KUHN MERGE MAXX 950 Operator'S Manual Download Page 120

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MERGE MAXX 950

120

11. - Troubleshooting guide

KN233BGB_C

Merger

11. Troubleshooting guide



Problem



Cause



Remedy

Pneumatic braking system

Malfunction of the pneumatic
braking system.

Water in the circuit.

- Empty the circuit.

Air leak.

- Check condition and

sealing of the circuit
components.

Incorrect air pressure in the
air reservoir.

- Contact your Kuhn dealer

to service and repair the
brake system.

Incorrect air pressure in the
brake cylinders.

Summary of Contents for MERGE MAXX 950

Page 1: ...Original instructions KN233BGB_C Read carefully before starting the machine Operator s manual Merger A1005 80B00001 A1005 80B9999 MERGE MAXX 950 KN233BGB_C English 09 2019 KN233BGB_C...

Page 2: ......

Page 3: ...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 parts These parts are manufactured and carefu...

Page 4: ...g the machine 16 4 2 5 Precautions when driving 17 4 2 6 Precautions when driving on public roads 17 4 2 7 Maximum speed 18 4 2 8 Precautions when coupling 19 4 2 9 Hydraulic circuit 20 4 2 10 PTO sha...

Page 5: ...36 5 1 Description and glossary 36 5 1 1 Designated use of the machine 36 5 2 Technical specifications 37 5 2 1 Designated parameters 37 5 3 Required equipment 38 5 3 1 Wheels 38 5 3 2 Braking system...

Page 6: ...pick up working height 66 8 2 2 Adjustment of the windguard aggressiveness 67 8 2 3 Ground pressure adjustment of the side pick ups 68 8 2 4 Flow control valve Conveyor 69 8 2 5 Adjustment of the tim...

Page 7: ...03 10 4 Maintenance 107 10 4 1 The belt tension 107 10 4 2 Fixing elements 111 10 4 3 Tank oil level 112 10 4 4 Step up gearbox oil level 113 10 4 5 Braking system 114 10 4 6 Tyre pressure 115 10 4 7...

Page 8: ...MERGE MAXX 950 8 3 Identification of the machine KN233BGB_C Merger 3 Identification of the machine 3 1 Front view transport position 3 2 Rear view working position...

Page 9: ...l 9a Machine serial number 9b Barcode Machine serial number 12 Weight empty Minimum Maximum 18 Data matrix 19 Plate reference 27 Place of manufacture 28 Manufactured by for 34 Special operation Certif...

Page 10: ...Plate reference 23 Logo EAC 25 Manufacturing year 26 Model year 54 Data matrix Importer plate BRASIL For machines to be sent to Brazil 1 Manufacturer name and address 4 KUHN logo 7 Model 9 Machine ser...

Page 11: ...m mass per axle 16 Maximum vertical static load applied by the machine on the towing eye 19 Plate reference 20 Towed tool Brake configuration T 1 Drawbar T 2 Stiff drawbar T 3 Middle axle B 1 Without...

Page 12: ...m permissible masses 14 Technically permissible maximum laden mass PTAC 15 Technically permissible maximum mass per axle 16 Maximum vertical static load applied by the machine on the towing eye 19 Pla...

Page 13: ...Optional equipment Tick box corresponding to the equipment fitted on your machine 1 3 8 6 spline pto shaft 1 3 8 21 spline pto shaft Quick hitch Wide wheels 500 45 22 5 14 ply Mudguard Windrow curtain...

Page 14: ...indicates 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...

Page 15: ...urer The manufacturer is not held liable for any damage resulting from machine applications other than those specified by the manufacturer Any use other than the designated operation is at the risk an...

Page 16: ...wear loose clothing which could become caught up in moving parts Wear the appropriate protective clothing for the work in hand gloves shoes goggles helmet ear defenders etc Ensure that all operating c...

Page 17: ...perating Carrying people or animals on the machine when working or in transport is strictly forbidden 4 2 6 Precautions when driving on public roads Dimensions Depending on the dimensions of the machi...

Page 18: ...lic roads place the machine into its transport position according to the instructions in this manual Lights and indicators Before transporting the machine on public roads ensure that all legally requi...

