KUHN Merge Maxx 900 Operator'S Manual Download

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KN093CGB C

OPERATOR'S MANUAL

Merger

Merge Maxx 900

KN093CGB C

- English - 04-2010

Summary of Contents for Merge Maxx 900

Page 1: ...KN093CGB C OPERATOR S MANUAL Merger Merge Maxx 900 KN093CGB C English 04 2010...

Page 2: ......

Page 3: ...fore reading this manual carefully KEEP THIS MANUAL AVAILABLE FOR REFERENCE Pass it on to the next owner if you re sell the machine Your KUHN dealer can offer a complete line of genuine KUHN service p...

Page 4: ...ment 6 Safety instructions 7 Location and description of safety decals on the machine 19 Road safety equipment and recommendations 22 Machine specifications 25 Description and glossary 25 Technical sp...

Page 5: ...he machine into work position 50 Adjustments in working position 53 Machine use 66 Optional equipment 78 Wide wheels 78 Maintenance and storage 79 Frequency chart 79 Lubrication 81 Maintenance 89 Stor...

Page 6: ...Merger 4 Merge Maxx 900 Identification of the machine Identification of the machine 1 Front view working position 2 Rear view working position...

Page 7: ...pe and serial number of the machine This information is to be indicated to the dealer for all spare parts orders Type MERGE MAXX 900 Serial no 4 Optional equipment Tick box corresponding to the equipm...

Page 8: ...s a potentially hazardous situation that if not avoided could result in serious bodily injury This symbol is used to identify special instructions or procedures which if not followed strictly could re...

Page 9: ...nly be operated maintained and repaired by competent persons who are familiar with machines specifications and operation and aware of safety regulations for preventing accidents The operator must impe...

Page 10: ...lace and in good condition Immediately replace any worn or damaged guard Precautions when driving Tractor handling stability performance and braking efficiency are all affected by weight distribution...

Page 11: ...l legally required lightings and signallings are in place Ensure that lightings and signallings are clean and in good working order Replace any missing or broken equipment Gross weight and weight per...

Page 12: ...ads with empty hoppers and tanks Description Units Description T kg Tractor unladen weight PTAC kg Gross Combined Weight Rating T1 kg Unladen load on tractor front axle T2 kg Empty load on tractor rea...

Page 13: ...3300 lb Add ballast weights until the minimum front axle load is exceeded Repeat checking procedure Stage 3 To measure Total weight t Tractor machine transport position Ballast weights Checking To go...

Page 14: ...and rim specifiations are in conformity with the requirements of the tractor manufacturer Example Load on rear axle t2 8500 kg 18740 lb Check in the tractor s operator s manual that the value measured...

Page 15: ...circuit To avoid making incorrect connections mark hydraulic couplers and corresponding hoses with colors WARNING Functions could be reversed for example lift lower and cause accidents Regularly chec...

Page 16: ...the machine disengage the PTO drive turn off the engine remove ignition key and wait for all moving parts have come to a complete stop If the primary PTO shaft is equipped with a slip clutch or a fre...

Page 17: ...tent persons who are equipped with standardized tools Before any work is performed on the wheels ensure that the machine rests on the ground and is perfectly stable so that it cannot move accidentally...

Page 18: ...keep the safety decals clean and readable and replace them when they are worn damaged missing or illegible Waste disposal Respect the environment Never spill pollutants oil grease filters etc on the...

Page 19: ...ctrical circuit Also disconnect alternator and battery terminals Repairs on elements under pressure or tension springs pressure accumulators etc must only be carried out by competent persons with regu...

Page 20: ...parts have come to a complete standstill If the machine hits an obstacle disengage the PTO drive stop the tractor engine remove the ignition key and wait for all moving parts to come to a complete st...

Page 21: ...Safety Merger Merge Maxx 900 19 3 Location and description of safety decals on the machine Location of safety decals...

Page 22: ...ine 2 Before leaving the tractor or before adjusting maintaining or repairing the machine disengage the PTO drive turn off the engine remove ignition key and wait until all moving parts have come to a...

Page 23: ...om the machine Crushing hazard Coupling device 6 Couple the machine to a tractor that is equipped with a system for locking the lift arms laterally and vertically To drive on roads respect the attachm...

