KUHN Merge Maxx 900 Operator's Manual
OPERATOR'S MANUAL
KN093CGB C
Merger
Merge Maxx 900
KN093CGB C
- English - 04-2010
Merger
Merge Maxx 900
$Dear Owner
In buying a Kuhn machine you have chosen wisely. Into it have gone years of thought, research and
improvement. You will find, as have thousands of owners all over the world, that you have the best that
engineering skill and actual field testing can produce. You have purchased a dependable machine, but only
through proper care and operation can you expect to receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your machine. The
performance you get from this machine is largely dependent on how well you read and understand th is manual
and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR
MACHINE before 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 parts. These parts ar e manufactured and
carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any
necessary replacements.
About improvements
We are continually striving to improve our products. It therefore reserves the right to make improvements or
changes when it becomes practical to do so, without incurring any obligations to make changes or additions to
the equipment sold previously.
Designated use of the machine
The MERGE MAXX 900 must only be used for the work for which it has been designed:
- Raking of previously cut green or wilted forage.
Document illustrations
The illustrations in this manual may be based on one typ e of machine only. However, all instructions apply to all
machines covered in this manual.
Dear Owner
1
Merger
Merge Maxx 900
$Contents
Dear Owner.....................................................................................................................1
Contents .........................................................................................................................2
Identification of the machine.........................................................................................4
Front view (working position) .........................................................................................................4
Rear view (working position)...........................................................................................................4
Model identification plate ................................................................................................................5
Optional equipment..........................................................................................................................5
Safety...............................................................................................................................6
Description of symbols used in this document.............................................................................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 specifications............. ... ... ... .... ... ... ... ... .... ............................................. ... ... .... ... ............26
Sound levels ......... ... ... .... ... ... ... .... ............................................. ......................................................28
Required equipment.......................................................................................................................27
Putting into service......................................................................................................29
Description of control elements....................................................................................................29
Coupling and uncoupling..............................................................................................................35
Instructions for transport............................................................................................46
Putting the machine into transport position................................................................................46
Conformity with the road regulations...........................................................................................49
2
Contents
Merger
Merge Maxx 900
Instructions for work...................................................................................................50
Putting the 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
Storage............................................................................................................................................96
Trouble shooting guide...............................................................................................97
Appendix ....................................................................................................................101
Limited warranty........................................................................................................ 107
Contents
3
$Identification of the machine
1. Front view (working position)
Merger
Merge Maxx 900
2. Rear view (working position)
4
Identification of the machine
3. Model identification plate
Please write below the type and serial number of the
machine. This information is to be indicated to the dealer
for all spare parts orders.
Merger
Merge Maxx 900
Type: MERGE MAXX 900
Serial no.:
4. Optional equipment
Tick box corresponding to the equipment fitted on your
machine:
Kit no. 1146870: Wide wheels (500/45-22.5 14 ply).
Part no. 1409957: Suction-grip holder..
Identification of the machine
5
$Safety
1. Description of symbols used in this document
This symbol indicates a potentially hazardous situation
that if not avoided, could result in serious bodily injury.
Merger
Merge Maxx 900
This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result in
machinery damage.
This symbol is used to communicate technical
information of particular interest.
6
Safety
Merger
Merge Maxx 900
2. Safety instructions
Introduction
The machine must only be operated, maintained and repaired by competent persons who are familiar with
machines' specifications and operation and aware of safety regulations fo r preventing accidents.
The operator must imperatively respect safety instructions in this manual and in the warnings posted on the
machine. The operator is also obliged to respect current le gislation concerning accident prevention, wo rk safety
and public traffic circulation.
Designated use of the machine also means following operation, maintenance and repair recommendations
given by the manufacturer, and using only genuine spare parts, equipment a nd acce sso ries, as r ecom mended
by the manufacturer.
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 and responsibility of
the operator.
