Vicon Extra 532 Operating Manual
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Vicon Extra 532 Operating Manual

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Extra 532 - 540
Operating manual
Translated from the original instruction manual
Revision
Date printed
Language
Machine number
Document number
Index
01
04.2014
EN
KT447406
A132101500
2014-03

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  • Page 1 Extra 532 - 540 Operating manual Translated from the original instruction manual Revision Date printed 04.2014 Language Machine number KT447406 Document number A132101500 Index 2014-03...
  • Page 2 In order for your dealer to assist you as efficiently as possible, you will need to provide some information about your machine. Please enter the details here. Designation Extra 532 - 540 Operating width 532: 3.2m (10’ 6”) ; 540: 4.0m (13’ 1½”) Weight 532: 1140kg (2513lb);...

  • Page 3: Table Of Contents

    Table of contents Table of contents Contents ............ Extra equipment ........125 Target group High skids The meaning of the symbols Quick release of knives Chain for locking the lift arms Safety ............Lighting kit For your own safety Coupling for the tractor's drawbar tongue 127 Who can operate the machine? Connecting Troubleshooting ........

  • Page 4: Contents

    Contents Target group Contents This manual is intended for trained farmers and others who are qualified to work in agriculture and who are familiar with assembling equipment. For your own safety Read this instruction manual thoroughly before use and assembly. This will enable you to have optimal working conditions and to work in safety.

  • Page 5: For Your Own Safety

    Safety For your own Safety This chapter includes general safety instructions. In addition, each chapter in the instruction manual includes specific safety instructions safety not set out here. The safety instructions must be complied with • For your own safety. •...
  • Page 6 Safety 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. STOP STOP...
  • Page 7 Safety The meaning of the Stop the tractor before working on the machine symbols Be careful! The tractor engine must ALWAYS be stopped and the ignition key removed before carrying out repairs or maintenance, cleaning, or lubricating the machine. Read and observe the instruction manual Be careful! Read and ensure you understand the instruction manual before the machine is used.
  • Page 8 Safety Risk of trapping fingers or hands Be careful as there is a risk that hands may be trapped. Be careful of moving parts. Risk from loose chippings Keep a safe distance from the machine. Do not allow any persons near the machine when it is working.

  • Page 9: Who Can Operate The Machine

    Safety Who can operate Operators of this machine should only be trained farmers and others who are qualified to work in agriculture and who are familiar with the machine? assembling equipment. Untrained or unauthorised persons must not use this machine. Connecting Correct attachment of the machine The machine must be correctly connected, following the instructions.

  • Page 10: Load Capacity

    Safety Only connect hydraulics when the system is depressurised You should only connect the hydraulic hoses to the tractor's hydraulics when the hydraulic system on both the tractor and the machine is depressurised. There is a risk that the machine will move accidentally. Unintentional movement of the machine may result in serious injuries.

  • Page 11: Transport On Public Roads

    Safety Transport on Ensure that the machine meets the Road Traffic Act's require- ments concerning its condition public roads When driving on public roads, the machine must comply with the Road Traffic Act's current requirements. This ensures your safety and that of other road users. Failure to meet the requirements can result in accidents.

  • Page 12: Use

    Safety The operator should receive careful instructions before using the machine The machine should only be used if the operator has been given thorough instructions. Thorough machine instruction allows safe usage. 95-002-1 fr Insufficient training may lead to incorrect usage of the machine and accidents.
  • Page 13 Safety Check the surrounding area before starting to use the machine Check the surrounding area before driving and using the machine. This prevents persons and animals in the vicinity from being harmed. If the surrounding area is not checked, it may result in serious injuries to persons or animals.

  • Page 14: Disconnection

    Safety Disconnection Increased risk of injury when disengaging There is an increased risk of injury when disengaging the machine from the tractor. Paying full attention to the above mentioned point ensures your safety 95-031 fr and that of others. Failure to pay attention to this point may result in serious injuries. Therefore, when disconnecting: •...