Page 24: ...imit for driving a tractor machine assembly on public roads Whatever the speed we recommend for everyones safety not to exceed a maximum speed of 25 km h 15 mph The rear safety device comprises 2 sign...

Page 25: ...Merger Merge Maxx 900 23 The side device comprises 3 amber reflectors 1 on each machine side Tyre pressure 1 Standard wheels 2 bar 29 psi Wide wheels 1 6 bar 23 psi Wheel nut torque 27 daN m 199 lbf...

Page 26: ...ds respect the attachment height specified in the operator s manual and lock the lift linkage Speed 1 Always keep to the legal speed limit of 25 km h 15 mph for driving a tractor machine assembly on p...

Page 27: ...Description and glossary 0 1 Right pick up 2 Central pick up 3 Left pick up 4 Comb 5 Hydraulic fluid reservoir 6 Step up gearbox 7 Parking stand 8 Coupling device 9 Three point hitch coupler 10 Drawba...

Page 28: ...9 50 m 31 2 Length in working position 7 13 m 23 5 Height in working position 2 70 m 8 10 Width in transport position with transport wheel 400 55 22 5 14 with transport wheel 500 45 22 5 14 3 00 m 9 1...

Page 29: ...ing set of tires Standard wheels 400 55 22 5 14 ply or Wide wheels 500 45 22 5 14 ply Braking system This equipment is fitted on the machine transport wheels in conformity with the legislation in forc...

Page 30: ...sured in accordance with the measuring methods as defined in NF EN 1553 Agricultural machinery Self propelled mounted semi mounted and trailed Common safety recommendations Weighted equivalent continu...

Page 31: ...tting into service 1 Description of control elements The machine is fitted with a control box to monitor all functions Model T15M Description of the box 0 1 Display 2 Indicator light 3 7 pin CAN conne...

Page 32: ...ing unlocking function 3 Machine unfolding folding function 4 Pick up pivoting function 5 Pick up height adjustment function 6 Function for setting the left pick up in headland turn position 7 Functio...

Page 33: ...is made up of 2 areas a and b The functions of area a are controlled by tractor valve I The functions of area b are controlled by tractor valve II The functions of area b are available when the Pick u...

Page 34: ...right 2 navigation keys These keys enable navigating between the various functions controlled by tractor valve I Keys for setting the machine into headland turn position 1 Left pick up 2 Right pick u...

Page 35: ...nt mode or to delete the error message Emergency stop The control box is fitted with an emergency stop for switching off the module and stopping all electric functions on the machine actuators 2 Assem...

Page 36: ...rt no 83233014 Fuse 2 Number of contact Colour of cable Function 1 82 Brown 12V 2 15 30 Brown 12V 3 31 Blue Ground Some tractors are factory equipped with a 3 pin socket to prevent any malfunction che...

Page 37: ...supply 4 hydraulic hoses connected to the hydraulic valve bank that controls the various functions 1 hydraulic hose to supply the braking system circuit depending upon specification 2 pneumatic hoses...

Page 38: ...for the control box When the machine is fitted with a hydraulic brake actuation system 1 hydraulic connection for the braking system When the machine is fitted with a pneumatic brake actuation system...

Page 39: ...ach lower links to the hitch pins on the inside of the yokes Category 2 a Category 3 b Secure each hitch pin with lynch pin Raise tractor lift linkage to free parking stand Pull on handle 1 to unlock...

Page 40: ...rs Pick up height adjustment cylinders Connect hydraulic hoses c and d of diameter 20 mm 0 8 on the same tractor double acting valve Hoses c and d supply the following cylinders Cylinders for setting...

Page 41: ...ke hoses to the tractor After connecting the lines check that there is no risk of them getting caught in operation Check that the brakes work correctly Press valve 1 to disengage brakes by hand Pull v...

Page 42: ...rol box Connect 7 pin plug 1 of module 3 to control box 2 Connect the module M400 3 wiring harness 4 to the tractor 3 pin plug 5 Lighting Connect 7 pin plug to the tractor After making the connections...

Page 43: ...y measure a clearance L of at least 10 mm 0 4 must be maintained When the PTO shaft is in its maximum extended position the tube overlap must be more than 250 mm 10 If this is not the case Mark length...

