Kverneland 4328LT Service Manual Download

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Cutter bar repair

Change of bearing intermediate
gearwheel

Cutter bar repair

Change of bearing intermediate
gearwheel

Cutter bar repair

Change of bearing intermediate
gearwheel

Cutter bar repair

Change of bearing intermediate
gearwheel

•

Remove tool T1 from the gear
wheel and remove all the broken
parts (typically 5 pieces) of the
circlip “A”.

NB!

Make sure that all the broken

parts from the circlip is removed
from the intermediate gear wheel.

•

Place the gear wheel on top of
tool T3.

NB!

The recessed surface has to be

faced upwards.

•

Make sure the gear wheel and
the new bearing is facing the
right way.

NB!

The groove in the bearing and

in the gear wheel has be faced
downward.

•

Place tool T2 on top of the gear
wheel as shown.

•

Place the new circlip in the
groove on the bearing.

•

Place the bearing in the cone
shaped tool T2.

NB!

The largest diameter of the tool

has to be faced upwards.

Maintenance

Summary of Contents for 4328LT

Page 1: ... 07 2018 Subject Kverneland 43xx T R CT CR Place Kverneland Group Kerteminde AS Taarupstrandvej 25 DK 5300 Kerteminde Denmark Realized for Who it might concern Details General and operating information Additional Information ...

Page 2: ...s 50 Cylinder info 55 Accumulator 70 Pressure relieve valve 70 Electric diagrams for the lights 71 Cutter bar and hubs 73 Cutter bar how to remove out of frame 77 Cutter bar repair instructions 78 Swivel gearbox 86 Main gearbox LH models 97 Main gearbox C models 104 Centre gearbox C models 110 Roller gearbox 116 PTO s 118 Tire 127 Replacement synchronizing rollers 128 Lubrication 135 Cutter bar to...

Page 3: ...3 General information Frame model L model LH drawbar ...

Page 4: ...4 General information Frame model C model Centre drawbar ...

Page 5: ...5 General Information Machine specifications 43xxT models ...

Page 6: ...6 General Information Machine specifications 43xxR models ...

Page 7: ...7 Weight of the machine Weight of the machine General information ...

Page 8: ...8 Dimensions for left hand drawbar Dimensions for left hand drawbar General information ...

Page 9: ...9 Dimensions for centre drawbar Dimensions for centre drawbar General information ...

Page 10: ...awbar safety symbols On the machine you will find labels relating to your safety These labels must not be removed If the labels become illegible or detached new labels can be ordered and affixed to the relevant areas ...

Page 11: ...odel safety symbols On the machine you will find labels relating to your safety These labels must not be removed If the labels become illegible or detached new labels can be ordered and affixed to the relevant areas ...

Page 12: ...12 The meaning of the symbols The meaning of the symbols Safety ...

Page 13: ...y decals for the US and Canada On the machine you will find labels relating to your safety These labels must not be removed If the labels become illegible or detached new labels can be ordered and affixed to the relevant areas ...

Page 14: ... symbols for the US and Canada On the machine you will find labels relating to your safety These labels must not be removed If the labels become illegible or detached new labels can be ordered and affixed to the relevant areas ...

Page 15: ...15 The meaning of the symbols for the US and Canada The meaning of the symbols for the US and Canada Safety ...

Page 16: ...the PTO length A Distance between the P T O shaft and the connection point on the drawbar tongue approx 356 mm 14 B Height between the P T O shaft and the connection point on the drawbar tongue approx 203 305 mm 8 12 C Height between the ground and the drawbar tongue approx 400 mm 15 3 4 Connecting to the tractor basic start Keep the correct side up bolts in the top and brackets pointing upwards S...

Page 17: ...the machine The tractor must be fitted with 2 sets of double acting hydraulic outlets which are connected as follows X for the drawbar for steering unit to the right or to the left Hoses with small diameter Y for lifting and lowering of the cutting unit Hoses with big diameter Connecting to the tractor basic start Y For lifting and lowering of the cutting unit use always double acting and be sure ...

Page 18: ...uld be run at a rotational speed of 1000rpm Force the corners of the lock plate away from the bolt heads Remove the bolts shown on both sides of the transmission Remove the transmission Remove the bolts shown on both sides of the transmission Remove the bracket Preparation RPM swivel gearbox If the swivel gear s profile X on the lower part of the swivel gear is narrow the machine should be run at ...

Page 19: ...it the transmission Do not forget the lock plate Fit the bolts on both sides of the transmission Tighten all bolts to a torque of 225 Nm 165 ft lb Fit the adapter Preparation RPM swivel gearbox Choice of 540 and 1000 rpm Choice of 540 and 1000 rpm Choice of 540 and 1000 rpm Repositioning gearbox Repositioning of gearbox Rotate the transmission 180 degrees Remove the air release plug and the oil pl...

Page 20: ...e friction clutch rotate freely for approx 5 seconds at the lowest possible speed until it is warm to the touch Do not allow the friction clutch to rotate for more than approx 5 seconds at a time as this may damage the friction discs Friction clutch X Bleeding of the clutch Bleeding of the clutch Torque s Tighten the bolts Loosen the bolts Torque s related to models Block the cutter bar Cutting wi...

Page 21: ...housing 1 The setting ring provides a min position and a max position 2 The clutch housing incorporates two locating positions for the setting ring 1 and 2 which are situated at different levels For each spring pack four torque settings are possible see table on next slide Differences in settings Friction clutch How to change the settings ...