  • Page 15: Maintenance

    Safety Maintenance Comply with the service and maintenance intervals given in the instructions Comply with the intervals for service and maintenance as given in the instructions. By complying with the maintenance intervals you ensure that the machine will operate without malfunctions and provide maximum protection for the environment.
  • Page 16 Safety Be careful when cleaning with high pressure cleaning equipment Only use low pressure cleaning equipment to clean bearings, hydraulic hoses, plastic components, electrical control boxes and electrical equipment. Using low water pressure to clean will protect the sensitive equipment on the machine.

  • Page 17: Further Safety Instructions

    Safety Further safety Follow the instructions when working on the machine The machine safety instructions should always be complied with. instructions This will protect you and others from injury. Failure to follow the safety instructions may result in serious injuries. In addition to the safety instructions the following should be complied with: 95-005 fr...

  • Page 18: About The Machine

    About the machine About the machine This chapter includes general information about your machine. In addition, the following information is included: • The machine's field of application. • The machine characteristics. • View of the machine. • Technical data. The machine's 532 - 540 is a trailed mower intended for mowing common grass and cereal crops.

  • Page 19: Machine Characteristics

    About the machine Machine Description of the machine 532 - 540 is a trailed mower which operates on the tractor's right-hand characteristics side. The machine is trailed behind the tractor via a drawbar which is coupled to the tractor's lift arms. The drawbar is connected to the main frame of the machine which carries the whole machine on 2 powerful wheels.

  • Page 20: Synopsis

    About the machine Synopsis Hydraulic cylinder Cutting unit Swivel hitch Drawbar Main frame Support leg Spring Guard Swivel hitch PTO shaft Main gear...

  • Page 21: Technical Data

    About the machine Technical data Machine dimensions...
  • Page 22 About the machine Dim. Unit mm (‘-”) 4530 (14’ 10”) 5000 (16’ 5”) mm (‘-”) 4220 (13’ 10”) 4900 (16’ 1”) mm (‘-”) 3380 (11’ 1”) 3380 (11’ 1”) mm (‘-”) 1530 (5’) 1530 (5’) mm (‘-”) 3200 (10’ 6”) 4000 (13’...
  • Page 23 About the machine Machine specifications Specification Unit 1140 1250 Unladen weight 2513 2756 PTO (Power takeoff) 540/1000 Power requirement Number of cutting discs parts Number of knives parts RPM, cutting discs 3000 20-100 Stubble height ”-4” l/min 15 - 50 Hydraulic flow min/max gal/min (imp) 3.3 - 11...

  • Page 24: Tractor Requirements

    About the machine Tractor Tractor weight and size The tractor must be of the appropriate size for its weight. Local requirements legislation governing this ratio must be observed. The correct ratio between tractor and machine ensures correct braking functions and manoeuvrability. An incorrect ratio between tractor and machine can be dangerous.

  • Page 25: Preparation

    Preparation Preparing the Preparation The machine is divided into its main components for transport to the user. The machine must be assembled in accordance with the specific machine assembly instructions delivered with each machine. The following chapter is for initial assembly and shortening of the PTO shaft, etc.
  • Page 26 Preparation The swivel gear's rpm can also be checked by observing the gear's pivot joint. Check the swivel 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 rotational speed of 1000 rpm.
  • Page 27 Preparation 1000 RPM If the machine is to be fitted to a tractor's PTO shaft running at 1000 RPM, the following procedure must be followed:  Remove the PTO shaft.  Remove the bolts shown on both sides of the transmission. Bracket ...
  • Page 28 Preparation  Remove the bolts shown on both sides of the transmission. Bolt  Remove the transmission. Air release plug  Remove the air release plug and the oilplug and switch them over.  Remove the adapter for the PTO shaft. Oilplug Adapter...
  • Page 29 Preparation  Rotate the transmission 180 degrees. Bolt  Fit 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.). ...
  • Page 30 Preparation  Fit the bracket. Bracket  Fit the bolts on both sides of the transmission.  Tighten all bolts to a torque of 225 Nm. (165 ft/lb.) 225 Nm 165 ft/lb. Bolt  Force the corners of the lock plate back in against all the bolt heads.
  • Page 31 Preparation Tool box The machine is equipped with a tool box for storing standard hand tools, extra knives, etc. The tool box is used as follows:  Remove the pin.  Pull the took box out. The tool box can be used to store standard hand tools, extra knives, etc.