Page 44: ...Attach PTO shaft guard chain in hole 1 on machine side Unfold pto shaft support 1 To avoid serious accidents the PTO drive shaft guards must be properly in place and fixed with the chains provided Im...

Page 45: ...g the machine Lateral adjustment of the lower linkage arms Balance the play on either sides of the lift linkage and lock lower link stabilizers Frame height Lower the tractor lift linkage so that hitc...

Page 46: ...g the machine Block machine with wheel chocks 1 Release and lower parking stand 2 Secure parking stand using lock 1 Uncouple and place PTO shaft in support 1 Park the machine on an even fairly level g...

Page 47: ...ses on holder 2 Disconnect and store signalling electric plug on holder 2 Disconnect and store module electric supply plug Disconnect and store control box in a dry and clean place Lower the tractor t...

Page 48: ...ately 1 second on the navigation key Indicator light 1 comes ON 3 is displayed on the screen Operate tractor hydraulic valve I The side pick ups lift Before placing the machine into transport position...

Page 49: ...ator light 1 comes ON 2 is displayed on the screen Operate tractor hydraulic valve I The machine folds Press for approximately 1 second on the navigation key Indicator light 1 comes ON 1 is displayed...

Page 50: ...ximately 1 second on key a Indicator light 1 flashes The hour counter is displayed all machine functions are deactivated Press on the button ON OFF b The machine is in transport position Never engage...

Page 51: ...lean and that the lighting equipment functions before transporting the machine on public roads Before driving the machine on public roads ensure that the machine complies with current highway code reg...

Page 52: ...the screen a hour 0 to 9999 b minute 0 to 59 Press for approximately 1 second on the navigation key Indicator light 1 comes ON 1 is displayed on the screen Operate tractor hydraulic valve I The machi...

Page 53: ...imately 1 second on the navigation key Indicator light 1 comes ON 3 is displayed on the screen Operate tractor hydraulic valve I The pick ups are lowered The 1 2 and 3 modes are active during 60 secon...

Page 54: ...work Press for approximately 1 second on the navigation key Indicator light 1 comes ON The hour counter is displayed The work functions are activated Activate tractor hydraulic valve II to lower the p...

Page 55: ...up height Indicator 1 enables to visualize the pick up working height Before making any adjustment Check that nobody is within the machine pivoting area If there is someone make sure the person moves...

Page 56: ...Remove screw 2 Place comb in the required position Position a More aggressive position Position b Intermediate position Position c Less aggressive position Repeat procedure on each comb Fit screw 2 T...

Page 57: ...e navigation keys Indicator light 1 comes ON The pressure must be adapted to the nature and moisture degree of the ground Conditions required The pick ups are fully raised Select the Pick up height ad...

Page 58: ...t valves 1 and 2 are shut off Operate and maintain hydraulic valve I control lever to pressurize the circuit Slowly open hydraulic unit valve 2 Check pressure increase on gauges 3 When the required pr...

Page 59: ...ve by hand When proceeding to the adjustment the pressure is below the required value refer to Ground pressure decrease section When the pressure in the ground pressure circuit goes below 125 bar 1812...

Page 60: ...livery Shut off the central pick up cylinder valve Remove roll pin 1 and washer 2 Remove pin 3 Place the springs in the hole corresponding to the required setting The 2 springs must adjusted to the sa...

Page 61: ...both sides to the same setting Reducing the balancing pressure of the side pick ups Activate tractor hydraulic valve II to lower the pick ups Place hydraulic valve control lever II in floating positi...

Page 62: ...ck movement synchronisation Repeat procedure if necessary Tighten the counter nut To put the pick up holding frame rotation movement forward Loosen counter nut 2 loosen screw 3 by an eighth of a turn...

Page 63: ...by an eighth of a turn Check movement synchronisation Repeat procedure if necessary Tighten counter nut 1 To advance the central pick up raising Loosen counter nut 1 loosen screw 2 by an eighth of a t...

Page 64: ...time delay adjustment Select transport mode Indicator light 1 flashes Simultaneously press keys and for approximately 5 seconds The message SEC ON is displayed Shortly press navigation key The message...

Page 65: ...the time delay 2 seconds minimum or Press key 2 to increase the time delay 10 seconds max Press on validation key 3 to save the modifications and return to the transport mode Press Esc key 4 to quit w...

