LEMKEN Karat 9 KA User manual

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 [phone], Fax [phone]
[email protected], 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.

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 type 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.

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CONTENTS
1General information................................................................................................11
1.1 Liability.........................................................................................................................11
1.2 Guarantee ....................................................................................................................11
1.3 Copyright .....................................................................................................................12
1.4 Optional accessories ..................................................................................................12
1.5 Type plate ....................................................................................................................13
2Symbols used in the Operating Instructions........................................................15
2.1 Hazard classes ............................................................................................................15
2.2 Information...................................................................................................................15
2.3 Environmental protection...........................................................................................15
2.4 Indication of passages................................................................................................16
3Safety measures and precautions.........................................................................17
3.1 Target group................................................................................................................17
3.2 Intended use................................................................................................................17
3.3 Safety features of the device......................................................................................18
3.4 Safety and warning signs...........................................................................................19
3.4.1 General information...................................................................................................19
3.4.2 Warning sticker positions...........................................................................................20
3.4.3 Meaning of warning signs..........................................................................................20
3.4.4 Meaning of other symbols..........................................................................................23
3.5 Special safety instructions.........................................................................................24
3.6 Danger areas................................................................................................................25
3.6.1 Danger areas during implement operation.................................................................25
3.6.2 Danger areas when folding and unfolding .................................................................26
3.7 Residual risks..............................................................................................................27
3.7.1 Hazard caused by mechanical systems.....................................................................27
3.7.2 Hazard caused by hydraulic systems ........................................................................27
3.7.3 Hazard during operation............................................................................................28

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3.8 Applicable rules and regulations...............................................................................28
3.9 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.............................................................................................30
3.9.6 Correct behaviour in road traffic ................................................................................31
3.10 Obligation of the operator ..........................................................................................31
3.11 Safe use of the implement..........................................................................................32
3.11.1 General ..................................................................................................................32
3.11.2 Personnel selection and qualifications ...................................................................33
4Handing over the Implement..................................................................................34
5Design and function................................................................................................35
5.1 Overview ......................................................................................................................35
5.2 Function.......................................................................................................................36
5.2.1 Three-point tower ......................................................................................................36
5.2.2 Hydraulic drawbar......................................................................................................36
5.2.3 Hydraulic cylinder for traction servo unit....................................................................37
5.2.4 Support wheels..........................................................................................................37
5.2.5 Frame........................................................................................................................37
5.2.6 Quick-change tines....................................................................................................37
5.2.7 Automatic tine overload protection ............................................................................37
5.2.8 Hollow discs...............................................................................................................37
5.2.9 Edge discs.................................................................................................................37
5.2.10 Side shields............................................................................................................38
5.2.11 Rollers....................................................................................................................38
5.2.12 Working depth adjustment of tines.........................................................................38
5.2.13 Running gear..........................................................................................................38
5.2.14 ContourTrack..........................................................................................................38
5.2.15 Compressed air braking system.............................................................................39
5.2.16 Hydraulic brake system..........................................................................................42

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6Preparation of the Tractor......................................................................................44
6.1 Tyres.............................................................................................................................44
6.2 Lift Rods.......................................................................................................................44
6.3 Check Chains or Sway Blocks of the Three Point Linkage .....................................44
6.4 Required voltage sources ..........................................................................................44
6.5 Hydraulic equipment required....................................................................................45
6.6 Brake system...............................................................................................................46
6.6.1 Air brake system........................................................................................................46
6.6.2 Hydraulic brake system .............................................................................................46
6.6.3 Without brake system................................................................................................47
6.7 Three-point linkage .....................................................................................................47
6.8 Upper link pin ..............................................................................................................49
6.9 Hydraulic system.........................................................................................................49
6.9.1 Transport...................................................................................................................49
6.9.2 Work assignment.......................................................................................................50
6.9.3 Coupling and uncoupling...........................................................................................50
7Preparations on implement....................................................................................51
7.1Final assembly.............................................................................................................51
7.2 Spring brake cylinders................................................................................................51
7.3 Traction servo unit......................................................................................................53
7.4 ContourTrack...............................................................................................................55
7.4.1 Preparing the control valve for operation with a load-sensing system.......................55
7.4.2 Preparing the control valve for operation with constant flow hydraulic assembly ......55
8Attachment...............................................................................................................56
8.1 Implement with three-point connection ....................................................................58
8.2 Implement with hydraulic drawbar ............................................................................61
8.3 Air brake system .........................................................................................................64
8.4 Hydraulic braking system...........................................................................................64

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8.5 Traction increase device ............................................................................................65
8.6 Safety chain.................................................................................................................65
9Folding the lateral parts in and out .......................................................................67
9.1 Folding in.....................................................................................................................67
9.2 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.............................................................................................71
10.4 Shut-off valves.............................................................................................................71
10.5 Protective equipment..................................................................................................72
10.6 Lighting system...........................................................................................................73
10.7 Transport dimensions.................................................................................................73
11 Operation .................................................................................................................75
11.1 Working depth of the tines.........................................................................................76
11.1.1 General information................................................................................................76
11.1.2 Depth adjustment of the tines.................................................................................76
11.1.3 Setting the working width on implements with ContourTrack .................................78
11.2 Support wheels............................................................................................................78
11.2.1 General information................................................................................................78
11.2.2 Basic setting...........................................................................................................80
11.2.3 Calibrating working depth.......................................................................................81
11.2.4 Basic setting of the touch wheels for ContourTrack ...............................................82
11.3 Working depth of hollow discs ..................................................................................82
11.4 Working depth of the edge discs...............................................................................85
11.5 Adjusting the side shields..........................................................................................86
11.6 Share position .............................................................................................................87