Page 22: ...orque settings Friction clutch Cutting width Torque 2 mtr 40 7 10 1730 Nm 2 mtr 80 9 2 1730 Nm 3 mtr 20 10 6 1730 Nm 3 mtr 50 11 10 1730 Nm 4 mtr 13 1 1900 Nm Only setting clutch of 4 mtr is in position IV the rest in III ...

Page 23: ...00 times per minute causing wearing on pivot point of tines 2 A Semi Swing tine will always try to reach the active centrifugal line 2 Concept of Semi Swing is preventing tines from reaching this position Force to move finger from working position is 22 kg 48lb Tines are fixed during normal work only in case of stone ore foreign obstacle higher force than 22 kg 48lb the tine will move back and let...

Page 24: ...cur relating to blocking of the rotor and the flow of the crop through the machine with heavy crop The conditioner plate is factory fitted in position 2 Use an appropriate tool and remove the pin bolt on both sides of the machine Allow the conditioner plate to drop down on top of the rotor so there is access between the conditioner plate and the upper plate on the machine Remove the pin bolt shown...

Page 25: ...swapping the pulleys Option kits are available for 500 rpm 1015 rpm to be used when crop for some reason won t reach the belt unit of the BX Remove the guard around the transmission Completely loosen the bolt on the spring Remove the V belts Swap the pulleys Check alignment of pulleys In case of misalignment rotor need to be moved sideways until you reach the correct setting Fit the V belts Tighte...

Page 26: ...o tighten the 2 parts together after aligning of the pulley s Torque for the bolts is 50 Nm 37 ft lbs Always check the alignment again after assembly as it s possible that the pulley has been moved sideways after reaching the correct torque Note It s important that both screws are tightened alternately and stepwise to the right moment If you just tighten one screw until it is fixed and then the ot...

Page 27: ...m pulley on the transmission 1200 rpm kit something you might need for the combination with BX swath belt Remove the pulley from the gearbox Fit the new pulley Check alignment of pulleys by using a long flat strip Fit the V belts Tighten the springs to the measurement shown Fit the guard Remove the transmission guard Completely loosen the bolt on the spring Remove the V belts Rollers RPM Diameter ...

Page 28: ...a clockwise direction increases the pressure of the rollers on the crop Tightening the spindles in an anticlockwise direction reduces the pressure of the rollers on the crop Tighten and secure the counter nut on the spring after the final adjustment The setting for the springs must be exactly the same on both sides of the machine Use the appropriate tools to loosen the counter nut shown which is l...

Page 29: ...er Reducing roller distance Reducing roller distance Reducing roller distance How to check the roller distance The recommended distance between the rollers is 5 mm 3 16 Place a 5 mm 3 16 spacer in between the rollers approximately 50 mm 2 from the outermost end of the roller on both the left and right hand sides Turn the rollers a little so that the spacers are placed in between the rollers Check ...

Page 30: ...ance between the rollers by screwing the nuts shown until you reach the right distance Roller conditioner In case for some reason one of the rollers has to be removed or replaced be sure that the timing is OK after assembling again That means same space on both sides How to increase the distance How to increase the distance How to increase the distance Timing ...

Page 31: ... extra hydraulic group on tractor side is needed X the rod for adjusting the necessary minimum clearance of 5 mm 3 16 between the rollers Note risk of a lower setting is that rollers could touch each other what will result in vibrations through the whole driveline Roller conditioner 5 mm 3 16 X X X ...

Page 32: ...32 Roller settings kit A144470830 option what fits on the models produced from model year 2018 Roller conditioner ...

Page 33: ...33 Roller settings kit A144470830 option what fits on the models produced from model year 2018 Roller conditioner ...

Page 34: ...34 Roller settings kit A144470830 option what fits on the models produced from model year 2018 Roller conditioner ...

Page 35: ...g links if necessary until the distance is as shown The following must be done if a short stubble height is required between 15 45 mm 5 8 1 3 4 Use a suitable tool to remove the pin from the pin bolt Remove the pin bolt Basic settings for low stubble Low stubble height adjustment Low stubble height adjustment Low stubble height adjustment Low stubble height adjustment 685mm 2631 32 65mm 29 16 Low ...

Page 36: ... Check the distance 65mm 29 16 between the upper plate and the spring bracket on both sides of the machine with the spindle in the middle position Adjust the connecting links if necessary until the distance is as shown Move the connecting link to pos 2 Fit the pin bolt and pin Check the measurement shown on the connecting link 680mm 2649 64 The measurement shown is only for guidance Basic settings...

Page 37: ... Turning the bolt clockwise increases the stubble height Turning the bolt counter clockwise reduces the stubble height Fit the lock plate Fit the linchpin The machine has variable settings for stubble height Stubble height is adjusted in the following way Remove the linchpin and lock plate Basic settings adjusting stubble height Fine adjustment stubble height Fine adjustment stubble height Fine ad...

Page 38: ...aced by a cylinder from model year 2018 due to some changes in the bracket and frame Adjustments needs to be done by an extra double acting group of the tractor Position will be shown on top of the machine by use of an indicator for what we have 2 versions latest model is shown on LH side Basic settings adjusting stubble height ...