  • Page 32: Assembly - Attachment

    Assembly - attachment Assembly - attachment Coupling a tractor and a machine There is an increased risk of injury when attaching the machine to the tractor. Attention to the task will ensure your safety and that of others. Failure to follow the safety instructions may result in serious injuries. Therefore, when connecting the machine and the tractor you should: •...

  • Page 33: Attachment Of The Tractor

    Assembly - attachment Attachment of the Lock the tractor's lift arms Lock the tractor's lift arms at the correct height. tractor If the lift arms are at the correct height,it will prevent damage to the PTO shaft and injury to persons in the vicinity. Lowering or raising the lift arms can lead to injury and can damage the PTO shaft.
  • Page 34 Assembly - attachment Connecting the machine When connecting the machine there is an increased risk of injury. Attention to the task will ensure your safety and that of others. Failure to follow the safety instructions may result in serious injuries. Secure the attachment with the locking pin The attachment must be secured to the machine with the locking pin.
  • Page 35 Assembly - attachment  Lock the lift arms with a chain or solid bar between the lift arms and Chain* or solid bar highest point. * Optional equipment. → »Extra equipment« page 125  Attach the PTO shaft to the tractor. When checking and shortening the PTO shaft, refer to the manufac- turer's instructions, delivered with the PTO shaft.

  • Page 36: Hydraulic

    Assembly - attachment Hydraulic Safety Only connect hydraulics when the system is depressurised You should only connect the hydraulic hoses to the tractor's hydraulics when the hydraulic system on both the tractor and the machine is depressurised. There is a risk that the machine will move accidentally. Unintentional movement of the machine may result in serious injuries.

  • Page 37: Connection

    Assembly - attachment Connection Hydraulic connection Drawbar The tractor must be fitted with 2 sets of double acting hydraulic outlets, which are connected as follows: Hydraulic hose for: Function right Drawbar left Cutting unit down When connecting the hydraulic hoses you should check that: Cutting unit •...

  • Page 38: First Start-Up Of Machine

    Assembly - attachment First start-up of The initial test drive of the machine is important When the machine is connected to the tractor for the first time it must machine be test driven. Attention to the task will ensure your safety and that of others. Failure to follow the safety instructions may result in serious injuries.
  • Page 39 Assembly - attachment Checking the cutting unit Equalising the hydraulic system After a prolonged period without use with the cutting unit raised, there is a risk that the machine's cutting unit may sink unevenly in the machine's hydraulic cylinder. This means that the cutting unit is not parallel with the machine's main frame.
  • Page 40 Assembly - attachment Friction clutch Safety in connection with maintenance work on the machine When working on the machine the tractor must be stopped and secured. This prevents the PTO shaft from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 41 Assembly - attachment  Pull out and release the lock for the guard.  Open the machine's front guard.  Block the cutterbar by placing a wooden block between the two cutting discs.  Start the tractor and connect the tractor's PTO outlet. Wooden block ...
  • Page 42 Assembly - attachment  Loosen all the bolts on the friction clutch. Bolt  Fit and fasten the friction clutch on the machine.  Remove the wooden block from the cutter bar. Wooden block  Pull out and release the lock for the guard. ...

  • Page 43: Machine In The Transport Position

    Assembly - attachment Machine in the Check the surrounding area before starting to use machine Check the surrounding area before driving and using the machine. transport position This prevents persons and animals in the vicinity from being harmed. If the surrounding area is not checked, it may result in serious injuries to persons or animals.
  • Page 44 Assembly - attachment  Pull out and release the lock for the guard.  Swivel both guards upwards as shown.