Page 66: ...e distance B on the rear edge of the wheel rims B A 24 mm 1 Remove steering rod 1 Remove nut 2 Remove screw 3 Remove roll pin 4 Remove washer 5 Remove pin 6 Position headstock 1 at 90 in relation to b...

Page 67: ...pin 6 Adjust yoke 7 Reinstall pin 6 Check wheel parallelism Adjusting the wheel toe in Remove pins 6 Tighten yokes by 3 5 turns Check the wheel toe in 2 4 B A 24 mm 1 Readjust if necessary Reinstall...

Page 68: ...s device drive onto a field difficult to access Groundspeed The machine can work at a speed of up to 15 km h 9 mph in very good working conditions Groundspeed must be adapted to the encountered workin...

Page 69: ...s on selection key The indicator light flashes for the whole period during which the conveyor belt direction of rotation is inverted and then stays on The time delay during which the conveyor belt dir...

Page 70: ...the whole period during which the conveyor belt direction of rotation is inverted and then stays on Operate tractor hydraulic valve II to lift the pick ups Activate tractor hydraulic valve II to lowe...

Page 71: ...ion of the conveyor direction of rotation The indicator lights flash for the whole period during which the conveyor belt direction of rotation is inverted and then they stay on The time delay during w...

Page 72: ...ss simultaneously the selection keys for approximately 1 second The indicator lights flash for the whole period during which the conveyor belt direction of rotation is inverted and then they stay on T...

Page 73: ...whole period during which the conveyor belt direction of rotation is inverted and then they stay on By pressing and holding down key allows leaving the windrow delivery mode The time delay during whi...

Page 74: ...ition Press selection key Indicator light 1 comes ON Operate tractor hydraulic valve II in the headland turn position direction The right pick up is raised Putting the machine into work position Opera...

Page 75: ...ey Indicator light 1 comes ON Operate tractor hydraulic valve II in the headland turn position direction The left pick up is raised Putting the machine into work position Operate tractor hydraulic val...

Page 76: ...ection key to deactivate the function Indicator light 1 is OFF Operate tractor hydraulic valve II in the headland turn position direction All the pick ups are raised Putting the machine into work posi...

Page 77: ...ion The symbol 3 indicates the pick up is in raised position Press shortly on the navigation key to quit viewing the pick up position and to return to the hour counter When symbol 2 is steady the cent...

Page 78: ...1 to switch to the deteriorated mode The message SEC OFF is displayed or Press key 2 to switch back to the normal use mode The message SEC ON is displayed Press on validation key 3 to save the modific...

Page 79: ...rger Merge Maxx 900 77 Error messages If an error code is displayed on the screen contact your Kuhn dealer Note the sofware versions of the T15M and M400 before contacting your Kuhn dealer Press Esc k...

Page 80: ...70 Technical specifications When fitting this equipment following technical specifications are modified Width in transport position 3 10 m 10 2 Tyres 500 45 22 5 14 PLY Tyre pressure 1 6 bar 23 20 psi...

Page 81: ...a standstill and remove PTO shaft Maintenance intervals are indicated for normal conditions of use Before using the machine for the first time After the first 10 hours of use After the first 20 hours...

Page 82: ...gearbox oil level 3 3 Tank oil level 3 Braking system 3 3 Fixing elements 3 3 Check transport wheel bolts for tightness 3 3 3 Replace Hydraulic tank filter cartridge 3 3 3 Before using the machine fo...

Page 83: ...nts to be greased Part no 09905400 Clean grease nipples before greasing PTO shaft Every 8 hours The U joints 1 constant velocity joint 4 Every 20 hours The transmission tube 2 Every 40 hours Guide rin...

Page 84: ...bolts 1 Remove cover 2 spring 3 and oil filter 4 Replace the oil filter 4 Part no A4079112 Reassemble all components Pour the correct oil quantity and quality through the opening of the filler plug R...

Page 85: ...plug 1 and its washer Replace if necessary Part no 82102229 Pour the correct oil quantity and quality through the opening of the filler plug Clean and tighten the filler plug extension 2 Before draini...

Page 86: ...Merger 84 Merge Maxx 900 Maintenance and storage Grease The steering system...

Page 87: ...Maintenance and storage Merger Merge Maxx 900 85 The left arm pivot points...