Page 39: ...orth America 40 mm 137 64 skid is for stubble 45 80 mm 149 64 35 32 60 mm 223 64 skid is for stubble 65 105 mm 29 16 49 64 80 mm 3 skid is for stubble 85 130 mm 311 32 51 8 Note never tip the cutter bar backwards like 1 degree or even more In such a position you will cut twice what will increase the power consumption X Assembly attachment 39 ...

Page 40: ...6 disc cutter bars Positions of high skids on a 10 disc cutter bar Positions of high skids on a 8 disc cutter bar Assembly attachment Positions of high skids on a 7 disc cutter bar 40 Positions of high skids on a 9 disc cutter bar ...

Page 41: ...n When checking the suspension position yourself in front of the cutting unit and lift the cutting unit up as shown The weight on both sides of the cutting unit must be approximately 40 60 kg 90 130 lb when lifting by hand Screw the bolt indicated When the bolt is screwed clockwise the cutting unit s downward pressure decreases When the bolt is screwed anticlockwise the cutting unit s downward pre...

Page 42: ... LH 85 16 46 4332LTD KT9228000063 RH LH 85 16 46 4332CT KT9221600063 RH 85 15 51 KT9228000063 LH 85 16 46 4332LR KT9228000063 RH LH 85 16 46 4336LT KT9221400063 RH 2x 85 13 56 KT9221500063 LH 2x 85 14 53 4336CT KT9221400063 RH 2x 85 13 56 KT9221500063 LH 2x 85 14 53 4336LR KT9221500063 RH 2x 85 14 53 KT9221500063 LH 2x 85 14 53 4336CR KT9221500063 RH 2x 85 14 53 KT9221500063 LH 2x 85 14 53 4340CT ...

Page 43: ...ill change when the drawbar cutting unit moves to the other side The deflector plates have 3 setting options To ensure that the swath is gathered in the best possible way it is recommended that the deflector plates are extended as close to the end plates as possible The length of the deflector plates is set as follows Remove the bolts shown and move the plates to the required length Fit the bolts ...

Page 44: ...44 Maintenance Basic ...

Page 45: ...45 Maintenance Intervals Y fingers or rollers ...

Page 46: ...46 Maintenance Intervals Rotor or roller bearings ...

Page 47: ...47 Maintenance Intervals Gearbox model with LH drawbar Gearbox model with center drawbar ...

Page 48: ...48 Maintenance Intervals Roller or tine conditioner May only be carried out by authorized service personnel CR model only ...

Page 49: ...49 Torques only for 8 8 bolts for special bolts you will find the relevant info in the operators manual and further on in this presentation Maintenance ...

Page 50: ...50 Hydraulic diagram Steering cylinder LH drawbar goes out to working position with unit in transport position This restrictor is not on the 4340C ...

Page 51: ...51 Hydraulic diagram Lifting cylinder LH drawbar goes out to bring unit downwards in working position This restrictor is not on the 4340C ...

Page 52: ...52 Hydraulic diagram Lifting cylinder LH drawbar goes in to bring unit upwards in working position This restrictor is not on the 4340C ...

Page 53: ...aulic diagram 9xx C model with flip over drawbar and crop flow to the left The sequence valves are preset at 140 Bar does not move the steering vanes before the drawbar has reached it s end position Stop valve ...

Page 54: ...xx C model with flip over drawbar and crop flow to the right Stop valve The sequence valves showed in the yellow square are preset at 140 Bar does not move the steering vanes before the drawbar has reached it s end position ...

Page 55: ...55 Lifting cylinder up to summer 2012 only filling when cylinder is complete in unit up Hydraulic ...

Page 56: ...complete in valve 12 will be activated when hitting the cylinder bottom With the cylinder complete out it s the bush with the role pin in the green area what will slide sideways when it hits the cylinder head and activates the valve 12 Note we recommend to do it with the cylinder complete out unit on the ground Hydraulic Gasket kit KT99413147 ...

Page 57: ...he cylinder complete in valve 12 will be activated when hitting the cylinder bottom With the cylinder complete out it s the bush with the role pin in the green area what will slide sideways when it hits the cylinder head and activates the valve 12 Note we recommend to do it with the cylinder complete out unit on the ground Hydraulic Gasket kit KT99413148 ...

Page 58: ...te in valve 12 will be activated when hitting the cylinder bottom With the cylinder complete out it s the bush with the role pin in the green area what will slide sideways when it hits the cylinder head and activates the valve 12 Note we recommend to do it with the cylinder complete out unit on the ground Hydraulic Gasket kit KT99413152 ...

Page 59: ... both sides of the machine Loosen the springs and remove the spindles on both sides of the machine Remove cotter bolts on both sides of the machine NB Protect the top plates on the machine with a piece of cardboard or something similar Remove cotter bolts on both sides of the machine Replace the hydraulic cylinders Fit the cotter bolts on both sides of the machine Fit the cotter bolts on both side...

Page 60: ...re the counter nut as shown for the 924 928R and T Attach the hydraulic system of the machine to the tractor and lower the cutting unit to top position Lower the cutting unit down onto the ground and continue activating the hydraulic system of the tractor in approx 2 5 minutes That insures the machine s hydraulic cylinders is filled with hydraulic oil After that carefully raise the cutting unit an...

Page 61: ...61 Hydraulic Steering cylinder 43xx L drawbar Gasket kit KT99413163 ...

Page 62: ...62 Hydraulic Steering cylinder 4332 C model Gasket kit KT99413221 ...