Page 19: ...nly be attached to the hitch points provided for this purpose Do not stand between the machine lower hitching points or between the tractor lower hitching points during coupling maneuvers Never stand...

Page 20: ...raulic hoses are damaged or worn In case of normal wear the hydraulic hoses must be replaced every 5 years Damaged or worn hoses must immediately be replaced When replacing the hydraulic hoses only us...

Page 21: ...aft or before doing any work on the machine disengage the PTO drive turn off the engine remove ignition key and wait for all moving parts to come to a complete stop If the primary PTO shaft is equippe...

Page 22: ...d replace protective shield on the PTO stub of the tractor Read and follow the instructions in the operator s manual provided with the PTO shaft 4 2 11 Precautions during manoeuvres When moving the ma...

Page 23: ...isk of suffocation in closed rooms Repairs maintenance or commissioning may only be carried out by competent persons Wait for the accumulator to cool down before handling it Only use nitrogen to prech...

Page 24: ...ine that need to be lifted for maintenance or repair work are firmly propped up Before any work is done on the electric circuit or before any electric welding is carried out on the attached machine di...

Page 25: ...ccordance with the instructions contained in this manual Keep all persons and animals away from the danger zone Check that nobody is within the side marker operating area on headlands Stay a safe dist...

Page 26: ...er surface of some parts can reach high temperatures and cause burns in case of contact Remain particularly cautious when working next to hot surfaces Wear protective gloves If possible let the machin...

Page 27: ...4 Safety MERGE MAXX 950 27 KN233BGB_C Merger 4 3 Location and description of safety decals on the machine 4 3 1 Location of safety decals 3 3 5 1 6 2 3 3 GB CE 4 GB CE 4 5 K9A148CE 0 K9A148CE 0 6 7...

Page 28: ...he machine 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 co...

Page 29: ...e machine Crushing hazard Do not step on the machine 6 Do not step on the machine Risk of falling or damaging the protection device Do not use a high pressure cleaner or water 7 Do not use a high pres...

Page 30: ...hatever this speed we recommend for everyone s safety not to exceed a speed of 25 km h 15 mph The rear device is made up of the following components 2 signalling lights 1 red lights brake lights flash...

Page 31: ...31 KN233BGB_C Merger The side device is made up of the following components 3 amber reflectors 1 on each machine side 4 4 1 Tyre pressure Standard wheels 400 55 22 5 2 bar 29 psi Wide wheels 500 45 22...

Page 32: ...e operator s manual and lock the lift linkage Speed Respect the maximum authorized speed of 25 kph 15 mph to travel on public roads with this tractor machine unit 4 4 3 Specific recommendations for th...

Page 33: ...g 134000 Specific requirements for countries member of the Eurasian Economic Community EAC marking 134001 Specific requirements for countries member of the Eurasian Economic Community EAC marking 1398...

Page 34: ...his type of equipment and with capacities that exceed the total weight of the unit as listed in this manual Check the machine weight in the technical specifications Position the machine on level hard...

Page 35: ...afety MERGE MAXX 950 35 KN233BGB_C Merger Lifting the machine by means of the car jack This pictogram indicates where to place a jack to raise the machine Changing of a wheel Refer to chapter Maintena...

Page 36: ...raulic fluid reservoir 5 Step up gearbox 6 Parking stand 7 Coupling device 8 Three point hitch coupler 9 Drawbar 10 Transport lock 11 Wheel 12 Conveyor 5 1 1 Designated use of the machine The MERGE MA...

Page 37: ...m 31 7 Side windrow delivery 7 623 m 25 Length in working position 6 082 m 19 11 Height in working position 2 179 m 7 2 Width in transport position with transport wheel 400 55 22 5 14 3 00 m 9 10 with...

Page 38: ...38 5 Machine specifications KN233BGB_C Merger 5 3 Required equipment The machine is factory delivered with the following equipment 5 3 1 Wheels Standard wheels 400 55 22 5 14 ply or Wide wheels 500 4...

Page 39: ...E MAXX 950 39 KN233BGB_C Merger 5 3 2 Braking system Hydraulic braking system or Pneumatic braking system 5 3 3 PTO shaft Pto shaft 1 3 8 6 spline pto shaft or 1 3 8 21 spline pto shaft Gearbox Housin...