  • Page 45: Transport On Public Roads

    Transport on public roads Safety Transport on public roads Read the safety instructions carefully before driving on public roads Before driving on public roads, you must read the safety instructions carefully. This will ensure that dangerous situations and accidents are avoided. Lack of information can cause accidents.

  • Page 46: Checking The Machine

    Transport on public roads Checking the Before travelling on the road the machine should be checked according to this check list: machine  Is the machine in the transport position?  Is the mowing device lifted all the way up? ...

  • Page 47: Operation

    Operation Safety Read the safety instructions before using the machine Operation Before using the machine, the operator should read the safety instruc- tions carefully. → »Safety« page 5 Attention to the task will ensure your safety and that of others. Failure to follow the instructions may result in serious injuries.

  • Page 48: Operation

    Operation Operation Safety The operator should receive careful instructions before using the machine The machine should only be used if the operator has been given thorough instructions. Thorough machine instruction allows safe usage. Insufficient training may lead to incorrect usage of the machine and accidents.
  • Page 49 Operation Setting Stubble height The stubble height is adjusted in the following way: • Making the top link longer reduces the stubble height. • Making the top link shorter increases the stubble height. Top link → The stubble height can be combined with fitting high skids* which can be used to set the stubble height as follows: Stubble height Note...
  • Page 50 Operation Balancing the cutting The balancing of the machine's cutting unit should be adjusted so that unit the downward pressure on the machine's cutting unit is about 40-60 kg (90-130 lb). The balancing of the cutting unit is adjusted in the following way: ...
  • Page 51 Operation Working in the field Check the surrounding area before starting to use the machine Check the surrounding area before driving and using the machine. This prevents persons and animals in the vicinity from being harmed. If the surrounding area is not checked, it may result in serious injuries to persons or animals.
  • Page 52 Operation  Check that the hydraulic mechanical safety valve is open. Valve  Connect the tractor's PTO outlet.  Carefully increase the speed on the PTO shaft to 540/1000 RPM. → »RPM on the PTO outlet« page 26  Activate the tractor hydraulics and turn the machine's drawbar to the right side of the tractor.
  • Page 53 Operation  Activate the tractor hydraulics and raise the cutting unit when turning at the headland.  Activate the tractor hydraulics and lower the cutting unit of the machine to its working position. Activate the tractor hydraulics until the hydraulic cylinders on the cutting unit are fully extended to their maximum length.

  • Page 54: Before Cleaning

    Cleaning Before cleaning Cleaning Higher risk when cleaning the equipment When cleaning, there is an increased risk of injury. Paying attention when carrying out cleaning work will ensure your safety and that of others. Failure to follow the safety instructions may result in serious injuries. Therefore, do the following before cleaning: •...

  • Page 55: Cleaning

    Cleaning Cleaning Use the correct cleaning agents Use only PH neutral cleaning agents when cleaning the machine. PH neutral cleaning agents give your machine maximum protection. Cleaning agents with either high or low PH value can be corrode plastic, rubber and painted surfaces. •...

  • Page 56: Parking And Storage

    Parking and Storage Before storage Parking and Storage At the end of the season, the machine should be prepared for storage:  Check and tighten all bolts. → »Torque moment« page 134  Repair any damaged components.  Replace any defective components. ...
  • Page 57 Parking and Storage Hydraulic Only disconnect hydraulics when the system is depressurised You should only disconnect the hydraulic hoses from the tractor's hydraulics if the hydraulic systems on both tractor and machine are depressurised. There is a risk that the machine will move accidentally. Unintentional movement of the machine may result in serious injuries.

  • Page 58: Storage

    Parking and Storage Storage At the end of the season, the machine should be prepared for storage: Carry out the following: • Clean the machine thoroughly. → »Cleaning« page 54 • Change the oil in all the machine's transmissions. → »Lubricants« page 134 •...

  • Page 59: Maintenance

    Maintenance For your own Maintenance Comply with the service and maintenance intervals given in the instructions safety Comply with the intervals for service and maintenance as given in the instructions. By complying with the maintenance intervals you ensure that the machine will operate without malfunctions and provide maximum protection for the environment.