Page 63: ...63 Hydraulic Steering cylinder 4336 4340 C model Gasket kit KT99413218 ...

Page 64: ...64 Hydraulic Cylinder A144018986 for stubble height kit option Gasket kit A144500300 ...

Page 65: ...65 Hydraulic Cylinder A144018986 for stubble height kit option Nr 22 position of restrictor 0 7 mm ...

Page 66: ...66 Hydraulic Cylinder A144437086 for roller settings kit A144470830 option Gasket kit A144500400 ...

Page 67: ...67 Hydraulic Diagram for roller settings kit A144470830 option 125 bar 10 bar 30 bar Ø0 8m m ...

Page 68: ...68 Hydraulic Roller settings kit A144470830 option Nr 15 position of restrictor 0 8 mm ...

Page 69: ...69 Hydraulic Roller settings kit A144470830 option Nr 11 Accumulator 0 75 ltr and 125 Barr Nr 12 Accumulator 0 75 ltr and 10 Barr ...

Page 70: ...bar 2105 PSI The check may only be undertaken by authorized persons The in line relief valve is factory set to open at 90 bar 1305 PSI at 50 l min For resetting the valve A Fit a pressure gauge between hose and valve Lower the machine with 50 l min 105 US pints B Loosen the counter nut C Set pressure to 90bar 1305 PSI by turning bolt after setting retighten the counter nut A B C Hydraulic Pressure...

Page 71: ...71 European version Diagram light kit ...

Page 72: ...72 North American version Diagram light kit ...

Page 73: ...ter bar part numbers Position 1 is where the PTO drives the cutter bar Nr 1 and 2 are BOM nrs of a kit including a box info bolts nuts etc so not the same numbers as on next page what is just the hub itself Maintenance ...

Page 74: ...74 Hub drive line side PTO Hub for the rest Maintenance ...

Page 75: ...andard hub A144144030 and A144143930 for PTO side 75 Maintenance Standard Hub PTO side has 4 extra tap holes in flange Part descriptions From machine nr KT472228 the new style hubs what cannot be repaired ...

Page 76: ...30 on PTO side That is including an A info showing how to do the job Contents of a spare part kit for bearing house A144144030 That is including an A info showing how to do the job Maintenance From machine nr KT472228 the new style hubs what cannot be repaired ...

Page 77: ...h sides the 5 bolts holding the cutter bar on the frame 7 Turn the blade under the disc on the LH side Turn the same disc in the position shown 8 Remove the 3 bolts holding the support bracket on the frame 9 Remove the bracket on the RH side by sliding it sideways from the shaft 10 Put something between the cutter bar and the support 6 1 to slide the cutter bar sideways out of the conical support ...

Page 78: ... The through going bolts is only used in the outer bearing units in both ends of the cutter bar Remove the bolts and nuts shown Remove the lock plates shown Remove the bearing unit from the cutter bar NB The bearing unit can be removed from the cutter bar without the oil is drained the inspection of the intermediate gear wheel can be done by carry out the inspection through the hole of the bearing...

Page 79: ...utter bar Guide the intermediate gear wheel out through the gap in the end of the cutter bar Use a longer bolt of the same size and screw the bolt in the shaft Force the shaft out of the cutter bar by use of a hammer Place the intermediate gear wheel on top of tool T2 Place tool T1 on top of the bearing as shown Force the bearing out of the gear wheel by use of a hammer and hit T1 NB The largest d...

Page 80: ...NB Make sure that all the broken parts from the circlip is removed from the intermediate gear wheel Place the gear wheel on top of tool T3 NB The recessed surface has to be faced upwards Make sure the gear wheel and the new bearing is facing the right way NB The groove in the bearing and in the gear wheel has be faced downward Place tool T2 on top of the gear wheel as shown Place the new circlip i...

Page 81: ... by the tool on the outer ring of the bearing when it is placed in the bearing house Guide the gear wheel trough the gap in the cutter bar Make sure the bearing is locked and fixed by the circlip NB Force the bearing backward and forward a bit to check the bearing is locked and fixed in the gear wheel Fit new O rings on the shafts and into the hole for the shafts Fit the intermediate gear wheel Pl...

Page 82: ...CTITE 242 when fitted in the shaft All the special nuts is provided with new O rings Tighten the lock bolts to 90 Nm 66 ft lbs by use of a torque wrench Use a nylon hammer and hit the shaft on top and re torque the bolt again Force the edge of the plate up a bit by use of tool T7 Carefully place all the special nuts in the cutter bar as shown NB Do not damage the O rings when the special nuts is p...

Page 83: ...orce the edge of the plate up a bit by use of tool T7 as shown Place the bushings for the through going bolts NB Do not damage the O rings when the special nuts is placed in the cutter bar Guide the end cap in to the cutter bar as shown Tighten the end cap NB Always use a new gasket when the end cap is fitted Fit the bolts NB Do not damage the O rings Place tool T6 as shown The special nuts in the...

Page 84: ... cutter bar Remove tool T6 after fitting of the bearing units NB Wait with the fitting of the last bearing unit Take care of the timing see pictures NB on cutter bars with uneven amount of hubs the timing of the hub for the driveline is pointing to the outside Fill the cutter bar with oil before you fit the last bearing unit For volume see on the left Maintenance Cutting width Liter approx Pints U...