Page 40: ...device loss or breakage during transport 5 4 Sound levels Sound levels have been measured in accordance with the measuring methods as defined in NF EN ISO 4254 1 Agricultural machinery Safety Part 1 G...

Page 41: ...d with a control terminal to carry out all of the functions Model AT10 Refer to the control terminal manual KC074 6 2 Description of the controls 1 Push button switch On Off 3 pushbuttons Functions Al...

Page 42: ...to the left 9 Move the cursor to the right 10 Push button switch Validation button 11 Push button switch Start Stop conveyors and pick ups 6 3 Assembly and fitting 6 3 1 Control terminal mounting The...

Page 43: ...s A pto shaft drives the machine s hydraulic pump for driving the pick ups and the conveyor belts An electric 7 pin plug for the signalling equipment A 3 pin plug for the on board computer power suppl...

Page 44: ...and maximum weight per axle are not exceeded See section Safety Safety instructions Precautions when driving on public roads The machine adapts to tractors fitted with a 2 point hitch coupler categor...

Page 45: ...le acting hydraulic outlet An electric 7 pin plug for the signalling equipment An electric 3 pin plug to supply the module When the machine is fitted with a hydraulic brake actuation system 1 hydrauli...

Page 46: ...4 4 Coupling the machine Before hitching your machine verify that the coupling pins the drawbar couplings or the ball joints do not show any signs of wear or fractures Immediately replace worn or dama...

Page 47: ...or lift linkage to free parking stand Pull lever 1 to unlock the parking stand Raise and lock parking stand Lock tractor lower link stabilisers The check chains must be replaced if one of their links...

Page 48: ...the tractor 6 4 5 Hydraulic connections When optional equipment is used follow specific procedures mentioned in the related section Optional equipment Windrow curtain Putting into service Coupling and...

Page 49: ...set cylinders of the work units in the direction of a windrow side delivery 1 black ring 1 red ring Hose b pressurizes the offset cylinders of the work units in the direction of a central windrow deli...

Page 50: ...ior to connecting the hoses Respect hose colour when connecting them Red a Feed line Yellow b Actuating line Connect the coiled air brake hoses to the tractor The push button of the valve is automatic...

Page 51: ...tank is full The push button of the valve is released It is possible to release the brakes to move the machine without connecting the brake hoses Conditions The push button of the valve is pushed in...

Page 52: ...ness 4 of module 3 to tractor 3 pin socket 5 Connect 7 pin plug to the tractor After connecting the harness check that there is no risk of them getting caught in operation 6 4 9 Primary PTO shaft Befo...

Page 53: ...When the PTO shaft is in its maximum overlap position retracted tubes should not butt against the yokes Keep a minimum safety travel L of 10 mm 0 4 When extended to the maximum the tube overlap must n...

Page 54: ...O shaft at an angle X exceeding 30 To avoid serious accidents the PTO drive shaft guards must be properly in place and fixed with the chains provided On machine side hook drive guard chain to ring 1 I...

Page 55: ...re at a distance H from the ground H 630 mm 2 1 6 4 11 Uncoupling the machine Park the machine on an even fairly level ground Preferably park the machine in transport position Block machine with wheel...

Page 56: ...aulic hoses in holder 2 Disconnect and store brake system hydraulic hoses on holder 2 Disconnect and store signalling electric plug on holder 2 Disconnect and store module electric supply plug Disconn...

Page 57: ...come to a complete stop and apply park brake Couple the machine to the tractor When lifting this equipment use appropriate lift straps chains or any other equipment in perfect working order complying...

Page 58: ...tating parts have come to a complete stop Check that nobody is within the machine pivoting area If there is someone make sure the person moves away The hydraulic functions are controlled using the AT1...

Page 59: ...ransport position The machine takes up the headland turn position Activate the offset valve to bring the work units closer Display of symbol 1 Press key F2 2 Activate the transport work cylinder contr...

Page 60: ...machine is in transport position 7 1 2 If the work units are close From the working position Activate the transport work cylinder control valve in the pivot into transport position The machine takes u...

Page 61: ...ormity with the road regulations Before driving the machine on public roads ensure that the machine complies with current highway code regulations Check that the light boards are clean and that the li...