Page 88: ...Merger 86 Merge Maxx 900 Maintenance and storage The right arm pivot points...

Page 89: ...Maintenance and storage Merger Merge Maxx 900 87 The undercarriage articulations...

Page 90: ...Merger 88 Merge Maxx 900 Maintenance and storage Oil The coupling yokes The parking stand The transport locks...

Page 91: ...easure L is below 1204 mm 3 11 40 The conveyor belt is slack Check tension of the side conveyor belts Measure distance L If measure L is comprised between 1505 and 1510 mm 4 11 25 4 11 45 The conveyor...

Page 92: ...tension Unscrew the 2 nuts 1 Loosen the 2 screws 2 Remove bolt 1 and nut 2 Rotate pin 3 counterclockwise to tension the conveyor Rotate pin 3 clockwise to slacken the conveyor belt Reinstall bolt 1 an...

Page 93: ...il the gearbox is horizontal Unscrew filler plug extension 2 Through filling hole check that oil height h is comprised between 170 and 180 mm 6 7 7 Top up if necessary Clean and tighten the filler plu...

Page 94: ...el The oil level must reach the maximum mark on level indicator 1 in particular when working on slopes Fixing elements Check transport wheel nuts 1 for tightness Torque 27 daN m 199 lbf ft Check the m...

Page 95: ...el of braking cylinders Brake system not active Measure dimension L Activate brake system Measure dimension L1 Length L1 must not exceed measure L by more than 35 mm 1 38 Check when it is cold The mac...

Page 96: ...6 bar 23 psi Emptying the air reservoir depending upon specification Pull ring 1 to empty water contained in the air reservoir Before carrying out any maintenance or repairs on the pneumatic braking...

Page 97: ...Loosen the 4 self locking screws 1 Remove upper filter cover plate 2 Grab spring 3 Replace the oil filter 4 Part no A4079112 Reassemble all components The OIL FIL message flashes when the hydraulic ta...

Page 98: ...aged paintwork Check and replace worn or damaged tools Put the machine under cover in a dry place Store control box in a dry place free of dust At the start of each season Re read the operators manual...

Page 99: ...power supply when switching on the control box Contact your Kuhn authorized dealer E 0010 Major fault Contact your Kuhn authorized dealer E 0032 A control key is in contact when switching the control...

Page 100: ...ery If the problem persists call your Kuhn dealer E 1405 Solenoid valve voltage is below 9 V Check connection of the 3 pin plug Check condition of the battery power cable Charge the battery If the pro...

Page 101: ...A1 Contact your Kuhn authorized dealer C 2412 Short circuit on A2 Contact your Kuhn authorized dealer C 2413 Short circuit on A3 Contact your Kuhn authorized dealer C 2414 Short circuit on A4 Contact...

Page 102: ...uhn dealer E 2412 Circuit open on A2 Check that the coil is connected If the problem persists call your Kuhn dealer E 2413 Circuit open on A3 Check that the coil is connected If the problem persists c...

Page 103: ...T kg Tractor unladen weight T1 kg Unladen load on tractor front axle T2 kg Empty load on tractor rear axle t kg Axle loads Tractor machine t1 kg Load on front axle Tractor machine t2 kg Load on rear...

Page 104: ...required minimum front load is reached Indicate front axle calculated load value and the one indicated in the tractor operators manual T1 real M1 x a b T1 x b M2 x c d b 4 Calculation of the total wei...

Page 105: ...al Double value of the authorized capacity per tyre 2 tyres Minimum front rear ballasting kg Total weight kg kg Load on front axle kg kg kg Load on rear axle kg kg kg The minimum ballasting must be ma...

Page 106: ...ight M2 and the position of its centre of gravity d Tractor only T1 Load on front axle Tractor only T2 Load on rear axle Tractor only If the data required to calculate the total weight axle loads and...

Page 107: ...Appendix Merger Merge Maxx 900 105 T Axle loads Tractor only...

Page 108: ...e loads Tractor machine Hopper empty Calculating the rear tool weight M2 M2 T t Calculating the distance d d b x T1 t1 M2 c If the total unit weight exceeds the tractor Gross Combined Weight Rating in...

Page 109: ...Limited warranty Merger Merge Maxx 900 107 Limited warranty...

Page 110: ...Merger 108 Merge Maxx 900 Limited warranty...

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