Pottinger MEX 5 Istruzioni per l'uso

Operator‘s manual

GB

"Translation of the original Operating Manual" Nr. 99 475.GB.80P.0

MEX 5

(Type 475 : + . . 01001)

Forage harvester

MEX 5

(Type 48830065/6+48830046/47/52/53)

Instruction Manual No. 001/2015

Your Machine Identification No.

2

Index page

Meaning of the warning signs

Putting into use

Putting into Use (general safety tips)

Opening of the blades disc lid

Travelling on public routes

Before starting work

Checks before use

Definition of the use of the machine

Correct charging

Location of the machine identification and its composition

The most important components of the machine

Technical information

First connection to the tractor

Hydraulic connection

Regulation of the hydraulic block

Connection of the hydraulic hoses/power source

Initial connection to the tractor (command functions)

Coupling the machine to the tractor

Lateral adjustment of the machine in relation to the tractor

Changing position of the transmission box

Metal detector (option)

Regulation/tuning

Tuning of the work speed

Adjusting the length of the cut

Alteration of speed of the feed rollers

Assembly or removal of the blades

Transport by road/safety devices

Transport by road

How to fold with a pipe

Fitting the safety devices

Operating in a field

Working recommendations

Regulation of the upper flap movement

Removing the safety devices

Regulation of the corn head to operate with 4 lines

Pipe blockage

How to switch off the machine

Cleaning

Assembly of the corn head

Assembly of the grass pickup

Adjusting and tuning the corn head

4

--

5

5/6

6

7

7/8

9

10

11/12

13

--

14

15/16

16

17

18/19

20

21/22

--

23

23/24

24

24/25

--

26

26/27

28/29

--

30

31

32/33/35

35

36

37/38

39/40

41

3

Maintenance and repairs

Maintenance and Repairs

Sharpening the blades

Adjusting the sharpening disc to the blades and vice-versa

Sharpening procedure

Adjusting the blades disc

Replacement of the blades and counter-blade

Installation of the corn chopper kit

Maintenance care (oil levels/winter storage)

Tuning the currents of the corn head

Clutch of the corn head (tuning)

Tuning the belts of the lateral spindles

Maintenance of the grass pickup (Lubrication/Tuning of the chains)

General lubrication

Breakdowns and possible solutions.

Possible breakdowns and their solutions

Breakdowns and solutions for electrical faults

Hydraulic scheme of the functioning of the machine

Cardans

Transmission cardan PTO-options

Declarations

“EC” compliance declaration

42/43

44

45

46

47

47/48

49/50

51

52/53

53/54

54

55/56

57/58/59/60

--

61/62

63

64

--

65/66

--

67

4

MEANING OF THE WARNING SIGNS

Switch off the motor and remove

the key before carrying out

maintenance and repairs

Keep the hands away from the crushing area while

there is a chance that the respective parts are in

motion

Keep away from the vertical displacement

area of the tractor's three-point hydraulic

system

Wait for a complete stop of all of the

machine's moving parts before touching

them.

Do not open or remove the covers from gears,

roller chains and belts, while these are moving

Install the protection cover before sharpening

the blades

Keep a safety distance from the

machine - danger of projection

Keep away from the articulation area

of the machine - danger of

pinching/crushing

Avoid the collision with electrical

cables, danger of electric

shock/electrocution Do not climb on the machine whenever

there are moving components, danger

of dragging

Rotating blades, danger of cutting,

perforation or crushing

to the hands or feet

Do not stay on the platform or

stair while the machine is being

displaced

5

4

PUTTING INTO USE

General safety tips for the use of the machine

Tips for manoeuvres with the machine

There is a danger of overturning when you work on slopes.

Driving should be adapted to the terrain and ground conditions.

The tractor vehicle should be equipped in a sufficient form with

weights at the front or at the back in order to guarantee the capacity

to drive and brake (a minimum of 20% of the tare weight of the

vehicle on the forward axle).

Transporting people on the machine is not permitted.

Tips for coupling and uncoupling

There is a risk of injury when you couple the device to the tractor!

While the machine is moving backwards, do not pass between it and

the trailer during the coupling.

It is strictly prohibited to place yourself between the tractor and the

machine if these have not been totally immobilised with a parking

brake and/or blocks on the wheels.

The coupling or uncoupling of the transmission cardan should only be

undertaken when the motor has stopped.

Take care when opening the lid of the blades disc!

For the purposes of maintenance, the lid of the blades disc

must be opened regularly.

After stopping the P.T.O. of the tractor, remove the transmission cardan,

there is risk of injury if the P.T.O. is started up accidentally.