  • Page 60: General Instructions

    Maintenance General instruc- These instructions concern general maintenance work. Specific maintenance work procedures for each machine will be described tions later. When performing any maintenance work the machine must be secured in the transport position. If the work position is necessary for performing maintenance work, you will find appropriate instructions to cover this.
  • Page 61 Maintenance Maintenance intervals • • Hydraulic hoses every 4 years • • Bearing/universal joint 66,65 • Cutting disc after 1 hour of use • • Cutting disc • Cutting disc after 1 hour of use • • Knives • • •...
  • Page 62 Maintenance • • Bevel gear • • • • • • Swivel hitch • • • • • • Universal joint • • • • Cutterbar • • • •...
  • Page 63 Maintenance Safety in connection with maintenance work on the machine When working on the machine the tractor must be stopped and secured. This prevents the PTO shaft from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.

  • Page 64: Lubrication

    Maintenance Lubrication Every 40 hours Drawbar  Press the nozzle of the grease gun over the grease nipples.  Pump the grease gun once or twice (max.). → »Maintenance intervals« page 61 → »Lubricants« page 134 58.237.000  Press the nozzle of the grease gun over the grease nipple. ...
  • Page 65 Maintenance Swivel hitch  Press the nozzle of the grease gun over the grease nipple.  Pump the grease gun once or twice (max.). → »Maintenance intervals« page 61 → »Lubricants« page 134 58.237.000 Cutting unit  Turn the cutting disc until both grease nipples are visible ...
  • Page 66 Maintenance Every 100 hours of PTO shaft  Find the hole in the band and turn the PTO shaft until the grease nipple is visible.  Press the nozzle of the grease gun over the grease nipples.  Pump the grease gun once or twice (max.). →...
  • Page 67 Maintenance As required Connecting links, etc.  Press the nozzle of the grease gun over the grease nipple.  Pump the grease gun once or twice (max.). → »Maintenance intervals« page 61 58.237.000 → »Lubricants« page 134 Spindle with springs ...

