LEMKEN Karat 9 User manual

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 [phone], Fax [phone]
E-mail: [email protected], Internet: http://www.lemken.com

1
Dear customer,
Thank you for the trust you have placed in us by purchasing this device. The de-
vice can only be used to its full advantage when operated and used properly.
When the device was delivered, you will already have been instructed in opera-
tion, adjustment and maintenance by your dealer. 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.
The operating instructions contain important information about how to operate the
device safely, properly and efficiently. Following the instructions will help to pre-
vent hazards, faults and down times and will increase reliability and service life.
Read the operating instructions carefully and attentively before commissioning.
Make sure that the operating instructions are always available at the location
where the device is used.
The operating instructions must be read and followed by anyone who is involved
in carrying out the following work:
Coupling and uncoupling
Adjustments
Operation
Maintenance and repairs
Troubleshooting, and
Final shutdown and disposal.
These operating instructions are deemed to be the original operating instructions.

2
Spare parts ordering
This device is supplied with a specification listing all assemblies that are relevant
for the product. The spare parts list valid for your device includes both those as-
semblies relevant to you and those that are not intended for your device. Make
sure that you only order spare parts that belong to the assemblies that can be
found on your specification or the enclosed print out. When ordering spare parts,
state the type designation and serial number of the device. This information can
be found on the rating plate. Enter this data in the fields below so that it is always
to hand.
Type designation:
Serial number:
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.
Service and spare parts
Information on service and spare parts is available from your local dealer or our
website at www.lemken.com.

Contents
3
CONTENTS
Contents...........................................................................................................................3
1General information..................................................................................................8
1.1 Liability...........................................................................................................................8
1.2 Guarantee.......................................................................................................................8
1.3 Copyright .......................................................................................................................9
1.4 Optional accessories ....................................................................................................9
2Symbols used in the Operating Instructions........................................................10
2.1 Hazard classes ............................................................................................................10
2.2 Information...................................................................................................................10
2.3 Environmental protection...........................................................................................10
2.4 Indication of passages................................................................................................11
3Safety measures and precautions.........................................................................12
3.1 Target group................................................................................................................12
3.2 Intended use................................................................................................................12
3.3 Safety equipment on the device.................................................................................13
3.4 Safety and warning signs...........................................................................................14
3.4.1 General information..................................................................................................14
3.4.2 Meaning of warning signs ........................................................................................14
3.4.3 Position of the safety and warning signs..................................................................16
3.5 Special safety instructions.........................................................................................17
3.6 Hazardous areas..........................................................................................................19
3.6.1 Hazardous areas during operation of the device......................................................19
3.7 Residual risks..............................................................................................................19
3.7.1 Hazard caused by mechanical systems...................................................................20
3.7.2 Hazard caused by hydraulic systems.......................................................................20
3.7.3 Hazard during operation...........................................................................................20
3.8 Applicable rules and regulations...............................................................................20

Contents
4
3.9 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........................................................................................25
3.11.1 General information..............................................................................................25
3.11.2 Personnel selection and qualifications..................................................................26
4Handing over the device.........................................................................................27
5Design and function................................................................................................28
5.1 Overview ......................................................................................................................28
5.2 Function.......................................................................................................................29
5.2.1 Three-point headstock .............................................................................................29
5.3 Frame ...........................................................................................................................29
5.4 Tines.............................................................................................................................30
5.4.1 Working depth adjustment of the tines.....................................................................30
5.4.2 Automatic overload safety device for the tines.........................................................30
5.5 Hollow discs ................................................................................................................31
5.6 Edge discs ...................................................................................................................31
5.7 Rollers..........................................................................................................................31
6Preparation of the Tractor......................................................................................32
6.1 Tyres.............................................................................................................................32
6.2 Lift Rods.......................................................................................................................32
6.3 Check Chains or Sway Blocks of the Three Point Linkage .....................................32
6.4 Required power sources.............................................................................................32
6.5 Required hydraulic equipment...................................................................................33
6.6 Three-point linkage .....................................................................................................34
6.7 Hydraulic system.........................................................................................................36