The manufacturer is not held liable for any damage or accident re sulting from machine modifications carried out
by the operator himself or by a third party without previous written agreement from the manufacturer.
Read and follow the safety instructions
Before using the machine, carefully read all the safety
instructions in this manual and the warnings placed on
the machine.
Before starting work, the operator must be familiar with
all machine controls, handling devices and their
functions. It is too late to learn once work has been
started!
Never let anyone operate the machine who is not traine d
to do so.
Should you have any difficulties in understanding certain
parts in this manual, please contact your KUHN dealer.
Precautions to be taken before carrying out
any operations on the machine
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 complete stop
and apply park brake.
Safety
7
Precautions to take before using the
machine
Do not 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 controls (ropes, cables, rods,
etc) are placed so as they cannot be operated
unintentionally and cause damage or injury.
Before operating the machine, check tightness of nuts
and bolts, particularly on fixing elements (tines, forks,
blades, knives, etc). Retighten if necessary.
Before operating the machine, ensure that all the safety
guards are firmly in place and in good condition.
Immediately replace any worn or damaged guard.
Merger
Merge Maxx 900
Precautions when driving
Tractor handling, stability, performance and braking
efficiency are all affected by weight distribution, trailed or
mounted implements, additional ballast and driving
conditions. It is therefore of great importance that the
operator exercises caution in every given situation.
Groundspeed must be adapted to ground conditions as
well as to roads and paths. Always avoid abrupt change s
of direction.
Be particularly cautious when turning corners, paying
attention to machine overhang, length, height and
weight.
Never use a narrow track tractor on very uneven or
steeply sloping ground.
Never leave the tractor seat while the machine is
operating.
Carrying people or animals on the machine when
working or in transport is strictly forbidden.
8
Safety
Precautions when driving on public roads
Dimensions
Depending on the dimensions of the machine, contact
the relevant authorities to ensure that it can be legally
transported on public roads.
If the machine is over the maximum legal size, follow the
local regulations for special transportation of oversize
equipment.
Transport position
Before transporting the machine on public roads, place
the machine into its transport position, according to the
instructions in this manual.
Lights and indicators
Before transporting the machine on public road s, ensure
that all 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.
Merger
Merge Maxx 900
Always obey current regulations for driving
on roads.
Gross weight and weight per axle
The drawings are not legally binding, their only aim is to illustrate the method to use.
Prior to driving on public roads, check t hat criteria are met t o be in conformity with the count rie's
regulations:
- When coupling a tool to the front and rear 3-point lift linkage, the maximum authorized
payload must not be exceeded.
- When coupling tools to the front and rear 3-point lift linkages, the maximum load on each
axle's tires must not be exceeded.
- The load on the tractor front axle must al ways represe nt 20 % of the tractor unla den weight.
Safety
9
For machines with hoppers or tanks:
- If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance
with the countrie's legislation, empty the hopper to travel on public roads.
- In any case, we recommend to travel on public roads with empty hoppers and tanks.
Description of symbols
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 rear axle
Merger
Merge Maxx 900
t kg Axle loads (Tractor + machine)
t1 kg Load on front axle (Tractor + machine)
t2 kg Load on rear axle (Tractor + machine)
t1 max kg Maximum load authorized on the tractor front axle according to the tires
t2 max kg Maximum load authorized on the tractor rear axle according to the tires
M1 kg Total weight of front tool or front ballast
Stage 1:
To measure:
- Tractor tare (T).
10
Safety
Stage 2:
- Couple the machine to the tractor.
To measure:
- Load on front axle (t1):
• Tractor + machine (transport position).
To do:
- If the front axle load (t1) is below 20% of the tractor
tare (T), add ballast weights (M1) to exceed the
minimum load on the front axle.
Example:
• (T) = 7500 kg (16535 lb)
• The front axle load must be of minimum 1500 kg
(3300 lb).(20% of T)
• (t1) = 700 kg (1545 lb).
• 700 kg (1545 lb) < 1500 kg (3300 lb).