Page 62: ...3BGB_C Merger 7 3 Machine transport using transport means 134035 Specific requirements for countries member of the Eurasian Economic Community EAC marking 134036 Specific requirements for countries me...

Page 63: ...in the machine pivoting area If there is someone make sure the person moves away 8 1 Putting the machine into work position The hydraulic functions are controlled using the AT10 terminal Menu Folding...

Page 64: ...50 64 8 Instructions for work KN233BGB_C Merger Activate the transport work cylinder control valve in the lower in work position The machine is unlocked Continue to activate the tractor valve The mach...

Page 65: ...rking position 8 2 Adjustments in working position Before making any adjustment Check that nobody is within the machine pivoting area If there is someone make sure the person moves away Before carryin...

Page 66: ...ween tines and ground can vary from 15 to 80 mm 0 59 3 15 Adjust the tine ends with regards to the ground to prevent premature wear and forage contamination Adjust pick up height using crank 1 Indicat...

Page 67: ...sen the check nut 1 Make the required adjustment using screw 2 Tighten counter nut 1 Adjustments Example 1 This adjustment allows working in short forage of low volume or widely spread forage Example...

Page 68: ...The pressure must be adapted to the nature and moisture degree of the ground Park the machine on an even fairly level ground All pick ups must rest on the ground Ground pressure increase a Loosen the...

Page 69: ...e the belt speed Right side Regulation valve 3 Turn thumbwheel 4 clockwise to reduce the belt speed Turn thumbwheel 4 counterclockwise to increase the belt speed Setting 0 0 min Setting 10 900 min 8 2...

Page 70: ...in The tractor power take off must rotate at a speed comprised between 1000 and 850 rpm Before the machine engages the crop Engage the tractor PTO Press button 1 Play Pause button Press button 2 F3 YE...

Page 71: ...t arrows indicate the preselected direction of rotation of the conveyor belts 8 3 1 Drive speed The machine can work at up to 15 kph 9 mph in very favourable conditions Groundspeed must be adapted to...

Page 72: ...ow delivery configuration Press key F3 Belt rotation stops by time delay then Activation of conveyor belts and pickups LH conveyor direction of rotation to the left RH conveyor direction of rotation t...

Page 73: ...delivery configuration Press key F3 Belt rotation stops by time delay then Activation of conveyor belts and pickups LH conveyor direction of rotation to the right RH conveyor direction of rotation to...

Page 74: ...tivation of conveyor belts and pickups LH conveyor direction of rotation to the left RH conveyor direction of rotation to the right The time delay during which the conveyor belt direction of rotation...

Page 75: ...e windrow delivery configuration Press key F1 Belt rotation stops by time delay then Activation of conveyor belts and pickups LH conveyor direction of rotation to the right RH conveyor direction of ro...

Page 76: ...en Activation of conveyor belts and pickups LH conveyor direction of rotation to the left RH conveyor direction of rotation to the left The time delay during which the conveyor belt direction of rotat...

Page 77: ...vation of conveyor belts and pickups LH conveyor direction of rotation to the right RH conveyor direction of rotation to the right The time delay during which the conveyor belt direction of rotation i...

Page 78: ...then Activation of conveyor belts and pickups LH conveyor direction of rotation to the left RH conveyor direction of rotation to the right The time delay during which the conveyor belt direction of ro...

Page 79: ...headland turn position direction The work units are raised a Side windrow delivery b Central windrow delivery Following screen is displayed Putting the machine into work position Set hydraulic valve...

Page 80: ...ht work unit Putting the machine in headland turn position Press key F3 Activate the tractor double acting valve in the headland turn position direction The right unit is raised a Side windrow deliver...

Page 81: ..._C Merger Putting the machine into work position Set hydraulic valve in floating position The right work unit is lowered a Side windrow delivery b Central windrow delivery Left work unit Putting the m...

Page 82: ...he headland turn position direction The left unit is raised a Side windrow delivery b Central windrow delivery Following screen is displayed Putting the machine into work position Set hydraulic valve...

Page 83: ...ensor 2 reduces the headland turn height 8 3 5 Use in deteriorated mode This mode enables neutralizing the position sensors when one of the sensors is faulty This allows continuing to work and to fold...

