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Technical Service Manual       

Trailed plain mower

Extra 532-540

Summary of Contents for Extra 532

Page 1: ...1 Technical Service Manual Trailed plain mower Extra 532 540...

Page 2: ...Subject Vicon Extra 532 and 540 Place Kverneland Group Kerteminde AS Taarupstrandvej 25 DK 5300 Kerteminde Denmark Realized for Who it might concern Details General and operating information Addition...

Page 3: ...5 3 3 Maintenance intervals 26 4 0 Components 4 1 PTO s clutch 27 4 2 1 Lifting cylinders 33 4 2 2 Replacement cylinder s 36 4 3 Steering cylinder 38 4 4 Press relieve valve 39 4 5 Hydraulic diagrams...

Page 4: ...Kubota 1 1 Machine specifications 4...

Page 5: ...Machine dimensions Machine dimensions Extra 532 Extra540 1 1 Machine specifications 5...

Page 6: ...ada 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 7: ...Safety symbols for the US and Canada 1 3 Safety labels US and Canada 7...

Page 8: ...Safety symbols for the US and Canada 1 3 Safety labels US and Canada 8...

Page 9: ...e replaced You can get new labels as spare parts from your dealer Reflective equipment for slow moving vehicles SMV This triangular sign must be placed in the center at the rear of the tractor or mach...

Page 10: ...n 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 1 3 S...

Page 11: ...Safety symbols 1 3 Safety labels 11...

Page 12: ...Safety symbols Safety symbols 1 3 Safety labels 12...

Page 13: ...l gear in the following way Observe the gear s profile in the middle of the swivel gear If the swivel gear s profile on the lower part of the swivel gear is wide the machine should be run at a rotatio...

Page 14: ...ts to a torque of 225 Nm 165 ft lb Force the corners of the lock plate back in against all the bolt heads Fit the PTO shaft Note the oil levels needs to be checked after the gearbox has been swapped a...

Page 15: ...Coupler shown on the RH side is optional Clevis Coupler is standard on machines for USA Canada Quick Coupler is optional Adjust the right and left lift arm so they are at the same height Swing the low...

Page 16: ...x 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 Clevis Couple...

Page 17: ...ing unit Note because of the chosen diameters of the hoses there is no need for restrictors in the system Y Hydraulic connection to tractor Two double acting valves Working position lifting cylinders...

Page 18: ...ck between the two cutting discs Start the tractor and connect the tractor s PTO outlet Let the friction clutch rotate freely for approx 5 seconds at the lowest possible speed until it is warm to the...

Page 19: ...ly positioned before start up Check that the mechanical safety valve is open Carefully connect the tractor s PTO shaft Carefully increase the speed on the PTO to 540 1000 RPM Check that the machine ru...

Page 20: ...ticlockwise the cutting unit s downward pressure increases Adjust the cutting unit s downward pressure for both springs Secure the counter nuts with the springs on both sides of the machine Check by l...

Page 21: ...High skids Higher stubble height Shorten the top link for a lower stubble height Extend the top link for a higher stubble height High skids are needed in case you like to cut higher than around 50 mm...

Page 22: ...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 ba...

Page 23: ...ids on 8 disc cutter bar North America positions of high skids on 8 disc cutter bar North America positions of high skids on 10 disc cutter bar Positions of high skids on 10 disc cutter bar 2 6 Settin...

Page 24: ...Basic instructions This table contains explanations of the most important terms related to maintenance 3 1 Basic instructions 24...

Page 25: ...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 3 2 Torques 25...

Page 26: ...Maintenance intervals Maintenance intervals 3 3 Intervals 26...

Page 27: ...with coated inner tube used up to machine nr KT457907 W2300 This PTO supposed to be replaced with one with a hardened inner tube beginning of season 2017 Parts list PTO tractor side with coated inner...

Page 28: ...PTO tractor side with hardened inner tube used from machine nr KT457907 W2300 Parts list PTO tractor side 4 1 PTO 28...

Page 29: ...PTO tractor side with nr A144508100 W2400 for Clevis This W2400 has been introduced in production since 2017 Parts list PTO tractor side 4 1 PTO 29...

Page 30: ...PTO tractor side with nr A144508000 W2400 for 2 point hitch 165 mm 61 2in longer This W2400 has been introduced in production since 2017 Parts list PTO tractor side 4 1 PTO 30...

Page 31: ...PTO drawbar including clutch Parts list PTO drawbar including clutch Torque 1500Nm 4 1 PTO Clutch 31...

Page 32: ...hten all the bolts on the friction clutch Remove the circlip shown Take the lock on the friction clutch apart and remove it Bend back the edges of the clutch housing shown Take the friction clutch apa...

Page 33: ...Lifting cylinder RH side KT9291800086 Seal kit A132098900 4 2 1 Lifting cylinder RH side 33...

