Vicon Extra 532 User manual

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

Extra 532 - 540
Machine identification
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
Operating width
Weight
Machine
number
Accessories
Address of
supplier
Address of
manufacturer
Copyright Kverneland Group Kerteminde AS, Denmark. Copying, reproduction in any form, translation, or use of excerpts or parts of this document
are not permitted without specific permission from Kverneland. All rights reserved. The contents of this manual may be changed without prior
warning. Rights reserved for technical amendments and printing errors in this manual.
Kverneland Group Kerteminde AS
Taarupstrandvej 25
DK -5300 Kerteminde - Denmark
Tel./fax: [phone]
web: www.kvernelandgroup.com
532: 3.2m (10’ 6”) ; 540: 4.0m (13’ 1½”)
532: 1140kg (2513lb); 540: 1250kg (2756lb)

Table of contents
3
Table of contents
Contents .................................................... 4
Target group 4
The meaning of the symbols 4
Safety ......................................................... 5
For your own safety 5
Who can operate the machine? 9
Connecting 9
Load capacity 10
Transport on public roads 11
Use 12
Disconnection 14
Maintenance 15
Further safety instructions 17
About the machine ................................... 18
The machine's field of application 18
Machine characteristics 19
Synopsis 20
Technical data 21
Tractor requirements 24
Preparation ................................................ 25
Preparing the machine 25
Assembly - attachment ............................ 32
Attachment of the tractor 33
Hydraulic 36
Connection 37
First start-up of machine 38
Machine in the transport position 43
Transport on public roads ....................... 45
Safety 45
Before travelling on public roads 45
Checking the machine 46
Travelling on public roads 46
Operation ................................................... 47
Safety 47
Before operating 47
Operation 48
Cleaning .................................................... 54
Before cleaning 54
Cleaning 55
After cleaning 55
Parking and Storage ................................. 56
Before storage 56
Parking/disconnection of the machine 56
Storage 58
Maintenance .............................................. 59
For your own safety 59
General instructions 60
Lubrication 64
Service - check 68
Replacement 100
Extra equipment ........................................ 125
High skids 125
Quick release of knives 125
Chain for locking the lift arms 126
Lighting kit 126
Coupling for the tractor's drawbar tongue 127
Troubleshooting ........................................ 128
Electric and hydraulic system 128
Cutterbar 128
PTO shaft 129
Warranty ..................................................... 130
Guidelines for warranty 130
Disposal ..................................................... 131
Metal parts 131
Rubber parts 131
Plastic 131
Hydraulic oil 131
Electronic parts 131
EU declaration of conformity ................... 132
EU Directive 2006/42/EC 132
Notes .......................................................... 133
Technical information ............................... 134
Conversion table 134
Lubricants 134
Torque moment 134
Index ........................................................... 135

Contents
4
Contents
Target group
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.
For the employer
Every employee must be trained in how to use this machinery at
regular intervals (at least once a year) in accordance with the
employer's insurance guidelines. Untrained or unauthorised persons
must not use this machine.
Instructions
Your dealer will assist with the instructions on how to use and maintain
this machinery.
The meaning of
the symbols
We have used different symbols to make the text clear. An explanation
follows:
•A dot symbol marks a list of instructions or information.
A triangle marks an action you must carry out.
→An arrow refers you to other parts of the text.
We have also used pictograms to help you find relevant places in the
text.
Denotes tips or instructions on use.
Denotes information that requires particular attention.
A spanner marks tips concerning assembly and adjustment of the
machine.
A warning triangle indicates important safety instructions. If these are
not adhered to, it may result in:
•Serious errors in the machine function.
•Damage to the machine.
•Injury or accident.

Safety
5
Safety
For your own
safety
This chapter includes general safety instructions. In addition, each
chapter in the instruction manual includes specific safety instructions
not set out here. The safety instructions must be complied with
•For your own safety.
•For the safety of others.
•To ensure the safety of the machine.
When working with agricultural machines, incorrect handling can
result in various dangers. Therefore, you should always be very
thorough and never work under pressure.
The operator must be receive regular training
Persons working with the machine must receive regular training on
these safety instructions.
The safety instructions should be complied with in accordance with
local legislation concerning agricultural machines.

Safety
6
Safety symbols
On the machine you will find labels relating to your safety. These
labels must not be removed. If thelabels become illegible or detached,
new labels can be ordered and affixed to the relevant areas.
STOP
STOP

Safety
7
The meaning of the
symbols
Stop the tractor before working on the machine
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.
Ensure no clothing/body parts get caught in the PTO shaft
Guards may not be removed or opened until the machine has stopped
rotating. The tractor engine must be stopped, the ignition key removed
and the handbrake applied.
Danger of being crushed by the machine's cutting unit
The safety valve must always be closed during repair or maintenance
operations on the machine's cutting unit. The tractor must always be
stationary, with the ignition key removed before repair or maintenance
operations are undertaken on the machine.
Use the correct support for the machine
Your body could become caught!
Never work under the machine without using the correct support. The
tractor engine must be stopped, the ignition key removed and the
handbrake applied.