• Add ballast weights until the minimum front axle
load is exceeded.
• Repeat checking procedure.
Merger
Merge Maxx 900
Stage 3:
To measure:
- Total weight (t):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- To go to the next stage:
• Check in the tractor's operator's manual that the
value measured is below the tractor's Gross
Combined Weight Rating.
To do:
- If t < PTAC go to the next stage.
- If the total unit weight exceeds the tractor Gross
Combined Weight Rating in accordance with the
countrie's legislation, empty the hopper to travel on
public roads.
Example:
• (t) = 10000 kg (24250 lb)
• PTAC = 13000 kg .
• t < PTAC : Go to the next stage.
Safety
11
Stage 4:
To measure:
- Load on rear axle (t2):
• Tractor + machine (transport position).
• Ballast weights.
Checking:
- Check in the tractor's operator's manual that the value
measured is below the maximum allowed tractor rear
axle load.
- Check that tyre 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 is below the maximum allowed
tractor rear axle load.
• Check that tyre and rim specifiations are in
conformity with the requirements of the tractor
manufacturer.
Merger
Merge Maxx 900
Maximum speed
Always keep to the legal speed limit for driving a tractormachine assembly on public roads.
12
Safety
Precautions when coupling
Before attaching the machine, make sure that it cannot
accidentally start moving (chock the wheels) and that the
parking stand is in the right position.
The machine must only be attached to the hitch points
provided for this purpose.
Never stand between the tractor and the machine when
operating the three point linkage.
Do not stand between the tractor and the machine
without ensuring that the parking brake is applied.
Hydraulic circuit
Caution! The hydraulic circuit is under high pressure.
Maximum pressure at work: 200 bar.
Before connecting hoses to the tractor hydraulics,
ensure that tractor and machine circuits are not under
pressure. Before disconnecting a hose, depressurize the
hydraulic circuit.
To avoid making incorrect connectio ns, mark hydraulic
couplers and corresponding hoses with colors.
WARNING! Functions could be reversed (for example:
lift/lower) and cause accidents.
Regularly check the hydraulic hoses. In case of normal
wear, replace the hydraulic hoses every 5 years.
Damaged or worn hoses must immediately be r eplaced.
When replacing the hydraulic hoses, only use hoses with
the specification recommended by the manufacturer of
the machine.
To locate a leak, use appropriate means. Protect body
and hands from liquid under pressure.
Any liquid under pressure (particularly oil from
hydraulics) can penetrate the skin and cause severe
injury. If injured, see a doctor immediately, there could
be danger of infection.
Before any adjustments, maintenance or repairs are
carried out, lower the machine to the ground,
depressurize the hydraulics, turn off the engine, remove
ignition key and wait until all moving parts have come to
a complete stop.
Merger
Merge Maxx 900
Safety
13
PTO shaft
Use only PTO shafts supplied with the machine or
recommended by the manufacturer.
The protective shield of the tractor PTO stub, the PTO
shaft guards and the protective covering of the machine
input shaft must always be in place and in good
condition.
Make sure that the PTO shaft guards are secured with
the safety chains provided.
Any worn or damaged guards must be replaced
immediately. A worn guard or an unpro tecte d PTO shaft
can cause a serious or even a lethal accident.
Do not wear loose clothing that could be caught in the
rotating PTO shaft.
Before attaching or removing a PTO shaft, 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 have come to a complete stop.
If the primary PTO shaft is equipped with a slip clutch or
a free wheel, these must be fitted on the machine side.
Ensure that the PTO shaft is always correctly fitted and
locked into place.
Before connecting the PTO shaft, ensure that the PTO
speed (rotational frequency) and directions of rotation
are in line with manufacturer's recommendat ion s.
Before engaging the PTO drive, make sure all people
and animals are clear from the machine. Never engage
the PTO drive when the tractor engine is stopped.