Opening of the blades disc lid

The blades disc lid is equipped with a safety system that prevents it from opening unless the blades disc

has completely stopped. It operates as follows:

Press the green button (2) to unlock the door (1). If the orange light (3) goes on, this means the blades

disc is still in motion (sensor 4 is still detecting motion) and the system is still preventing the lid from

opening. If the green light (5) also goes on, this means the disc is already

stopped; it will blink for 5 seconds until it goes on permanently, indicating the

system is unlocked, and allowing you to open the door (1) by pulling handle (6).

After 15 seconds, the system locks again. If the door (1) is still closed,

press the green button again.

6

While the door (1) is open, or if it is not properly closed, light (7) remains on.

In case of electrical malfunction or in the absence of electric power supply (maintenance/storage) the

system stays locked; to unlock it, use key (8), supplied with the machine, and turn it to UNLOCK.

After repairing the malfunction or after making the electrical connection to the tractor, lock the system

again by turning the key to LOCK; if you forget to do so, the light will stay on, turning off as soon as you

turn the key to LOCK.

Remove the key and keep it together with your tractor's key.

Parking/storing the equipment:

When the equipment is parked, remove the transmission cardan and store it or secure it with a chain.

Only use the machine in accordance with the regulations!

Usage Regulations:

- See "Technical Information" Chapter.

- See "Definition of use of the machine" Chapter.

The load limits of the machine may not be exceeded.

Additionally, comply with the power limits of the tractor to be used.

Travelling on public routes

- Comply with the traffic rules in force.

- Lighting devices should be installed, applied perpendicular to the route.

- Pay attention to the total height of the machine, it must not exceed 4 m from the ground; for this, use

the hydraulic articulation of the discharge pipe (see chapter “how to fold down the pipe”)

7

PUTTING INTO USE

Before starting work

a. Before starting work, the operator should have knowledge about all of the functioning devices

and their functions. It is too late to learn these aspects if work has already begun!

b. The machine should be tested for safety in travelling and functioning before each operation.

c. There is a danger of crushing or dismembering in the areas of the pickup, cutting unit, rear lid

and higher extension zones. Everyone should stand well back from these areas before the

hydraulic equipment and the transmission are switched on.

d. Before driving the vehicle, the driver should ensure that no one is in danger and that there

are no obstructions. If the driver is not able to see and to have a general view of the road

directly behind the machine, he should be helped by somebody during manoeuvres in

reverse.

e. Comply with the safety tips in relation to the machine. You may find an explanation of the

meaning of the graphic warning symbols on page 4.

f. Comply also with the tips in the relevant chapters and in the supplement to this functioning

manual.

g. Check the hydraulic hoses regularly and replace old and damaged hydraulic hoses. The

replacement hoses should comply with the technical requirements of the manufacturer.

h. For all maintenance, service and modification works, switch off the transmission motor and

remove the universal transmission.

Check before use

The following tips should make the operation of the machine simpler for you. You

may find detailed information on specific points in the relevant chapters of this

instruction manual.

1. Check that all of the safety equipment (covers, shields, etc.) is in good condition and installed

in the correct position.

2. Lubricate the machine in accordance with the lubrication scheme. Check the oil levels.

3. Check the correct rpm of the P.T.O.

4. Carry out the electrical connections to the tractor and check whether they are correct. Take

note of the tips in the instruction manual!

5. Carry out the coupling of the machine to the 3 points of the tractor, at the front or at the

back, as required; in order to do this, see chapter “Coupling the machine to the tractor”.

6. Affix the machine using only the fittings supplied.

7. Install the transmission P.T.O. between the tractor and the machine. See chapter “Coupling

the machine to the tractor”.

8

8. Check the functioning of the electric controls.

9. Connect the hydraulic hoses to the tractor.

- Check the hydraulic hoses against the existence of damages and wear and tear.

- Certify that the connections are correct.

9

Definition of the use of the machine

The machine “MEX 5 ” is designed only for normal use in agricultural work.

Corn cutting, collecting and milling machine: For the harvesting of silage corn

Machine for collecting and cutting green forage (grass): For collecting and cutting grass

Any other use apart from this is held as inadequate. The manufacturer does not bear any

responsibility for any damage that results from this. The risk is borne only by the user.

The maintenance of the functioning, service and maintenance requirements stipulated by the

manufacturer is also under the designation of "defined use".

Safety tips

1. Connect the P.T.O.

Connect the P.T.O. only when all of the safety devices (covers,

protective aprons, coatings, etc.) are in

g

ood conditions and are affixed

to the device in the correct protective positions.

