using the guide pins (5). If necessary, slight movement upwards can be permit- ted. Position of blades The blades are generally screwed onto the blade frame (7) in the front position. In case of wear, the blades (6) can be moved backwards.
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Page 63: Pressure Load On Rollers
Adjustments Pressure load on rollers The pressure load on the rollers is deter- mined by the position of the top link (1). The hydraulic system on the tractor must be switched to the float position. The higher the top link (1) is mounted on the three-point tower of the mounted im- plement, the lower the pressure load on the rollers. - Page 64 Adjustments Risk of injury from unsecured top link pin If the top link pin is not secured, it may slip out or get lost. CAUTION As a result, the device may fall down or be damaged. As a result, people in the immediate vicinity may be injured. ...
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Page 65: 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 66: Tine With Integrated Share Foot
Switching over to different share systems 10.2 Tine with integrated share foot To switch over to a different share system, the corresponding components of the tine (1) must be removed and replaced with the components required for the de- sired share system. ... -
Page 67: Tine With Quick-Change System
Lock the control units of the tractor and switch the tractor engine off. Using the LEMKEN hook wrench (4), swivel the retaining wire (5) of the linch pin (3) backwards. Hold the share foot (2) in the detent po- sition by pressing the guide plate (5) against the tine (1). - Page 68 Switching over to different share systems Hold the share foot (2) with both hands and swivel the share foot (2) forwards to detach it from the tine (1). Pull the share foot (2) downwards and deposit it outside the device. The share foot with share tip, guide plate and wing share weighs approx.
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Page 69: Attaching The Share Foot
Switching over to different share systems 10.3.2 Attaching the share foot The share foot (2) is attached to the tine (1) in reverse sequence to its removal. When the device has been lifted out, it must be secured with the aid of a suitable support to prevent it from unintentionally drop- ping. - Page 70 Switching over to different share systems Danger due to unsupported device DANGER If the lifted out device is not secured on supports to prevent it from dropping, people underneath may be injured or killed. It is imperative to support the lifted out device if people are car- rying out maintenance or service work in the hazardous area of the device.
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Page 71: Switching Off The Device
Switching off the device SWITCHING OFF THE DEVICE 11.1 Shutting down the device in an emergency In an emergency shut down the device via the tractor. Switch the tractor engine off. Remove the key. Damage caused by improper storage of the device If incorrectly or improperly stored, the device may be damaged, CAUTION e.g. -
Page 72: Maintenance And Repairs
Maintenance and repairs MAINTENANCE AND REPAIRS 12.1 Special safety instructions 12.1.1 General Risk of injury during maintenance and repair work During maintenance and repair work, there is always a risk of in- jury. WARNING Only use suitable tools, climbing equipment, platforms and sup- ports. -
Page 73: Shutting Down The Device For Maintenance And Repairs
Maintenance and repairs 12.1.4 Shutting down the device for maintenance and repairs Risk of accident due to tractor starting up Injuries may occur if the tractor starts moving during maintenance and repair work. WARNING Switch off the tractor engine before carrying out any work on the device. -
Page 74: Working Under The Raised Device
Maintenance and repairs 12.1.7 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 WARNING components and devices. Always secure the tractor to prevent it from rolling away. Re- move the ignition key and secure the tractor to prevent it from being started up by unauthorised persons. -
Page 75: 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 76: Maintenance Intervals
The hydraulic hoses must be replaced at the latest 6 years after the date of manufacture. Use hydraulic ho- ses authorised by LEMKEN only. Safety equipment Check that the safety equipment functions properly. -
Page 77: Weekly Inspection
Maintenance and repairs 12.3.3 Weekly inspection Check What to do? Wheel nuts Check that all wheel nuts are tight and, if re- quired, retighten the wheel nuts to the appro- priate torque. Screw connections Retighten all other bolts and nuts on the device to the appropriate torque. -
Page 78: Tightening Torques
Maintenance and repairs 12.4 Tightening torques 12.4.1 Wheel nuts Diameter / Tightening tor- Thread [Nm] M12x1.5 M14x1.5 M18x1.5 M20x1.5 M22x1.5 12.4.2 Other screw connections Diameter / Strength - Strength cate- Strength - Thread category 8.8 gory 10.9 [Nm] category 12.9 [Nm] [Nm] 13,6... -
Page 79: Checking Connections To The Tractor
Maintenance and repairs 12.5 Checking connections to the tractor Visually inspect the hydraulic couplings. Check that the hydraulic couplings are not leaking hydraulic fluid. Connect the hydraulic lines to the tractor and check for leaks under pressure. Defective or leaking couplings must be repaired or replaced immediately by a specialist workshop. -
Page 80: Tyres And Air Pressure
Maintenance and repairs 12.6 Tyres and air pressure WARNING Danger due to incorrect air pressure Too high air pressure in the tyres may cause the tyres to burst and too low air pressure may overload the tyres. Depending on the tyre size, the following minimum and maximum permitted air pressures are authorised for the profile and the PR number or the load index. -
Page 81: Identification Plate
Identification plate IDENTIFICATION PLATE The identification plate (1) is situated on the front of the frame. -
Page 82: Noise, Airborne Sound
Noise, Airborne Sound NOISE, AIRBORNE SOUND The noise level of the implement does not exceed 70 dB (A) during work. It is advisable for: tractors with a cab, to keep the cab door closed when working. tractors without a cab, to wear suitable hearing protection. 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. -
Page 83: Index
Index INDEX Air pressure ......................69 Axle loads ......................21 Blade rollers......................52 Check Chains ....................... 30 Coupling ....................... 34 Draw rail ....................... 38 Edge discs ......................47 Hollow discs......................47 hydraulic equipment ..................... 31 MAINTENANCE ....................63 Overload protection ....................50 Power sources......................