Page 34: ...Lifting cylinder LH side KT9291700086 Seal kit A132098800 4 2 1 Lifting cylinder LH side 34...

Page 35: ...ransport position green pin will touch the bottom side and opens the valve to fill the cylinder with oil Cylinder complete out machine on the ground in working position best way to do red pin will tou...

Page 36: ...machine Replace the hydraulic cylinders Note cylinders are not the same in diameter RH side 55 mm 211 64 LH side 65 mm 29 16 Fit the cotter bolts on both sides of the machine Fit the spindles on the s...

Page 37: ...f the machine to the tractor and keep the unit on the ground Activate the hydraulic system of the tractor in such a way that you extend both cylinders completely be aware that this can take approx 2 5...

Page 38: ...Steering cylinder Seal kit KT99413163 4 3 Steering cylinder 38...

Page 39: ...0 l min 13 2 gallon For resetting the valve A Fit a pressure gauge between hose and valve Lower the machine with 50 l min 13 2 gallon B Loosen the counter nut C Set pressure to 90bar by turning bolt a...

Page 40: ...r goes out to working position with unit in transport position Master slave cylinders for lifting the cutting unit No restrictors in this system the long 3 8 hydraulic lines provide the necessary rest...

Page 41: ...Hydraulic diagram lifting cylinder goes out to bring unit downwards in working position 4 5 Hydraulic diagrams 41...

Page 42: ...Hydraulic diagram lifting cylinder goes in to bring unit upwards in working position 4 5 Hydraulic diagrams 42...

Page 43: ...Swivel gearbox A132098430 Swivel gearbox A132098430 4 6 Details swivel gearbox 43...

Page 44: ...ols Chisel hammer snap ring pliers extractor Disassemble oil seal 30 cap 29 using a chisel and hammer Disassemble snap rings 23 take away shims 5 Disassembly of A132098430 Unscrew bolts 19 disassemble...

Page 45: ...from extensions pick up gear 6 protective washer 20 shim 4a and inner ring 17a Disassemble gear 7 shim 4 protective washer 20 and inner ring 17 from shaft 11 using an extractor Disassembly of A1320984...

Page 46: ...aining grease and silicone Replace any particular damaged When assembling taper roller bearings pay attention to not make any pressure on the cages in order to avoid any damage When assembling oil sea...

Page 47: ...cknut 13 Assemble and screw the locknut 13 Hit the extension in order to set the axis Verify the axial preload taper roller bearings that must be 110 120 kgcm Assembly of A132098430 Assemble protectiv...

Page 48: ...d Assemble taper roller bearing 17 shim 5 and snap ring 23 Assembly of A132098430 Tools Pipe hammer snap ring pliers torque meter Assemble outer ring 16 using pipe and hammer snap ring 23 Check axis p...

Page 49: ...n thread bolts 19 Assemble gearbox 8a bolts 19 and tighten to 7 7 8 3 kgm Assembly of A132098430 In order to have the correct backlash change shims set 4a 5 figure 2 4 2 5 please be aware that when yo...

Page 50: ...ve both the gears in order to increase or decrease the backlash B Gear backlash must be respect the following relation 0 03 0 08 x module if module m 5 gear backlash must be 0 15 0 40 mm C Tightening...

Page 51: ...evel gearbox KT91635000 complete Bevel gearbox KT91635000 complete what is including the sealing ring KT9195500061 for the shaft see X and page 57 X see also page 57 4 7 Details Gearbox machine side 5...

Page 52: ...in the same positions Unscrew bolts 21 and disassemble cover 20 Disassemble oil seal 22 using chisel and hammer Tools Fork wrench n 13 17 19 22 chisel hammer snap ring pliers pipe Unscrew plugs 13 24...

Page 53: ...wheel 9 and inner ring 7 from inside housing Disassemble inner ring 7a from shaft 1 using an extractor Disassemble parallel key 8 from shaft 1 Disassemble snap ring 5 shim 6 Disassemble outer ring 7 u...

Page 54: ...que meter Disassemble snap ring 17 Assemble shims 15 19 snap ring 17 Hit the pinion shaft 18 from both sides in order to set the axis Check assembled axis preload value W using a torque meter The diff...

Page 55: ...st to be 0 10 0 28 mm In order to have the correct backlash change shims setting 6 pls be aware that when you change the shims set you also will have to re set the preload Disassemble bolts 4 cover 3...

Page 56: ...out 0 6 bar for 10 minute Dry the gearbox Fill the gearbox with 0 9 ltr oil SAE GL5 EPX 80W 90 Assemble plug 24 and tighten to 3 kgm C Tightening of bolts must be carried out making use of torque mete...

Page 57: ...00061 Extra seal ring supplied with each gearbox ordered as spare part it s to prevent material getting inside the bearing Seal in position Support the seal by using a piece of tube to bring the seal...