Page 85: ...en all the bolts on the bearing units to 90 Nm 66 ft lbs by use of a torque wrench NB Do not use LOCTITE or similar product on these bolts when fitted Then the bolts will not able to be removed from the nut during a disassemble Provide the bearing units with new lock plates NB After removal of the bearing unit new lock plates and new bolts has to be provided when fitting of the bearing unit Bend t...

Page 86: ...86 For part numbers see next two pages Swivel Gearbox KT38798000 Maintenance ...

Page 87: ...87 Swivel Gearbox KT38798000 Maintenance Part numbers ...

Page 88: ...88 23 Swivel Gearbox KT38798000 Maintenance Part numbers ...

Page 89: ... pliers Disassemble oil seal 19 using chisel and hammer Unscrew bolts 22 and disassemble cover 23 Disassemble outer ring 21 using an extractor take away shim 20 from cover 23 Unscrew bolts 16 and disassemble housings 1a and 1b from extension 30 using a chisel and hammer Disassemble cap 8 using a chisel and hammer Hit the shaft 18 from side A in order to extract it from housing 1 Disassemble outer ...

Page 90: ...a chisel and hammer Hit the shaft 18 from side A in order to extract it from housing 1 Disassemble outer ring 7 using an extractor from housing 1 Disassemble inner ring 7 using a pipe and hammer take away shim 5 and disassemble snap ring 4 from shaft 18 Put the gear 24 face B against a pipe and hit the shaft 18 from side C in order to extract it from gear 24 pick up inner ring 21 shim 33 and gear ...

Page 91: ... disassemble extension 28 from extension 30 pick up o ring 29 protective washer 11 and inner ring 13 Disassemble outer rings 13 Using an extractor Disassemble oil seal 15 using a pipe and hammer Disassemble outer rings 12 from extension 28 using an extractor Disassemble oil seals 14 using a chisel and hammer Disassemble inner ring 13 using an extractor take away protective washer 11 Maintenance ...

Page 92: ...oil seals 14 inside extension 28 using pipe and hammer put a film of grease on oil seal lips Assemble shim 31 and outer rings 12 using a pipe and hammer Tools Pipe hammer pliers torque meter Assemble oil seal 15 inside extension 30 using pipe and hammer put a film of grease on oil seal lip Assemble outer rings 13 inside the extension 30 using a pipe and hammer Put adhesive tape on extension thread...

Page 93: ...mounted cover 23 bolts 22 and tighten manually Hit the shaft 18 from both sides in order to set the axis Check the assembled axis preload using a torque meter the value must be to 0 3 Kgcm If the value is not correct change the shim set 20 Assemble outer ring 7 inside housing 1 using a pipe and hammer Assemble snap ring 4 shim 5 and inner ring 7 on shaft 18 using a pipe and hammer Assemble paralle...

Page 94: ...ut an adhesive tape on splined shaft 18 in order to prevent any damage to oil seal lip 19 Assemble oil seal 19 and cap 8 using pipe and hammer Assemble shim 20 outer ring 21 using a pipe and hammer inside cover 23 Assemble pre mounted cover 23 bolts 22 and tighten manually Hit the shaft 18 from both sides in order to set the axis Check the assembled axis preload using a torque meter the value must...

Page 95: ...ms set you will also have to re set the preload Disassemble bolts 16b and extension 30 Put a Silicone film in the contact faces between housing 1b and extension 30 Put a Loctite 270 film on thread bolts 16b Assemble pre mounted extension 30 bolts 16b and tighten to 7 7 8 3 kgm Assemble upper gearbox 1a bolts 16 and tighten manually Put a Loctite 270 film on thread bolts 16 Assemble pre mounted ext...

Page 96: ...ear backlash must be 0 15 0 40 mm 3 Tightening of bolts must be carried out making use or torque meter wrench 4 Insert oil seals taking care or greasing the zone of contact between oil seal and shaft 5 Gearbox operators with lubricating oil 6 Lubrication Gearbox operates with oil lubrication The type of oil recommended SAE GL5 EPX 80W 90 Quantity 1 7 Liter lower gearbox 1 2 Liter upper gearbox 7 O...

Page 97: ...97 Main Gearbox KT99250803 for models with LH drawbar part 1 Part numbers Maintenance ...

Page 98: ...98 Main Gearbox KT99250803 for models with LH drawbar part 2 Part numbers Maintenance ...

Page 99: ...ositions Unscrew bolts 29 and disassemble extension 11 Unscrew bolts 28 and disassemble cover 41 Tools Wrench n 13 17 19 22 chisel hammer pipe snap ring pliers Unscrew plugs 21 35 and empty the oil from gearbox Unscrew bolts 27 28 and disassemble covers 12 13 Disassemble from extension 11 oil seal 37 using a chisel and hammer snap ring 31 shims 3 4 Hit the shaft 14 in order to extract it Pick up i...

Page 100: ...ticular damaged When assembling the taper roller bearings pay attention to not make any pressure on the cages in order to avoid any damage When assembling oil seals avoid contact with cutting parts in order to prevent any damage to the inner lip Disassemble oil seal 39 snap ring 30 shim 7 bearing 22 using an extractor Hit the pinion shaft 16 from side B in order to extract it Disassemble outer rin...

Page 101: ...ousing 10 using pipe and hammer assemble pre mounted pinion 16 Assemble bearing 22 using pipe and hammer shims 7 and snap ring 30 Hit the pinion shaft 16 from both sides in order to set the axis Check the value axis preload with a torque meter that must be to 2 5 5 Kgcm If the value is not correct disassemble snap ring 30 and change the shim setting 7 in order to obtain the right value Disassemble...