Page 84: ...tion for tractors equipped with a 1 3 8 6 spline pto stub 9 2 1 3 8 21 spline pto shaft A specific pto shaft is available as option for tractors equipped with a 1 3 8 21 spline pto stub 9 3 Quick hitc...

Page 85: ...al specifications In certain countries the machine exceeds the maximum legal size to drive on public roads 9 5 Mudguard 9 6 Windrow curtain Before using the machine Check that nobody is within the mac...

Page 86: ...oupling Preparing the tractor The tractor must be fitted with the following components 1 double acting hydraulic outlet Coupling and uncoupling Hydraulic connections Connect hydraulic hoses e and f to...

Page 87: ...w curtain can be adjusted in different positions a Right side b Left side Remove windrow curtain Remove the 3 nuts 1 Remove the 3 washers 2 Remove windrow curtain Fitting Right side Reinstall windrow...

Page 88: ...n Reinstall the 3 washers 2 Reinstall the 3 nuts 1 9 6 4 Instructions for transport Operate the tractor valve to fully retract the windrow curtain Fold the machine See section Instructions for transpo...

Page 89: ...ign can be fitted on the machine 9 8 Abrasion resistant skids 9 9 Synthetic skids Recommended for dry and stony conditions only For maximum preservation of the synthetic skids adjust spring suspension...

Page 90: ...come to a standstill and remove PTO shaft 10 1 Frequency chart Maintenance intervals are indicated for normal conditions of use Before using the machine for the first time After the first 10 hours of...

Page 91: ...t arm pivot points The right arm pivot points Skid shoe pivot points The coupling yokes The parking stand Maintenance Check The belt tension Step up gearbox oil level Tank oil level Braking system Fix...

Page 92: ...g housing wear remove foreign bodies wrapped around them If using a high pressure cleaner do not aim the jet at the cylinder seals hoses bearings or electrical components Eliminate possible forage wra...

Page 93: ...e machine disengage the PTO drive turn off the engine remove ignition key and wait until all moving parts have come to a complete stop and apply park brake The pictorials show the points to be greased...

Page 94: ...rs of maximum authorized power it is recommended to grease at closer intervals Every 50 hours U joints 1 transmission tube 2 Guide rings 3 locking pins 4 10 3 2 Draining Hydraulic tank Before draining...

Page 95: ...10 Maintenance and storage MERGE MAXX 950 95 KN233BGB_C Merger Loosen screw 1 Pivot cover 2 Unscrew filler plug 1 2 1 1...

Page 96: ...rain plug 2 Remove drain plug 2 Allow oil to drain completely Wait for dripping to stop Clean and reinstall drain plug 2 and its washer 3 Replace it if necessary Torque 4 5 daNm 33 2 lbf ft Replacing...

Page 97: ...Clean all components Check condition of the seals 4 Replace them if necessary Coat O rings 4 as well as threads and sealing surfaces of the container and filter head with clean service fluid Reassembl...

Page 98: ...nd quality through the opening of the filler plug Reinstall filler plug 1 Not respecting these instructions will result in destruction of the filter cartridge Pivot cover 1 Tighten screw 2 Step up gea...

Page 99: ...From the working position Adjust the height of the lift linkage until the gearbox is horizontal Place a container of sufficient capacity under drain plug 1 Remove drain plug 1 and its washer Unscrew...

Page 100: ...MERGE MAXX 950 100 10 Maintenance and storage KN233BGB_C Merger Cylinder pins Folding links...

Page 101: ...10 Maintenance and storage MERGE MAXX 950 101 KN233BGB_C Merger The right arm pivot points The left arm pivot points The aggressiveness adjustment system of the roller type reels...

Page 102: ...storage KN233BGB_C Merger The windrow reels Right pick up 2 greasers Left pick up 2 greasers Roller housings Perform the operation on each side of the machine Position the belt to enable accessing the...

Page 103: ...10 Maintenance and storage MERGE MAXX 950 103 KN233BGB_C Merger Tensioner side Forwards On the motor side 10 3 4 Lubrication Lubricate with all purpose oil SAE80W90...

Page 104: ...MERGE MAXX 950 104 10 Maintenance and storage KN233BGB_C Merger The coupling yokes The parking stand The transport locks...