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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...............................................................................................................96
11.10.2 Knife rollers.........................................................................................................97
11.10.3 Pressure load on packer profile roller and packer double roller ..........................99
11.11 ContourTrack.............................................................................................................100
11.11.1 Switch off ..........................................................................................................100
11.11.2 Switch on ..........................................................................................................101
11.12 Turning at the headland............................................................................................102
12 Use without a roller...............................................................................................103
12.1 General information ..................................................................................................103
12.2 Changeover from use with a roller to use without a roller ....................................103
12.2.1 Detaching the roller ..............................................................................................103
12.2.2 Attaching the pendulum lock ................................................................................104
12.2.3 Attaching the supporting tube for the wheelmark eradicators...............................104
12.2.4 Attaching the wheelmark eradicators ...................................................................105
12.3 Operation for use without a roller............................................................................107
12.3.1 General information..............................................................................................107
12.3.2 Adjusting the depth control...................................................................................107
12.3.3 Adjusting the wheelmark eradicators....................................................................108
12.3.4 Swivelling in the spiral tines for transportation......................................................109
12.4 Changeover from use without a roller to use with a roller ....................................110
12.4.1 Detaching the wheelmark eradicators..................................................................110
12.4.2 Detaching the supporting tube..............................................................................110
12.4.3 Detaching the pendulum lock...............................................................................111
12.4.4 Removing the clips for depth control....................................................................111
12.4.5 Attaching the roller ...............................................................................................112

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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.........................................................119
14.1 Share tips, guide plates and wing shares...............................................................119
14.2 Tines with integrated share base.............................................................................119
14.3 Tines with quick-change system .............................................................................120
14.3.1 Removing the share base.....................................................................................121
14.3.2 Attaching the share base......................................................................................123
15 Put the implement out of operation.....................................................................125
15.1 Shutting down the implement in an emergency.....................................................125
15.2 Disposal .....................................................................................................................125
16 Maintenance and repairs......................................................................................126
16.1 Special safety instructions.......................................................................................126
16.1.1 General ................................................................................................................126
16.1.2 Personnel qualifications .......................................................................................126
16.1.3 Protective equipment............................................................................................126
16.1.4 Immobilise the implement for maintenance and repairs .......................................127
16.1.5 Working on the hydraulics....................................................................................127
16.1.6 Working on the electrics.......................................................................................127
16.1.7 Working under the raised device..........................................................................128
16.1.8 Utilised tool...........................................................................................................128
16.2 Environmental protection.........................................................................................129
16.3 Lubrication.................................................................................................................129

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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............................................................................135
16.6 Braking system..........................................................................................................135
16.7 Cleaning the filter......................................................................................................135
16.8 Replacing hollow discs.............................................................................................136
16.9 Replacing the side shields .......................................................................................137
16.10 Calibrating the hydraulic drawbar ...........................................................................138
16.11 Tightening torques....................................................................................................139
16.11.1 Wheel nuts........................................................................................................139
16.11.2 Other bolt connections......................................................................................139
16.11.3 Points................................................................................................................140
16.12 Checking connections to the tractor.......................................................................141
16.12.1 Couplings..........................................................................................................141
16.12.2 Connectors and cables .....................................................................................141
16.13 Air pressure of tyres .................................................................................................142
16.14 Traction servo unit system pressure.......................................................................142
16.14.1 Reading off system pressure ............................................................................142
16.14.2 Generating system pressure.............................................................................143
16.15 Scrapers.....................................................................................................................145
16.15.1 Scrapers on rubber ring roller ...........................................................................145
16.15.2 Scrapers on packer-profile roller.......................................................................146
16.15.3 Scrapers on the packer double roller ................................................................148
16.15.4 Flex ring roller scrapers.....................................................................................149

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17 Technical data .......................................................................................................150
18 Noise, Airborne Sound .........................................................................................153
19 Notes ......................................................................................................................153
Index .............................................................................................................................154

General information
11
1 GENERAL INFORMATION
1.1 Liability
The "Standard Terms and Conditions of Sales and Delivery" of LEMKEN GmbH &
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:
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 that has not been conducted properly or in good time,
the use of spare parts that are not original LEMKEN GmbH & Co. KG spare
parts,
accidents or damage through outside influences or force majeure
1.2 Guarantee
The "Standard Terms and Conditions of Sales and Delivery" of LEMKEN GmbH &
Co. KG shall apply at all times.
The guarantee period shall be one year from the date of receipt of the implement.
We shall rectify any implement faults in accordance with the LEMKEN guarantee
guidelines.

General information
12
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, Germany
These operating instructions are intended to be used by the user of the imple-
ment. 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 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.

General information
13
1.5 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 or implement
equipment.
In the operating instructions, contents are
marked that are only valid for a certain im-
plement type or certain implement
equipment.
Use the type plate to determine the imple-
ment type and the implement equipment.
Design of the type plate
Figure: Sample of a type plate (standard)
Figure: Sample of a type plate, only France
1
Series

General information
14
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)
12
Permissible axle load [kg] (axle 2)
13
CE label
14
EAC label
15
Company name and address of the manu-
facturer
15a
Address of the manufacturer
16
Company logo
17
Manufacturer
18
Date of homologation
19
Type / Equipment / Version
*For implements with an EU type-approval number, the permissible gross weight
is equal to the sum of the permissible axle loads.

Symbols used in the Operating Instructions
15
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
16
2.4 Indication of passages
The following symbols are used for particular passages in the operating instruc-
tions:
Indicates work steps
Indicates enumerations

Safety measures and precautions
17
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.
The machine is only suitable for the usual agricultural use.

Safety measures and precautions
18
3.3 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
Front release support