Page 102: ...ng 3 in order to obtain the right value Verify the right mesh between gears see the technical specifications on page 13 the value must to be to 0 22 0 6 mm for gears 17 and 0 12 0 32 mm for gears 16 18 In order to have the correct backlash change the shim setting 5 6 figure 2 1 please be aware that when you change the shim setting 5 6 you will have to change the opposite shim setting 9 and please ...

Page 103: ...arbox with oil SAE GL5 EPX 80W 90 Quantity 1 5 liter Assemble plug 21 and tighten to 3 kgm Gearbox operates with lubricating oil The type of oil recommended SAE GL5 EPX 80W 90 Quantity 1 5 liter Oil change First oil change is recommended after the first 50 hours of work other change after 600 hours and or once per year at least The contact of crown wheel and pinion must be located like in Fig A ma...

Page 104: ...104 Part numbers Main Gearbox KT99250803 for models with centre drawbar Maintenance ...

Page 105: ...g Main Gearbox Centre drawbar Disassembling Main Gearbox Centre drawbar Warning Disassembled shims must to be assembled in the same positions Unscrew bolts 19 and take away cover 28 Disassemble oil seals 24 25 26 using chisel and hammer Tools Fork screw n 13 17 19 chisel hammer snap ring pliers Unscrew plugs 13 23 and empty the oil from gearbox Unscrew bolts 18 19 and disassemble covers 7 and 8 Di...

Page 106: ...nion shaft 9 than hit the shaft 6 newly and extract it from housing 5 Pick up inner ring 16 crown wheel 10 shaft 6 and outer ring 15 from housing 5 Disassemble inner ring 15 using chisel and hammer from shaft 6 Disassemble outer ring 16 from housing 5 using pipe and hammer Hit the pinion shaft 9 from side B in order to extract it from housing 5 pick up inner ring 14 Disassemble outer rings 14 17 f...

Page 107: ...st be to 2 5 Kgcm Then take 0 05 mm of shim setting If the value is not correct disassemble snap ring 21 and change the shim setting 4 in order to obtain the right value Tools Pipe hammer snap ring pliers chisel torque meter Assemble outer ring 16 inside housing 5 using pipe and hammer Assemble shims 11 12 and snap ring 22 Disassemble snap ring 21 and take away shim 4 Hit the shaft 6 from side A a...

Page 108: ...ng 21 In order to test the right meshing put a color like Prussian blue on gear s toothing Lock pinion shaft 9 and rotate manually in the work direction the shaft 6 Verify the right mesh between gears see the technical specifications on page 12 the value must to be to 0 12 0 32 mm Assemble bearing 14 using pipe and hammer shims 2 3 and snap ring 20 Hit the pinion shaft 9 from both sides in order t...

Page 109: ...t insufflate from the hole plug 13 to pressure bar 0 35 and put the gearbox in a tank if you prefer you can verify any pressure drop with a manometer positioned inside hole oil plug 23 scale about 0 6 bar for 10 minute Dry the gearbox Fill the gearbox with oil SAE GL5 EPX 80W 90 Quantity 1 37 liter Assemble plug 13 and tighten to 3 kgm Gearbox operates with lubricating oil The type of oil recommen...

Page 110: ...110 Part numbers Centre Gearbox KT99250801 for models with centre drawbar Maintenance ...

Page 111: ...ssembled shaft 8 from housing 13 Tools Allen screw wrench n 5 16 fork wrench n 17 19 chisel hammer extractor pipe Unscrew plugs 1 16 and empty the oil from gearbox Disassemble oil seals 7 using a chisel and hammer Disassemble outer ring 6 and shim 5 from cover 9 using an extractor Unscrew bolt 10 take away blank washer 14 Put the gear 4 face B against a pipe and hit the shaft 8 from side A in orde...

Page 112: ...0 disassemble cover 9 and assembled shaft 8 from housing 13 Disassemble outer rings 12 from housing 13 using an extractor Disassemble outer ring 6 and shim 5 from cover 9 using an extractor Unscrew bolt 10 take away blank washer 14 Put the gear 4 face B against a pipe and hit the shaft 8 from side A in order to extract it from gear 4 pick up inner ring 6 and gear 4 Disassemble inner ring 12 from s...

Page 113: ...m 5 outer ring 6 inside cover 9 using pipe and hammer Assemble shims 3 2 inner ring 12 using pipe and hammer on shaft 8 Assemble blank washer 14 bolt 10 and tighten to 5 6 5 kgm Assemble gear 4 Assemble shim 11 and inner ring 6 using pipe and hammer Tools Pipe hammer fork wrench n 17 dynamometric wrench torque meter Assemble outer rings 12 inside housing 13 using pipe and hammer Assemble the pre m...

Page 114: ...and rotate manually the shaft 8 in the work direction Verify the right mesh between gears see the technical specifications on page 11 the value must be to 0 19 0 52 mm In order to have the correct backlash change shims set 2 11 figure 2 2 please be aware that when you change the shims set you will also have to re set the preload Assemble the pre mounted shaft 8a Assemble pre mounted cover 9a bolts...