2. Connect the machine only in the workin

g

position and do no

t

exceed the prescribed start-up speed (for example, max. 1000

rpm).

A sticker located close to the gears will advise you on the speed for

which the machine is equipped.

3. Pay attention to the correct rotation direction of the P.T.O.!

4. Use ear protection

- The noise level at the place of work could differ from the measured

values (see Technical Information) in part due to the different types o

f

cabins in various tractors.

- If the noise level of 85 dB (A) is reached or exceeded, the farmer

should have adequate ear protection available.

Safety indication

for the supplementary installation of electrical and electronic installations

and/or components

- See supplement

Correct charging

Corn model Grass model

10

POSITION OF THE SERIAL NUMBER/FRAMEWORK OF THE MACHINE AND

IDENTIFICATION OF THE BASE DEVICE AND THE ACCESSORIES

The serial number of the machine is en

g

raved on the plaque presented

and also on the structure.

The requests for activation of the guarantee and questions shall not be

dealt with if this number is not supplied.

Please write the number on the first pa

g

e of the instructions manual

immediately after receiving the vehicle/machine.

ASSEMBLED VERSION MEX 5-CORN------

OR

ASSEMBLED VERSION MEX 5-GRASS----

---

3 or 4-LINE HEAD FOR CORN----

(WIDTH OF CUT: 2.00 m or 2,35 m)

GRASS PICKUP

(width of collection X=1900 mm)

11

THE MOST IMPORTANT COMPONENTS

1 = Collection drums (corn)

2 = Front guide nozzles (corn)

3 = Spindles for collecting fallen corn (corn)

4 = Upper guide (corn)

5 = Hydraulic cylinder for regulating the height of the cut (corn)

6 = Stoppers for regulating the height of the cut (corn)

7 = Coupling to the tractor

8 = Lateral hydraulic displacement

9 = Transmission box

10 = Control box for the machine functions

11 = Regulators (stoppers) of the pipe descent

12 = Protection of the front nozzles

13 = Blades disc lid

14 = System for sharpening the blades

15 = System for rotating the pipe

16 = Hydraulic block

17 = Pipe articulation cylinder

18 = Ejector pipe

19 = Flap regulating cylinder

20 = Pipe extension W=1.00 m.

20A= Pipe extension W=1.40 m. (option)

20B= Pipe extension W=1.80 m. (option)

21 = Discharge nozzle

22 = Pipe articulation with vertical extension of 0.21 m.

22A= Pipe articulation with vertical extension of 0.76 m. (option)

23 = Collecting and milling unit

24 = Hydraulic hoses for connecting to the tractor

25 = P.T.O. cardan 1 3/8”-Z=6/Z=21/Z=8x32x38

26 = Control box for the metal detector (option)

27 = Blades disc

28 = Lower intake rollers

29 = Upper intake rollers

30 = Corn chopping system (corn)

31 = Collection drum (grass)

32 = Deflector (grass)

33 = Security tube (grass)

34 = Auger (grass)

35 = Support wheel (grass)

36 = Closing device (grass)

12

27 28

30

29

23

20B

36

35 31

32

34

33

13

Technical information

(Subject to modification for the purposes of technical development)

Power requirements:

3-line head for corn:

P.T.O. rotation

Diameter of the blades disc

Opening for forage

Number of blades

Permanent level of sound emission

Weights:

Mex5 machine with discharge pipe

Accessories:

3-line head for corn:

Pickup 1.90 m

Dimensions:

Mex5 machine for corn or grass

Length

Width

Height with extension of 0.5 m at work

Height with extension of 0.7 m at work

Height with extension of 0.5 m at transport

Height with extension of 0.7 m at transport

Necessary plugs

1 double-effect hydraulic plug

min. pressure.: 140 bar

max. pressure.: 180 bar

1 plug with 3 pins (12 volt) (see appendix)

of 110 KW (150 HP)

1000 rpm

1220 mm

800 cm

max. 10

89.2 dB(A)

approx. 1300 kg

approx. 850 kg

Approx. 510 kg

2.80 m (corn)-2.40 m (grass)

2.20 m (corn)-2.25 m (grass)

4.56 m

4.76 m

2.70 m

3.20 m

Tyres Application Max. pressure

(bar)

L.I.

(Kg)

S.I.

Km/h

13x5.00-6 Grass pickup 2,5 52 (200 kg) A6 (30 km/h)

Optional equipment:

- Horizontal extension of the pipe (1.0/1.40/1.80 m)

- Vertical extension of the pipe (0.21/0.76 m)

- Metal detector

- Transmission cardan in accordance with the P.T.O. of the tractor

- Load sensing system

All of the information is subject to revision.