Contents
5
6.7.1 Transport..................................................................................................................36
6.7.2 Work assignment .....................................................................................................36
6.7.3 Coupling and uncoupling..........................................................................................36
7Coupling and uncoupling.......................................................................................37
7.1 Coupling.......................................................................................................................37
7.2 Uncoupling...................................................................................................................41
7.3 Draw rail.......................................................................................................................42
7.3.1 Mounting position.....................................................................................................42
7.3.2 Changing the mounting position...............................................................................43
7.4 Top link ........................................................................................................................44
7.4.1 Mounting position.....................................................................................................44
7.4.2 Changing the mounting position...............................................................................45
8Safety equipment ....................................................................................................46
8.1 General information ....................................................................................................46
8.2 Warning sign with light...............................................................................................46
8.3 Transport dimensions.................................................................................................46
9Adjustments.............................................................................................................47
9.1 Working depth of tines................................................................................................48
9.1.1 General information..................................................................................................48
9.1.2 Hydraulic working depth adjustment ........................................................................49
9.2 Lowering depth of the rollers.....................................................................................49
9.3 Support wheels............................................................................................................50
9.4 Working depth of the hollow discs............................................................................52
9.5 Working depth of the edge discs...............................................................................53
9.6 Share position .............................................................................................................54
9.7 Automatic overload protection ..................................................................................56
9.7.1 Tine..........................................................................................................................56
9.7.2 Hollow discs.............................................................................................................56
9.7.3 Edge discs................................................................................................................57
9.8 Rollers..........................................................................................................................58

Contents
6
9.8.1 General information..................................................................................................58
9.8.2 Blade rollers.............................................................................................................59
9.9 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 .................................................................................65
10.3.1 Removing the share foot.......................................................................................65
10.3.2 Attaching the share foot........................................................................................67
11 Switching off the device.........................................................................................69
11.1 Shutting down the device in an emergency..............................................................69
11.2 Disposal .......................................................................................................................69
12 Maintenance and repairs........................................................................................70
12.1 Special safety instructions.........................................................................................70
12.1.1 General.................................................................................................................70
12.1.2 Personnel qualifications........................................................................................70
12.1.3 Protective clothing................................................................................................70
12.1.4 Shutting down the device for maintenance and repairs........................................71
12.1.5 Working on the hydraulics ....................................................................................71
12.1.6 Working on the electrics .......................................................................................71
12.1.7 Working under the raised device..........................................................................72
12.1.8 Utilised tool...........................................................................................................72
12.2 Environmental protection...........................................................................................73
12.3 Maintenance intervals.................................................................................................74
12.3.1 After the initial start-up (at the latest after 2 hours)...............................................74
12.3.2 Daily inspection ....................................................................................................74
12.3.3 Weekly inspection.................................................................................................75
12.4 Tightening torques......................................................................................................76
12.4.1 Wheel nuts............................................................................................................76
12.4.2 Other screw connections......................................................................................76
12.5 Checking connections to the tractor.........................................................................77

Contents
7
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

General information
8
1 GENERAL INFORMATION
1.1 Liability
In principle the "Standard Terms and Conditions of Sales and Delivery" of LEM-
KEN GmbH & Co. KG shall apply.
LEMKEN GmbH & Co. KG excludes liability claims in respect of injury and/or
damage which can be attributed to one or more of the following causes:
improper use of the device, see also section entitled "Intended use",
non-compliance with the operating instructions and the enclosed safety instruc-
tions,
unauthorised changes to the device,
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.
1.2 Guarantee
In principle the "Standard Terms and Conditions of Sales and Delivery" of LEM-
KEN GmbH & Co. KG shall apply.
The guarantee period is one year from receipt of the device. We shall rectify any
device faults according to the LEMKEN warranty guidelines

General information
9
1.3 Copyright
These operating instructions represent a document in terms of the law on unfair
competition.
Copyright is retained by
LEMKEN GmbH & Co. KG
Weseler Straße 5
D-46519 Alpen
These operating instructions are intended to be used by the operator of the de-
vice. They contain texts and drawings which must not be
reproduced,
divulged or
communicated in any other way in whole or in part without the express permis-
sion of the manufacturer.
Infringements will result in a claim for damages.
1.4 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.