Page 115: ... the following test insufflate from the hole plug 16 to pressure bar 0 35 and put the gearbox in a tank if you prefer you can verify any pressure drop with a manometer assembled on hole plug 1 scale about 0 6 bar for 10 minute The contact of crown wheel and pinion must be located like in Fig A mark obtained without load on crown wheel and pinion Use the shims in order to obtain the right contact G...

Page 116: ...116 Part numbers complete gearbox is Nr 1 Roller Gearbox KT90226000 Part 1 bolted on side plate and connected to bottom roller Maintenance ...

Page 117: ...117 Roller Gearbox KT90226000 Part 2 connected to top roller and part one Part numbers Maintenance ...

Page 118: ...118 PTO KT99244475 on tractor side for machines with 2 point hitch Part numbers Maintenance ...

Page 119: ...119 PTO A132460600 with 6 splines for tractor side for ANSI models North America with clevis hitch Part numbers Maintenance ...

Page 120: ...120 PTO A132528200 with 21 splines for tractor side for ANSI North America models 3 6 mtr 11 10 and 4 mtr 13 1 with 2 point hitch Part numbers Maintenance ...

Page 121: ...121 PTO KT99244629 under drawbar of models with the LH drawbar Maintenance Part numbers On tractor side you will find the combination of overrun and slip clutch On the machine side the double yoke ...

Page 122: ...for the 4 mtr 13 1 Clutch KT99244535 for the 4 mtr 13 1 Part numbers All models have a torque of 1730 Nm except for the 4 mtr 13 1 what is 1900 Nm Clutch parts are the same but the setting is different for more details see page 20 23 Maintenance ...

Page 123: ...123 PTO KT99244513 under drawbar of all models with centre drawbar Part numbers Maintenance ...

Page 124: ...124 PTO Part numbers Maintenance PTO KT99244559 under pivot point drawbar of all models with centre drawbar ...

Page 125: ...125 PTO Part numbers Maintenance PTO KT99244631 from pivot point drawbar to cutting unit on all models with centre drawbar ...

Page 126: ...126 PTO KT55246200 to drive the cutter bar Part numbers Maintenance ...

Page 127: ...127 Tire Tire Maintenance Model Tire Dimension Tire pressure Bar PSI Bolt torque Nm ft lbs 4324 10 0 75 15 3 3 9 57 300 220 Other models 15 0 55 17 2 6 37 300 220 ...

Page 128: ...ve both deflector plates Remove the side plate on RH side Removal of rollers Replacement synchronizing of rollers Remove the cover plate in the groove on the RH side Remove the guard on the LH side of the machine Removal of rollers Replacement synchronizing of rollers Removal of rollers Remove the bracket with the grease nipple and both the V belt and V belt pulley Loosen the nut for the jockey ro...

Page 129: ... the moveable and fixed transmission box Maintenance Replacement synchronizing of rollers Remove the bearing Removal of rollers X Y Use a wooden block to fill up the gab between LH tire and upper plate Remove the linchpin and lock plate position X Turn the bolt X clockwise until the top plate will rest on the wooden block and the rod Y can be moved freely Remove the rod and bracket Z Z Removal of ...

Page 130: ...llers Remove the gear wheel and bearing on the lower roller Remove the gear wheel and bearing on the upper roller Maintenance Replacement synchronizing of rollers Removal of rollers Top roller Remove bolt and cover plate for the slot in the LH side of the machine Remove and guide the upper roller out through the LH side of the machine During the removal of the roller use e g a fork lift for suppor...

Page 131: ... During the fitting of the roller use e g a fork lift for support Carefully guide the end of the upper roller in and through the slot on the LH side of the machine Fit the cover plate for the slot Lower roller Guide and fit carefully the lower roller in through the RH side of the machine During the fitting of the roller use e g a fork lift for support Fit the bearing on the shaft on the LH side of...

Page 132: ...ollers Fit both the bearing and the gear wheel on the upper roller Fit the tools on to the bearings as shown bolt without the head Fitting of rollers Fitting of rollers Fit the fixed transmission box to the machine The ring in the LH side on the lower roller is tighten and secured on the shaft Fitting of rollers Place something between the rollers as shown to get the same distance on both sides Pl...

Page 133: ...repeated until correct synchronizing of the rollers is achieved Fitting of rollers Fitting of rollers Fitting of rollers NOTE In case of the synchronizing did not succeed Remove the moveable transmission box again Lift up the upper roller Turn the lower roller 1 4 turn Place the tools between the rollers and lower the upper roller down Carefully fit the moveable transmission box on to the rollers ...

Page 134: ...tions 1 2 Fit the bracket Z for height adjustment Fit the rod Y Turn the bolt X counter clockwise until the top plate will come loose from the wooden and remove the block Fit the linchpin and lock plate position X Y X Z Oil plug 1 Oil plug 2 Fit Pulleys check alignment belts tension 75 mm or 3 brackets with springs belt cover and side plates etc back again Adjust the rollers with a minimum distanc...

Page 135: ...every 40 hours Recommended grease Multipurpose Grease NLGI 2 EP2 Warning Do not use grease with solid particles such as graphite or molybdenum to the ball needle and roller bearings Roller conditioner Tine conditioner Maintenance ...

Page 136: ...s Recommended grease Multipurpose Grease NLGI 2 EP2 Warning Do not use grease with solid particles such as graphite or molybdenum to the ball needle and roller bearings Picture below shows how the center disc gets lubricated by use of an internal lubrication channel ...