14

FIRST CONNECTION TO THE TRACTOR

HYDRAULIC CONNECTION

VERY IMPORTANT: Before making the hydraulic

connection to the tractor, check the oil condition. If it

is contaminated, change it, otherwise the hydraulic

block and remaining hydraulic components of your

machine could be damaged.

The machine needs 1 double hydraulic circuit, to

activate the hydraulic block, in order to do this:

- Connect the pressure line (1) and the oil return tube (2) (the

tube with the bigger diameter is the oil return tube), the

command lever of the line on the tractor has to be positioned so

that the hose of the greatest diameter is making the return to

the tank.

Note:

If the oil heats up during functioning, and the tractor only has a

constant flow rate pump, then it should be linked to a

simple effect line (see image).

- Connect the pressure hose (1) to the single action control unit.

Connect the oil return hose (2) (with the bigger diameter) to a

direct connection to the oil deposit.

If the tractor allows it, reduce the oil flow rate

REGULATION OF THE HYDRAULIC BLOCK:

Pos. "H±10 mm" to closed hydraulic system

Tractor with variable flow rate pump

Before making the connection, the LS screw on the hydraulic

block should be adjusted to the quota of ±10 mm (totally fasten

LS)

Pos. "H±17 mm" to open hydraulic system

Tractor with constant flow rate pump

The position of the LS screw on the hydraulic block should be

adjusted to a quota of ± 17 mm. (totally unfasten LS)- (factory

configuration).

Warning!

If this is not done, the overload valve on the hydraulic system of

the tractor is continuously in use and an excessive heating of the

oil will take place.

If the tractor has a closed hydraulic system and the hydraulic block

is in the position "A=17" then the hydraulic oil will heat up

(especially due to the constant pumping of the maximum quantity

of oil).

Solution: Place the tuner LS on pos. “A=10 mm”

LS = Load detection

LS

A

15

P

L

s

R

FIRST CONNECTION TO THE TRACTOR

Connection of the hydraulic hoses, for tractors with

fixed flow rate pump.

- Disconnect the P.T.O. before making the connection

- Place the lever (ST) of the control unit in the fluctuating position

(neutral position),

- Ensure that the rapid valves are clean.

- Make the hydraulic connection of the hydraulic block. A double effect

- Check if the hose of the smaller diameter is the one with pressure.

Connection of the h

y

draulic hoses, for tractors with variable flow rate

p

um

p

.

-Disconnect the P.T.O. before making the connection

- Connect the return hose (larger diameter-3/4”) to valve

(R), the pressure hose (1/2”) to valve (P) and, finally, the

smaller diameter hose (1/4”) to valve (LS).

Power source

Necessary connections to the tractor

3-prong current plug

- Connect the attached 3-prong plug to the rear of the tractor

- Power source through a relay (9)

The relay is connected to the ignition switch (10).

- The diameter of the conductor is at least 4 mm2

- Fuse 16A (11)

You ma

y

find a com

p

lete dia

g

ram of the electrical connections on the list of s

p

are

p

arts.

This connection may only be made by a specialist

Do not connect directly to the ignition switch

- There is a risk of fire or damage to the electrical unit.

• Use only fuses at the recommended power as the use of stronger fuses will destroy

the electrical unit!

16

Establish the connection with the tractor

- After concluding the work as demonstrated, connect the three-pin

jack to the tractor power socket.

- Check if the lights on the command panel (13) are working

- Install the command (magnetic base) in the interior of the tractor in

an

accessible

(

metallic

)p

lace with

g

ood visibilit

y

.

INITIAL CONNECTION TO THE TRACTOR

- Switch the lever (ST) to the "ON" position and affix it.

Check if the hose of the smaller diameter is the one with

pressure, otherwise reverse the connection of the hoses or

reverse the position of the ST lever, affixing it again.

- The system is protected with a 15A fuse on the power jack

of the command (5)

Explanation of the command functions

A = This button has two functions: When it is continuously

pressed, it switches on and off the command, when it is

pressed with one simple touch it commutes the functions in

accordance with the colour of the bulb (green or red)

B1/C1 (red) = Executes function 1 for orientation of the

discharge nozzle

D1/E1 (red) = Executes function 2 for the rotation of the

discharge pipe

F/G (red)= Executes function 3 of coming closer/ /moving

away from the ground of the corn/grass.

H (red) = Executes function 5 which reverses the rotation of

the head and the feed rollers, whereby you just need to press

the button. When you stop pressing, the direction of rotation

returns to the initial one.