Page 58: ...nr KT480197 Cutter bar part numbers up to machine nr KT480197 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 4...

Page 59: ...Hub drive line side up to machine nr KT480197 Hub for the rest up to machine nr KT480197 4 8 Details hub 59...

Page 60: ...it for bearing house KT55243300 PTO side That is including an A info showing how to do the job Contents of a spare part kit for bearing house KT55245300 That is including an A info showing how to do t...

Page 61: ...0197 Cutter bar part numbers Latest model from machine nr KT480197 has the new style hubs what cannot be repaired NB As spare part you can only order a complete hub and no longer parts like bearing ge...

Page 62: ...t is including an A info showing how to do the job Contents of a spare part kit for bearing house A144144030 From machine nr KT480197 That is including an A info showing how to do the job 62 Latest mo...

Page 63: ...cutter bars and new hubs on old cutter bars 5 4 1 Cutter bar details NEW OLD Standard hub A144144030 and A144143930 for PTO side From machine nr KT480197 Latest model from machine nr KT480197 has the...

Page 64: ...44143930 for PTO side From machine nr KT480197 Standard Hub PTO side has 4 extra tap holes in flange Part descriptions 64 Latest model from machine nr KT480197 has the new style hubs what cannot be re...

Page 65: ...or the forks of a fork truck Release pressure out of suspension Lower the cutter bar on the supports or forks Close hydraulic system Remove the stone guard on the RH side Remove the 5 bolts holding th...

Page 66: ...side Remove the 5 bolts on the LH side Move cutter bar just far enough sideways to get the conus out of the conical hole in the LH support bar on the LH side by using a crowfoot Lift the cutting unit...

Page 67: ...ind in Quest Remove the through bolts NB 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 Rem...

Page 68: ...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...

Page 69: ...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 t...

Page 70: ...he 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...

Page 71: ...tted 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 bo...

Page 72: ...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...

Page 73: ...ring is placed correct in the groove of the bearing unit Fit the bearing units on the cutter bar Remove tool T6 after fitting of the bearing units NB Wait with the fitting of the last bearing unit Ta...

Page 74: ...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 d...

Page 75: ...set of 2 washers with the wide ribs on the inside and tighten them to the torque shown Apply Loctite 242 or a similar product to all bolts Fit the bolts and tighten to the torque shown Torque PTO Torq...

Page 76: ...Nm 67 ft lb You no longer need the bushes as the aluminium parts have the same height around the bolt holes Fit the 2 insert inside the grove and bolt them on the cone Note In case Nor Lock washers ca...

Page 77: ...bjects If so please check the key in the hub Place the correct support under the machine s cutting unit Carry out a visual inspection of the machine s stone guard and counter knife for wear Stone guar...

Page 78: ...e machine s cutter bar fully Close the mechanical safety valve Open the machine s front guard After the first 50 hrs thereafter every 200 hours or once a year Place a wooden block or similar under the...

Page 79: ...out of the transmission for approx 10 15 minutes Fit the oil plug Oil amount when changing oil Remove the dipstick Pour the oil through the hole where the dipstick is fitted Follow the instructions on...

Page 80: ...new oil through the hole for oil plug 1 The correct oil level is reached when the oil reaches the edge of the hole for oil plug 2 Fit oil plugs 1 and 2 and tighten them Fit the guard Oil amount when c...

Page 81: ...ubrication every 40 hours Note a too dry shaft and yoke will give too much load on the bearings inside the hub on top of the cutter bar the cutter bar housing itself and the gearbox 4 10 Lubrication 8...

Page 82: ...Lubrication every 100 hours Lubrication as required 4 10 Lubrication 82...

Page 83: ...e pressure and if necessary top up the tire to the pressure shown in the table below Position Part nr Amount Description 4 VG38800820 1 bearing tappered roller VN40119108 11 VNB1604878 1 wheel hub 6 h...

Page 84: ...can easily be changed or turned in just a few seconds with the help of a simple tool Standard for the US and Canada A lighting kit and reflector are available as extra equipment to ensure that the mac...

Page 85: ...afety chain for road transport 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...

Page 86: ...d prevent wrapping of long material around the cones Kit nr KT38521100 21 spline yoke 1 3 8 21 spline yoke 1 3 8 21 spline yoke 1 3 8 To create a clean area between swath and standing crop 5 0 Options...

Page 87: ...Wheels for NA Wheels for NA 5 0 Options 87 Cutter bar protection Cutter bar protection To protect discs on outer ends of cutter bar against stones etc...

Page 88: ...Hydraulic system 6 0 Trouble shooting 88...

Page 89: ...h stripes are more likely to occur when mowing short strong spring crops in less than ideal weather conditions Always begin by checking that the knives on the cutting discs are sharp 2 Extra equipment...

Page 90: ...PTO 6 0 Trouble shooting 90...

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