When uncoupling the machine, rest the PTO shaft on the
support specially provided, and replace protective cover
on the PTO stub of the tractor.
Read and follow the instructions in the operator's manual
provided with the PTO shaft.
Merger
Merge Maxx 900
14
Safety
Precautions during manoeuvres
When moving the machine from the transport position to
the working position and vice versa, make sure that
nobody is within the machine pivoting area.
Remote controlled components
Danger of crushing and shearing can exist when
components are operated by hydraulic or pneumatic
controls. Keep away from these danger zones.
Tyres
Regularly check the tyre pressure. Respect
manufacturers' recommendations on pressure.
Assembly, disassembly and repair of wheels and tyres
must only be carried out by competent 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 (put chocks in place).
Merger
Merge Maxx 900
Hydro-pneumatic accumulator
A hydro-pneumatic accumulator contains nitrogen under
pressure (risk 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 precharge it.
Depressurize the gaz and oil sides of the hydraulic
accumulator before opening it.
It is strictly forbidden to weld, grind or drill onto a hydropneumatic accumulator.
Make sure that the accumulator and its' fittings are in
good condition.
Safety
15
Safety decals
Safety warning decals are placed in pictorial form on
various parts of the machine. They are ther e to warn you
of potential dangers and to tell you how to avoid
accidents.
Always keep the safety decals clea n 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 ground, never pour them
down the drain and never discard them in any other
place where they could pollute the environment. Never
throw away or burn a tyre. Always take waste to
specialized recycling or waste disposal centers.
Merger
Merge Maxx 900
16
Safety
Precautions for maintenance and repair work
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 complete stop
and apply park brake.
Rest the machine on the ground, release the pressure
from the hydraulic circuit and leave the machine to cool
down.
Make sure that the parts of the machine 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, disconnect the machine from the tractor
electrical 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 regulation equipment.
Wear the appropriate protective clothing for the work in
hand (gloves, shoes, goggles, helmet, ear defenders,
etc.).
Do not solder, weld or use a blow torch near fluids under
pressure or inflammable products.
For your own safety and for correct machine operation,
only use original manufacturer parts.
Merger
Merge Maxx 900
Projection of stones and foreign objects
For driver safety, always use a tractor equipped with a
cab. Never start a gyrorake when there are people
nearby. Even when the machine is used in accordance
with its purpose, objects may be projected. Stones and
other foreign objects projected by the moving parts can
travel a considerable distance. Keep all persons and
animals away from the danger zone.
Safety
17
Precautions for machine use
After each use, check the seeding tools (shares,
coulters) and their attachment hardware in accordance
with the instructions given in the present manual.
Check the guards regularly. Immediately replace any
damaged or missing elements.
Make sure all the guards are in place. Keep all persons
and animals away from the danger zone.
Stay a safe distance from the machine when the cutting
tools are in movement.
Never reverse while raking.
After disengaging the PTO drive, tools can continue
rotating for some time. Stay away from the machine until
all moving 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
standstill. Check the entire machine for any damage
before resuming work.
Merger
Merge Maxx 900
Precautions to take before using the
control box
Place the control box so that it cannot interfere with other
tractor controls and be activated inadvertently.
Before switching the control box on, check that nobody
is within the machine pivoting area: switching on the
control box can activate functions on the machine.
Precautions to take when using the control
box
Do not operate the control box while a person is carrying
out work on the machine.
Switch off control box before carrying out any
maintenance or repair work on the machine.
18
Safety
3. Location and description of safety decals on the machine
Location of safety decals
Merger
Merge Maxx 900
Safety
19
Description of safety decals
Operating instructions (1)
The operators' manual contains all the information
necessary for using the machine safely. It is imperative
to read and comply with all instructions.
Working on the 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 come to a complete stop
and apply park brake.
Merger
Merge Maxx 900
Projections (3)
Stones and other debris pro jected by the moving parts
can travel a long distance. Always stay at a safe distance
from the machine.