B2/C2 (green) = Executes function 6 for lateral

displacement of the machine (offset)

D2/E2 (green) = Executes function 4 for the articulation of

the discharge pipe

5

6

1

4

2

3

5

13

Command indicator lamp

Green/red

F

G

H

A

B1

B2

C1

C2

D1

D2

E1

E2

D1

E1

B1

C1

17

Coupling the machine to the tractor

- Before coupling the machine, check whether the tractor has counterweights at the front or at the back

(in accordance with the machine application at the back or at the front, respectively), required to balance

the weight of the machine (2150 Kg).

- Couple the machine to the 3 points of the tractor, so that it is parallel to the ground; in order to do this,

adjust the bar (1) and, if necessary, the coupling (2)

- The distance between the tractor's PTO end and the machine's PTO should be approximately 800 mm

(min.); if the arms of the tractor do not allow it, you will have to use an extension (3) and choose the

required distance, which can be of 125; 160 or 195.

If necessary, shorten the cardan, but you are only allowed to do it in the ridged side

Check that there is no interference of the sliding zones by lowering and raising the machine; should it

occur, it could damage the transmission box of the machine.

Attention!

- The admissible angle (35º) of the transmission cardan should not be exceeded, when raising the

machine to carry out manoeuvres, disconnect the PTO of the tractor.

- The minimum quota of overlapping of the transmission cardan sliding zones should be 150 mm (see

chapter on the P.T.O. transmission cardan).

- Couple the machine to the tractor only when all of the safety shields are in place.

- When you couple trailers or accessories to the tractor you should take special care!

There is a risk of in

j

ury by crushin

g

and cuttin

g

points in the area of couplin

g

at 3 points of the tractor!

3

800

1 2

18

1

3

2

4

2

3 4 1

Lateral adjustment of the machine in relation to the tractor.

The machine may work centrally aligned with the tractor or displaced about 300 mm to the right (if the

width of the tractor is over 2.3 m); for each of the positions, the front transmission box will have to be

positioned differently, so that the cardan angle does not exceed what is recommended.

The position change is carried out by the hydraulic cylinder (5), activated in the command.

-Hang the machine on the tractor arms

-Remove the latch (3)

-Activate the cylinder (5)

-The tubular stay (2) holding the machine, slides in the support cat. II or III.

-Replace the latch (3) in the new position.

-Replace the strut (4) of point 3, so that it is centred with the machine.

Centred position Off-centred position

Positioning of the transmission box to the Positioning of the transmission box to the

centred position, with the machine installed off-centred position, with the machine installed

at the back of the tractor.[From 150 CV (corn)] at the back of the tractor.

[From 150 CV (corn)]

280

5

Maximum

960 RPM on blades disc

To sharpen the blades

Reverses the direction of

rotation

Z=62

Z=49

Z=47

Minimum

Connection to the tractor (1000 RPM)-

corn

C titthtt(540RPM)

960 RPM on blades disc-corn

520 RPM on blades disc-

g

rass

To sharpen the blades

Reverses the direction of

rotation

Z=49

Z=47

Z=62

19

Positioning of the transmission box to the Positioning of the transmission box to the

centred position, with the machine installed off-centred position, with the machine installed

at the back of the tractor. (Up to 145 CV) at the back of the tractor. (Up to 145 CV)

Positioning of the transmission box to the Positioning of the transmission box to the

centred position, with the machine installed off-centred position, with the machine installed

at the front of the tractor. (1000 RPM on PTO) at the front of the tractor. (1000 RPM on

PTO)

Positioning of the transmission box to the Positioning of the transmission box to the

centred position, with the machine installed off-centred position, with the machine installed

at the front of the tractor. (540 RPM on PTO) at the front of the tractor. (540 RPM on

PTO)

Connection to the tractor (1000)

Z=62

Z=49

Z=47

Z=62

Z=49

Z=47

760 RPM on blades disc 760 RPM on blades disc

To sharpen the blades

Reverses the direction of

T

o sharpen the blades

R

everses the direction of

Z=62

Z=49

638 RPM on blades disc

To sharpen the blades

Reverses the direction of Connection to the tractor (540)

Z=62

Z=47

To sharpen the blades

Reverses the direction of

Z=49

638 RPM on blades disc

Z=62

Z=49

790 RPM on blades disc

To sharpen the blades

Reverses the direction of

Z=47

Connection to the tractor (1000)

790 RPM on blades disc

Z=62

Z=49

Z=47

To sharpen the blades

Reverses the direction of

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