Page 105: ...10 Maintenance and storage MERGE MAXX 950 105 KN233BGB_C Merger Skid shoe pivot points...

Page 106: ...MERGE MAXX 950 106 10 Maintenance and storage KN233BGB_C Merger The right arm pivot points The left arm pivot points...

Page 107: ...e remove ignition key and wait until all moving parts have come to a complete stop and apply park brake Regularly check belt tension Check when it is cold The conveyor belts stretch during their first...

Page 108: ...lt tension adjustment Prior to adjusting the conveyor belt tension check that the conveyor belt is positioned on top of the 2 side guides 1 located on either sides of the conveyor belt Unscrew the 2 b...

Page 109: ...N233BGB_C Merger Remove lynch pin 1 and pin 2 Unscrew the 3 bolts 1 Loosen nut 2 Increase the distance L between guard 3 and belt 4 a Screw lever 1 to loosen conveyor belt b Unscrew lever 1 to stretch...

Page 110: ...in 1 Push lever 2 to stretch the conveyor belt Reinstall R clip 1 Check the conveyor belt tension Repeat procedure if necessary Measure dimension x The tension is correct when central bar 1 of the con...

Page 111: ...between guard 1 and belt 2 L 10 mm 0 39 Tighten nut 3 Tighten the 3 bolts 4 Tighten the 2 bolts 1 10 4 2 Fixing elements Check transport wheel nuts 1 for tightness Wheel nut torque 27 daN m 199 lbf f...

Page 112: ...MERGE MAXX 950 112 10 Maintenance and storage KN233BGB_C Merger 10 4 3 Tank oil level This decal indicates the cold oil level Refer to the decal fitted on the machine...

Page 113: ...linkage until the gearbox is horizontal Unscrew filler plug extension 1 Check through opening that oil height correxponds to a value h comprised between 170 and 180 mm 6 7 7 1 Top up if necessary Clea...

Page 114: ...Hydraulic configuration Pneumatic configuration Check piston travel of braking cylinders Brake system not active Measure dimension L Activate brake system Measure dimension L1 Length L1 must not exce...

Page 115: ...e higher than the maximum permissible air pressure indicated on the sidewall of the tires Main Wheels Drive speed 25 km h 15 mph 40 km h 25 mph 50 km h 31 mph Tire size Minimum tire pressure bar psi 4...

Page 116: ...ctor Unlock nuts of wheel 1 Place a jack under the machine axle as close as possible to the wheel to be replaced See chapter Safety Machine handling Lifting the machine It is also possible to lift the...

Page 117: ...epending upon specification Before carrying out any maintenance or repairs on the pneumatic braking system circuit apply machine brake and or block wheels using wheel chocks Pull ring 1 to empty water...

Page 118: ...as of damaged paintwork Check and replace worn or damaged tools Put the machine under cover in a dry place Store the control terminal in a dry place free of dust 10 5 2 At the start of each season Re...

Page 119: ...the Eurasian Economic Community EAC marking 10 6 Dismantling and scrapping of the machine At the end of the machine s life the various machine components must be disposed of or recycled in compliance...

Page 120: ...c braking system Malfunction of the pneumatic braking system Water in the circuit Empty the circuit Air leak Check condition and sealing of the circuit components Incorrect air pressure in the air res...

Page 121: ...anufacturer concerned in as much as the latter justifies such a claim This Limited Warranty does not apply to failure through normal wear and tear to damage resulting from negligence or from lack of i...

Page 122: ...d quantity of lubricants used must always be in accordance with Company specifications The safety measures mentioned in the Operator s manual and on the machine itself have been followed and all the g...

Page 123: ...forms to the requirements of following European harmonized standards conforms to the requirements of the European directive 2006 42 CE Brand Brand Machine Machine Type Model Type Model Serial no Seria...

Page 124: ...HARD SAS 24 route de Nantes F 44680 CHEMERE FRANCE KUHN HUARD SAS B P 49 F 44142 CHATEAUBRIANT CEDEX FRANCE KUHN GELDROP B V P O Box 9 5660 AA GELDROP THE NETHERLANDS KUHN NORTH AMERICA INC P O Box 16...

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