Manoeuvring area (4)
Stay a safe distance from the machine. Crushing hazard.
20
Safety
Body crushing (5)
Stay a safe distance from the machine.
Crushing hazard.
Coupling device (6)
Couple the machine to a tractor that is equi pped with a
system for locking the lift arms laterally and vertically.
To drive on roads, respect the attachment height
specified in the operator's manual and lock the lift
linkage.
Merger
Merge Maxx 900
Safety
21
4. Road safety equipment and recommendations
The road safety equipment is mounted in the factory or
by your authorized Kuhn dealer according to current
safety regulations. Always keep to the legal speed limit
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 signalling panels (1).
- 2 signalling lights (2) (red light / stop light / turn signal
light).
- 2 red reflectors (3).
- 1 identification plate light (4).
Merger
Merge Maxx 900
4
2
2
11
The front safety device comprises:
- 2 signalling panels (1).
- 2 white reflectors (2).
- 2 white lights (3).
3 3
22
Safety
The side device comprises:
- 3 amber reflectors (1) on each machine side.
Merger
Merge Maxx 900
Tyre pressure (1)
- Standard wheels: 2 bar (29 psi)
- Wide wheels: 1.6 bar (23 psi).
- Wheel nut torque:
• 27 daN m (199 lbf ft)
1 1
Safety
23
Instructions specific to France
Coupling device (1)
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 attachment height
specified in the operator's manual and lock the lift
linkage.
Merger
Merge Maxx 900
Speed (1)
Always keep to the legal speed limit of 25 km/h (15 mp h)
for driving a tractor-machine assembly on public roads.
Instructions specific to the following
countries: The United States, Canada.
The rear safety device comprises:
- 2 signalling lights (1) (Hazard warning lights).
- 1 support for a SMV emblem (Triangle not supplied).
24
Safety
$Machine specifications
1. Description and glossary
0
Merger
Merge Maxx 900
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 : Drawbar
11 : Transport lock 12 : Folding cylinder
13 : Wheel 14 : Deflector
15 : Conveyor
Machine specifications
25
Merger
Merge Maxx 900
2. Technical specifications
Merge Maxx 900
Coupling device 2 point linkage category 2 and 3
Working width (DIN11220)
- Central windrow delivery
- Side windrow delivery
Swath width from 1.40 to 1.80 m (4’7’’ - 5’11’’) (approximately)
Width in working position 9.50 m (31’2’’)
Length in working position 7.13 m (23’5’’)
Height in working position 2.70 m (8’10’’)
10.50 m (34’5’’) (approximately)
9.10 m (29’10’’)
Width in transport position
- with transport wheel: 400/55 - 22.5 14
- with transport wheel: 500/45 - 22.5 14
Length in transport position 7.13 m (23’5’’)
Height in transport position 3.96 m (13’)
Minimum PTO power requirement 50 kW (70 hp)
PTO speed 1000 min
Weight 6600 kg (14550 lb)
Tyres
- Transport wheels
Tyre pressure (Transport wheels)
400/55 - 22.5 14
500/45 - 22.5 14
3.00 m (9’10’’)
3.10 m (10’2’’)
-1
400/55 - 22.5 14 ply
500/45 - 22.5 14 ply
2 bar (29 psi)
1.6 bar (23 psi)
26
Machine specifications
3. Required equipment
Wheels
The machine is factory supplied with the following set of
tires:
- Standard wheels (400/55-22.5 14 ply)
Merger
Merge Maxx 900
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 force in the
country concerned.
The machine is factory fitted with one of the following
braking systems:
- Hydraulic braking system.
Machine specifications
27
or
- Pneumatic braking system.
Merger
Merge Maxx 900
4. Sound levels
Sound levels have been measured 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 continuous acoustic pressure level at the driver's seat (closed cabin) L (A) eq:
Tractor only: 71.8 dB(A).
Tractor + machine: 72.2 dB(A).
28
Machine specifications
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