  • Page 68: Service - Check

    Maintenance Service - check Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 69 Maintenance Inspection - oil service Every day → »Maintenance intervals« page 61 The oil level for the cutterbar is checked as follows:  Place the machine on a level surface.  Activate the tractor hydraulics and raise the machine's cutterbar fully.
  • Page 70 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Check that the cutterbar is horizontal in the direction shown using a spirit level or similar tool. If the cutterbar is not horizontal, carry out the following: ...
  • Page 71 Maintenance Locate the oilplug on the left side of the cutterbar and remove it. • With warm oil: Wait approximately 3 minutes • With cold oil: Wait approximately 15 minutes  Check the oil level as shown and refill if necessary. •...
  • Page 72 Maintenance  Adjust the tractor's lift arms to the height shown. 620 - 630 mm (24 ’’ - 24 ’’) Chain or solid bar  Lock the lift arms with a chain or solid bar between the lift arm and highest point.
  • Page 73 Maintenance Gearbox Pay attention when carrying out oil change Use barrier cream or protective gloves when changing oil. It will protect your hands against skin injuries. Direct contact with the oil could lead to serious skin injuries. Use the correct oil type Always use the correct oil type for the transmission.
  • Page 74 Maintenance Swivel hitch Checking the oil level Every 80 hours of use → »Maintenance intervals« page 61 The oil level is checked as follows: The upper part of the swivel hitch  Remove oilplug 2.  Check that the oil is filled all the way up to the hole. Oilplug 2 ...
  • Page 75 Maintenance The lower part of the swivel hitch Oilplug 4  Remove oilplug 5.  Check that the oil is filled all the way up to the hole.  When topping up, remove oilplug 4.  Fill the oil through the hole for oilplug 4. •...
  • Page 76 Maintenance Knives Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 77 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Turn the cutting discs by hand until the damaged knife is in the position shown. 95 Nm +/- 5  Inspect the condition of the knives for wear. (70 ft/ lb.
  • Page 78 Maintenance Knife If the machine is fitted with knife quick release*, the same requirement applies for bolt wear. → »Knives« page 110 * Extra equipment → »Quick release of knives« Page 125. Min. φ16 mm (φ ”) Spring  Pull out and release the lock for the guard. ...
  • Page 79 Maintenance Cutting disc Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 80 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard. 80 Nm +/- 5 (59 ft/lb. +/- 4)  Inspect the condition of the cutting discs for deformities and cracks.  Use a suitable tool and tighten the cutting disc to a torque of 80 Nm (59 ft/lb.) ...
  • Page 81 Maintenance  Open the mechanical safety valve. Valve  Activate the tractor hydraulics and lower the cutting unit of the machine.
  • Page 82 Maintenance Cone Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 83 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Remove dirt from the cones on both sides of the machine. Clean the cones regularly  Pull out and release the lock for the guard. ...
  • Page 84 Maintenance  Open the mechanical safety valve. Valve  Activate the tractor hydraulics and lower the cutting unit of the machine. Internal inspection Every season → »Maintenance intervals« page 61 An internal check of the cones is carried out in the following way: ...
  • Page 85 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Remove the guard around the cutterbar's transmission. Guard...
  • Page 86 Maintenance  Carry out an inspection of the cone for dirt.  Clean the cone, if necessary.  Fit the guard around the cutterbar's transmission. Guard Top cover  Remove the top cover on the cones on the opposite side of the cutterbar.
  • Page 87 Maintenance  Open the mechanical safety valve. Valve  Activate the tractor hydraulics and lower the cutting unit of the machine.
  • Page 88 Maintenance Universal joint Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 89 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Remove the guard around the PTO shaft between the transmission and the cutterbar. Guard...
  • Page 90 Maintenance  Inspect both universal joints for wear. Universal joint Universal joint Bolts  Check for broken or loose bolts.  Replace the broken bolts.  Apply Loctite 242 or a similar product to all bolts.  Fit the bolts and tighten to the torque shown. 79 Nm (58 ft/lb.) Loctite 242...
  • Page 91 Maintenance If there are loose bolts the following procedure should be followed: Bolts  Remove and clean the bolts.  Apply Loctite 242 or a similar product to all bolts.  Fit the bolts and tighten to the torque shown. 79 Nm (58 ft/lb.) Loctite 242...
  • Page 92 Maintenance  Open the mechanical safety valve. Valve  Activate the tractor hydraulics and lower the cutting unit of the machine.
  • Page 93 Maintenance Stone guard and Safety concerning maintenance work on the cutting unit counter knife When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 94 Maintenance  Carry out a visual inspection of the machine's stone guard and counter knife for wear. Stone guards and counter knives with visible holes caused by heavy wear must be replaced immediately. → »Stone guard and counter knife« page 120 ...
  • Page 95 Maintenance Friction clutch Safety concerning maintenance work on the transmission When working on the transmission the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 96 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Block the cutterbar by placing a wooden block between the two cutting discs.  Start the tractor and connect the tractor's PTO outlet. Wooden block ...
  • Page 97 Maintenance  Loosen all the bolts on the friction clutch. Bolt  Fit and fasten the friction clutch on the machine.  Remove the wooden block from the cutter bar. Wooden block  Pull out and release the lock for the guard. ...
  • Page 98 Maintenance Wheel After 10 working hours Thereafter, every season Bolts → »Maintenance intervals« page 61  Use a suitable torque wrench adjusted to the torque shown in the table below.  Place the wrench on the wheel bolts.  Check all the bolts on the wheels and tighten them to the torque shown.
  • Page 99 Maintenance Tarpaulin Safety concerning maintenance work on the cutterbar When working on the cutterbar, the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.