Safety
8
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. If the guard is damaged, it must
be replaced.
Risk of injury to feet
Keep away from the machine. The protection must always be in place
when the machine is working.
Risk of injury to feet
The safety guard must always be in place when the machine is
working.
STOP

Safety
9
Who can operate
the machine?
Operators of this machine should only be trained farmers and others
who are qualified to work in agriculture and who are familiar with
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.
The machine can become detached from the tractor if the connection
is not carried out properly.
Incorrect attachment can lead to accidents.
When attaching the machine to the tractor you must therefore:
•Make sure that the tractor cannot roll.
•Make sure that the tractor and the machine belong to the same
category.
•Never stand between the tractor and the machine during
attachment.
•Use the hydraulic three point suspension slowly and carefully.
Paying full attention to the above mentioned points ensures your
safety and that of others.
Failure to follow the above instructions may result in serious injuries.
PTO shaft check
Refer to the manufacturer's maintenance and safety instructions
delivered with the PTO shaft.
Make electrical connection after attachment
When fitting the lighting device, the power supply to the tractor must
be turned off.
This will prevent short circuits and damage to the electric circuit.
There is a risk of burns and other serious injuries if the electrical
systems short circuit.
95-021 f
r
95-015 fr

Safety
10
Only connect hydraulics when the system is depressurised
You should onlyconnect the hydraulic hoses tothe 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.
The hydraulic system should be checked regularly
All hoses and fittings should be checked regularly for visible damage.
Hydraulic hoses also wear without any visible damage.
Defective hydraulic hoses can cause injury or fire.
Colour marking of hydraulic connections
The hydraulic connections between the tractor and the machine must
be marked in different colours.
By marking the hydraulic connections you prevent the machine from
being incorrectly operated.
Incorrect operation or unintentional movement of the machine may
result in serious injuries.
Load capacity
Compliance with total weight, axle pressure, carrying capacity of
the tyres, and minimum weight
Neither the tractor's total weight, axle pressure or thecarrying capacity
of the tyres may be exceeded with front mounted and rear mounted
machines.
To ensure the manoeuvrability of the tractor, the load on the front axle
must be at least 20% of the tractor's weight.
Failure to do so can result in a loss of driving control and accidents.
Be careful when working around the PTO shaft
When working on the PTO shaft, the tractor PTO outlet must be
disconnected, the tractor must be stopped and the ignition key
removed.
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.
Weight/power ratio between machine and tractor
The machine may only be connected to a tractor of the correct size
and performance.
The tractor's size and P.T.O outlet must correspond to the power
consumption of the machine and its weight.
Wrong weight/power ratio can result in damage to both machine and
tractor.
95-009
fr
95-006-2 fr
95-006-1 fr
95-006-3 fr
kg
HP/kW

Safety
11
Transport on
public roads
Ensure that the machine meets the Road Traffic Act's require-
ments concerning its condition
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.
Compliance with the Road Traffic Act'scurrent requirementsincludes,
for example:
•Mounting of lights, warning and safety equipment.
•Compliance with permitted transport width, weight, axle pressure,
tyre carrying capacity and total weight.
Carrying passengers on the machine is prohibited
It is dangerous and illegal to carry passengers on the machine.
The machine is not approved for personal transportation.
Transporting persons on the machine may result in serious injuries
and death.
Mounted machines will change the driving and braking abilities
of the tractor
Be aware of changed driving and braking abilities when driving with
mounted machines.
You should be especially aware of the machine's width and length
when driving around bends and turns.
Serious accidents and a loss of driving control may result if this is not
taken into account.
Adjust the speed according to the road conditions
Adjust driving speed according to the conditions on the road.
Poor road conditions and high speeds can lead to parts of the tractor
and machine being overloaded.
Driving too fast can lead to accidents and damage both the machine
and the tractor.
95-012 fr
95-011
fr
95-011
fr

Safety
12
Use
Theoperatorshouldreceivecarefulinstructionsbeforeusingthe
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.
Check that the machine has no technical faults
Only use the machine if it has no technical faults.
This ensures that the machine is operating correctly and safely.
A machine with technical faults and defects can be dangerous.
Do not remove the protective guards
Check that all protective guards are in place before use.
This ensures that the machine will give maximum protection to the
operator.
If the safety guards are removed or not used, it may result in serious
injuries and accidents.
Check the tyre pressure regularly
Carry out regular checks of the tyre pressure.
This ensures the machine is being driven under optimum conditions
and prevents accidental banking on curves or corners.
Careening on bends and turns can lead to accidents.
Carrying passengers on the machine is prohibited
It is dangerous and illegal to carry passengers on the machine.
The machine is not approved for personal transportation.
Transporting persons on the machine may result in serious injuries
and death.
95-002-1
fr
95-031 fr
95-093
fr
95-011
fr