Symbols used in the Operating Instructions
10
2 SYMBOLS USED IN THE OPERATING INSTRUCTIONS
2.1 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.
WARNING
Denotes a possible hazard with medium risk, which could result in
death or severe physical injury, if not avoided.
CAUTION
Denotes a low-risk hazard, which could cause light or medium
physical injury or property damage, if not avoided.
2.2 Information
Denotes special user tips and other particularly useful or important
information for operation and efficient utilisation.
2.3 Environmental protection
Indication of special recycling and environmental protection
measures.

Symbols used in the Operating Instructions
11
2.4 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

Safety measures and precautions
12
3 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. Each safety-relevant work step includes other safety instructions specific
to the work step.
3.1 Target group
These operating instructions are restricted exclusively to the use of the device by
trained technicians and instructed persons.
3.2 Intended use
The device is manufactured in accordance with state-of-the-art standards and the
recognised safety rules. However, the use of the device may result in a risk to life
and limb of the user or third parties, or cause damage to the device and other ma-
terial property. The device may be operated in a technically perfect condition only,
in accordance with its designated use and by safety-conscious persons in compli-
ance with the operating instructions.
Intended use also includes:
compliance with the operating instructions and implementation of the work
steps indicated in the operating instructions,
compliance with the safety and warning signs on the device,
observance of the power limits of the tractor and device,
observance of all maintenance specifications and additional checks,
the use of original spare parts,
the use of the listed auxiliary and operating materials as well as their environ-
mentally friendly disposal.
Safe operation is not guaranteed unless all instructions, settings and power limits
applicable to the device are observed.

Safety measures and precautions
13
3.3 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

Safety measures and precautions
14
3.4 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. The indicated article numbers are
used as order numbers.
3.4.2 Meaning of warning signs
Familiarise yourself with the meaning of the warning signs.
The following explanations provide detailed information.
ATTENTION: Please read and observe the operating instructions
and safety instructions before starting up the device
for the first time!
ATTENTION: Before carrying out maintenance or repair work,
switch off the engine and remove key!

Safety measures and precautions
15
ATTENTION: Do not remain in the operating and
swivel area of the device!
ATTENTION: Danger of crushing!

Safety measures and precautions
16
3.4.3 Position of the safety and warning signs
390 0510
390 0510
390 0506
390 0506
390 0555
390 0509

Safety measures and precautions
17
3.5 Special safety instructions
WARNING
Risk of injury due to non-observance of the currently valid
occupational safety guidelines
If the currently valid occupational safety guidelines are bypassed
or safety equipment is rendered unusable when handling the de-
vice, there is a risk of injury.
The operator must personally monitor all work on and with the
device.
The operator instructs his personnel in occupational safety ac-
cording to the currently valid occupational safety guidelines.
WARNING
Risk of injury due to foreign objects ejected at high speed
During work there is a risk of injury to the face and body by lumps
of earth, soil constituents or stones ejected at high speed.
During work there must be nobody directly in front of, behind or
next to the device.
During work nobody must accompany the device.

Safety measures and precautions
18
WARNING
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".
As a result, functions may run in the opposite direction or may be
inverted.
Before actuating the hydraulics, check that the hydraulic con-
nections of the device are connected to the tractor according to
the colour coding.
If there is no identification on the tractor and on the device or if the
connections are not connected to the tractor according to their
identification, it may not be possible to free the person safely.
If in doubt, leave casualties to be freed by specially trained rescue
personnel.