  • Page 100: Replacement

    Maintenance Replacement Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 101 Maintenance  Activate the tractor hydraulics and raise the machine's cutterbar fully. Valve  Close the mechanical safety valve.  Pull out and release the lock for the guard.  Open the machine's front guard.
  • Page 102 Maintenance It is important that the machine is correctly secured with a sturdy support before work is started.  Locate the oilplug on the left-hand side of the cutterbar.  Remove the oilplug.  Let the oil flow into a suitable container. ...
  • Page 103 Maintenance  Remove the oilplug to check the oil level.  Fill up with the new oil until the oil level is as shown. Model Litre Pint (US) Pint (imp) (approx.) (approx.) (approx.) 10.8  Check the oil level using a measuring instrument. →...
  • Page 104 Maintenance  Open the mechanical safety valve. Valve  Adjust the tractor's lift arms to the height shown. It is important that the PTO shaft between the tractor and machines is horizontal. If the PTO shaft is not horizontal, the universal joint in the axle may be damaged.
  • Page 105 Maintenance Transmission Pay attention when carrying out oil change Use barrier cream or protective gloves when changing oil. It will protect your hands against skin injuries. Direct contact with the oil could lead to serious skin injuries. Use the correct oil type Always use the correct oil type for the transmission.
  • Page 106 Maintenance  Remove the dipstick.  Pour the oil through the hole where the dipstick is fitted. Dipstick  Follow the instructions on the machine.  Check that the oil level is up to the “max” indication on the dipstick. ...
  • Page 107 Maintenance Swivel hitch Changing oil After 10 working hours Thereafter, every season The upper part of the swivel hitch Oil amount when changing oil: Litre Pints (US) Pints (Imp.) (approx.) (approx.) (Approx.) The oil is changed as follows:  Remove the guard. ...
  • Page 108 Maintenance  Remove oilplug 1 and 2. Oilplug 1  Fill the new oil through the hole for oilplug 1. • The correct oil level is reached when the oil reaches the edge of the hole for oilplug 2.  Fit oilplugs 1 and 2 and tighten them. →...
  • Page 109 Maintenance The lower part of the swivel hitch → »Maintenance intervals« page 61 Oil amount when changing oil: Litre Pints (US) Pints (Imp.) (approx.) (approx.) (Approx.) The oil is changed as follows: Oilplug 4  Use a suitable tool to remove oilplug 6. ...
  • Page 110 Maintenance Knives Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 111 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Turn the cutting discs by hand until the damaged knife is in the 95 Nm +/- 5 position shown. (70 ft/ lb. +/- 4) ...
  • Page 112 Maintenance Knife If the machine is fitted with knife quick release*, the same requirement applies for bolt wear. → »Knives« page 76 * Extra equipment → »Quick release of knives« Page 125. Min. φ16 mm ( ”) Spring  Pull out and release the lock for the guard. ...
  • Page 113 Maintenance Cutting disc Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 114 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Use a suitable tool to remove the cutting disc. Bolt  Remove the bolt and knife from the cutting disc. 95 Nm +/- 5 (70 ft/ lb.
  • Page 115 Maintenance  Apply Loctite 242 or a similar product to all bolts.  Fit the cutting disc on the cutterbar. 80 Nm +/- 5 (59 ft/lb. +/- 4)  Use a torque wrench to tighten the bolt to the torque shown. Loctite 242 Bolt ...
  • Page 116 Maintenance  Activate the tractor hydraulics and lower the cutting unit of the machine.
  • Page 117 Maintenance Universal joint Safety concerning maintenance work on the cutting unit When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 118 Maintenance  Pull out and release the lock for the guard.  Open the machine's front guard.  Fit the guard around the PTO shaft between the transmission and the cutterbar. Guard Bolts  Remove the bolts and replace the PTO shaft. ...
  • Page 119 Maintenance  Pull out and release the lock for the guard.  Close the machine's front guard. Valve  Open the mechanical safety valve.  Activate the tractor hydraulics and lower the cutting unit of the machine.
  • Page 120 Maintenance Stone guard and Safety concerning maintenance work on the cutting unit counter knife When working on the cutting unit the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 121 Maintenance  Remove the worn stone guard and counter knife.  Fit the new stone guard and counter knife. Stone guards and counter knives with visible holes caused by heavy wear must be replaced immediately.  Remove the support. Valve ...
  • Page 122 Maintenance Friction clutch Safety concerning maintenance work on the transmission When working on the transmission the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.
  • Page 123 Maintenance  Bend back the edges of the clutch housing shown. Edge of the friction housing  Take the friction clutch apart and replace the friction discs.  Assemble the friction clutch. Edge of the friction housing  Bend the edges of the clutch housing shown back in again. ...
  • Page 124 Maintenance Tarpaulin Safety concerning maintenance work on the cutterbar When working on the cutterbar, the tractor must be stopped and secured. This prevents the machine from suddenly starting to rotate. If the tractor and the PTO shaft have not been connected in accordance with the instructions, serious accidents causing damage to limbs can occur.