Page 137: ...ubrication model with Centre drawbar every 100 hours Recommended grease Multipurpose Grease NLGI 2 EP2 Warning Do not use grease with solid particles such as graphite or molybdenum to the ball needle and roller bearings ...

Page 138: ...ly Loctite 242 or a similar product to all bolts Fit the bolts and tighten to the torque shown Torque PTO Torque discs Torque blade bolts Torque Cone Apply Loctite 242 or a similar product to all bolts for the cone Fit the 12 9 bolts and Nord Lock washers and tighten to the torque shown Note the Nord Lock washer Is a set of 2 washers with the wide ribs on the inside Maintenance ...

Page 139: ...ly tightened If not use a suitable tool and tighten the bolt to a torque of 95 Nm 70 ft lb Inspect the timing of the discs Out of timing could be caused by an impact of foreign objects If so please check the key in the hub Wearing bolts How to check alignment discs Cutter bar connections Wearing quick fit If the machine is fitted with knife quick release the same requirement applies for bolt wear ...

Page 140: ...of soles skids Check wearing of soles skids Check wearing of soles skids Activate the tractor hydraulics and raise the machine fully Close the mechanical safety valve Place a suitable support under the machine s cutting unit Note It is important that the machine is correctly secured with a sturdy support before work is started Check wearing of soles skids Remove the worn stone guard and counter kn...

Page 141: ...is less than 9 mm 3 8 in the worn areas it must be replaced Check of conditioners Inspection of rollers Use a suitable tool and remove the bolt nut Remove the bolt and the lock plate and replace the damaged Y finger Fit the bolt with the lock plate and Y fingers Tighten the bolt The Y fingers should be able to move freely Tine conditioner Inspection of rotor Tine conditioner Inspection of rotor Ac...

Page 142: ... Nord lock washers Is a set of 2 washers with the wide ribs on the inside Torque 81 Nm 58 ft lbs for the M12 bolts used for the gearbox under the drawbar on the machines with center drawbar Torque 197Nm 145 ft lbs for the M16 bolts of the gearbox driving the cutter bar Torque for bolts of gearboxes Torque for bolts of gearboxes Use Nord lock washers and or the lock plates Torque 225Nm 165 ft lb Fo...

Page 143: ... fill plug 2 level plug 3 drain plug For gearboxes always use SAE GL5 EPX 80W 90 1 drain plug 2 level and fill plug 3 drain plug 4 level and fill plug 4 fill plug 5 level plug 6 drain plug Oil plug 1 Oil plug 2 Oil plug 3 Oil plug 4 Oil levels Oil levels Oil levels Oil levels Maintenance ...

Page 144: ...x indication on the dipstick Repeat the procedure until the correct oil level is reached The oil level on the main gear must always be between min and max as shown on the stick Fit the guard Use a suitable tool to remove the oil plug Let the oil flow into a suitable container Allow the last of the oil to drip out of the transmission for approx 10 15 minutes Fit the oil plug and tighten it Oil leve...

Page 145: ...fill if necessary Min 6 mm 1 4 Max 9 mm 3 8 Cutter bar Check of oil level cutter bar Check of oil level cutter bar Draining oil Changing oil Note do not overfill Overfilling could result in a higher power consumption temperature and pressure inside the cutter bar Cutting with Liter approx Pints US approx Pints Imp approx 2 4 mtr 7 10 3 1 ltr 1 3 1 2 8 mtr 9 2 3 6 ltr 7 6 6 3 3 2 mtr 10 6 4 1 ltr 8...

Page 146: ...itching between mowing with or without gathering the swath without the changeover time The machine can be fitted with a flip over spreading device that ensures a perfect spreading of the crop The spreading device is simple to use and can be swung round when in use Fitting throwing wings is recommended to rectify any stripe problems with spring crops caused by grass blocking the cutting discs The t...

Page 147: ...ple tool The machine can be fitted with weights that are mounted on the machine s wheels Weights are used on hilly land to stabilize the machine Options Chain for locking the lift arms Chain for locking the lift arms A chain is available as extra equipment to prevent the tractor s lift arms from lowering The chain is fitted between the highest point on the tractor and one of the lift arms High ski...

Page 148: ...ughout its service life Trip function which can be reset to individually record the hours the machine has been running for The hour counter only records time when the PTO shaft is coupled to the machine The machine can be fitted with a reflective warning sign which ensures that the machine is correctly marked for transport on public roads The hour counter also has the following features A light fu...

Page 149: ...ended that this extra equipment be used for cutting whole crops Roller rpm 1200 rpm Roller rpm 1200 rpm 932R 936R 932CR 936CR only The machine can be fitted with a set consisting of a V belt pulley and 3 V belt parts which change the speed of the rollers to 1200 rpm This could be usefull in combination with the BX as this kit creates more speed in the material it results in a better flow to the be...

Page 150: ...e tractor lifting arms Option for US and Canada Option for rest of the world Options Cutter bar protection Cutter bar protection Can be bolted on the outer ends of the cutter bar Note for a model with 3 2 mtr cutter bar this results in a too wide cutter bar for some countries as it gets wider than 3 mtr in transport ...

Page 151: ...151 Trouble shooting Hydraulic system and PTO ...

Page 152: ...152 Trouble shooting Cutter bar and tine conditioner ...

Page 153: ...153 Trouble shooting Cutter bar and tine conditioner ...

Page 154: ...154 Trouble shooting Roller conditioner ...

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Kverneland 4328LT, Service Manual

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