  • Page 125: Extra Equipment

    Extra equipment High skids Extra equipment The machine can be fitted with high skids if a higher stubble height is required. The skids are available in the following heights: • 20 mm • 40 mm • 80 mm High skids are recommended for uneven fields with lots of stones or molehills.

  • Page 126: Chain For Locking The Lift Arms

    Extra equipment Chain for locking 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 the lift arms tractor and one of the lift arms. →...

  • Page 127: Coupling For The Tractor's Drawbar Tongue

    Extra equipment Coupling for the A specially designed coupling for the tractor's drawbar tongue and a jack are available as extra equipment. tractor's drawbar tongue...

  • Page 128: Troubleshooting

    Troubleshooting Electric and Troubleshooting hydraulic system Fault Possible cause Remedy Page Check that the hydraulic hoses are correctly connected to the tractor's The machine's hydraulic functions do hydraulic outlet not work Hydraulic system Make sure that the tractor hydraulics are engaged. The machine's hydraulic functions Insufficient amount of oil from the seem sluggish...

  • Page 129: Pto Shaft

    Troubleshooting PTO shaft Fault Possible cause Remedy Page The RPM on the PTO shaft is too low Check RPM The friction clutch on the PTO shaft Check the friction discs in the coupling The friction discs in the coupling are becomes worn abnormally warm...

  • Page 130: Guidelines For Warranty

    Warranty Guidelines for Warranty The warranty period for our product is 12 months from the date of purchase. The warranty does not include the parts subject to wear. warranty Warranty claims can be made with Kverneland warranty application which must be filled out by your local Kverneland dealer where your machine/equipment was purchased.

  • Page 131: Disposal

    Disposal Disposal When the machine reaches the end of its service life, it must be disposed of in the correct way. Observe the following: Metal parts Send usable parts to an authorised recycling plant. Larger scrap parts must be taken to an authorised breaker's yard where they can be processed in accordance with current regulations.

  • Page 132: Eu Declaration Of Conformity

    42/EC Taarupstrandvej 25 DK - 5300 Kerteminde Denmark hereby declare under our sole responsibility that the following product: Extra 532 - 540 and ancillary equipment Applicable as from machine No: KT447406 CE plate and type plate which the declaration refers to complies with the fundamental safety requirements in the EU Directive 2006/42/EC.

  • Page 133: Notes

    Notes Notes...

  • Page 134: Technical Information

    Technical information Conversion table Technical information Basic unit: SI - unit Conversion figures: Length 39.4 in = 3.3 ft = 1.1 yrd = 0.00062 miles (US) Area 1.2 yd = 10.8 ft = 0.00025 acre = 0.0001 ha Volume 1 dm (1 l) 61 in = 0.035 ft...

  • Page 135: Index

    Index Index Assembly - attachment Notes Attachment of the tractor Machine in the transport position Parking Disconnection of the machine Before the machine is connected Storage Preparing the machine Checking the cutting unit Cleaning Conversion table Replacement Cutting disc Friction clutch Knives Disposal Oil, bevel gear...
  • Page 136 Index Tractor requirements Transport on public roads Checking the machine Travelling on public roads Travelling on public roads Troubleshooting Warranty...

This manual is also suitable for:

Extra 540

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