Safety
13
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.
Keep away from the machine
No unauthorised persons should be close to the machine during
operation.
This will ensure that no dangerous situations can arise.
Persons close to the machine during operation are at risk of being
severely injured.
Checking bolts on moving parts
Check that all bolts on moving parts are correctly tightened.
Tightening parts prevents moving parts jarring.
Parts which are not correctly tightened can work loose and damage
the machine.
Maintain the rotational speed on the tractor PTO outlet
It is dangerous to connect a tractor with PTO = 1000 rpm to a machine
intended for PTO = 540 rpm.
The machine is not designed for this speed.
It can result in damage to the machine and be dangerous to any
persons in the vicinity.
Check the transmission oil level regularly
Check that the transmission is filled with oil and that the oil level is
correct.
A correct oil level ensures the transmission a long and trouble free
service life.
An incorrect oil level will damage the transmission.
Stop the machine immediately in case of malfunction
In case of malfunction, the machine should be stopped immediately.
A machine malfunction can be endanger any persons and animals in
the vicinity.
Malfunctioning machines can cause dangerous situations to arise.
95-018
fr
95-006-1 fr
95-017
fr
95-031 fr

Safety
14
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
and that of others.
Failure to pay attention to this point may result in serious injuries.
Therefore, when disconnecting:
•Make sure that the tractor cannot roll.
•Never stand between the tractor and the machine during
disconnection.
•Use the hydraulic three point suspension slowly and carefully.
•Make sure that the machine is standing on a safe, level surface.
•When depressurising the hydraulic system for both tractor and
machine, first disconnect the hydraulic hoses.
95-031 fr

Safety
15
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.
An incorrectly maintained machine is a danger to the environment.
Always use original spare parts on the machine
Always use original spare parts.
Original spare parts should be used for safety reasons
The manufacturer takes on no warranty responsibility in cases where
non-original spare parts are used.
High risk when performing service and maintenance work
When performing service or maintenance work there is a higher risk
of injury.
Paying full attention to the above mentioned point ensures your safety
and that of others.
Failure to pay attention to this point may result in serious injuries.
Therefore, when you perform maintenance work:
•Disconnect the P.T.O shaft.
•Depressurise the hydraulic system.
•Stop or disconnect the tractor.
•Check that the machine is parked safely, support it if necessary.
•Do not use parts of the machine to climb onto it, the correct units
for climbing must be used.
•Make sure that the machine can not start rolling.
Disconnect the power source when working on the electrical
systems
Always disconnect the power source before you start working on the
electrical system.
This will prevent short circuits and damage to the electric circuit.
There is a risk of burns and other serious injuries if the electrical
systems short circuit.
Replacing the hydraulic hoses
Replace the hydraulic hoses at least once every 4 years.
Hydraulic hoses also wear without any visible damage.
Defective hydraulic hoses may cause serious injury.
95-007 fr
95-009
fr

Safety
16
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.
Using high water pressure to clean could damage vital parts of the
machine.
Disconnect the battery and the alternator before welding
The tractor battery and alternator should be disconnected before
performing welding work on the machine.
This will protect the tractor alternator during welding work.
The tractor alternator could be damaged or destroyed if the electric
connections are not disconnected before welding.
Tighten all fittings on moving parts
Check that bolts on moving parts are tightened after performing
maintenance work.
Tightening parts prevents moving parts jarring.
Parts which are not correctly tightened can work loose and damage
the machine.
Do not alter the machine construction
The technical construction of the machine should not be altered and
machine maintenance should be performed.
A well maintained machine will offer maximum protection.
A poorly maintained machine will not offer proper protection and could
be dangerous.
95-018
fr
95-014 fr

Safety
17
Further safety
instructions
Follow the instructions when working on the machine
The machine safety instructions should always be complied with.
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:
•Environmental legislation.
•The general technical, medical and road act regulations.
•Instructions in this instruction manual.
•Instructions for use, maintenance and service.
95-005
fr
95-013 fr

About the machine
18
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
field of application
532 - 540 is a trailed mower intended for mowing common grass and
cereal crops. The instructions for use are given in the following
chapters.
Correct usage of the
machine
The machine can be used in fields for mowing the following crops:
•All types of grass
•All types of clover
•Whole crop
•Alfalfa
•Sorghum
Incorrect use of the
machine
The machine must not, under any circumstances, be used for the
following:
•Cutting grass in park facilities and lawns
•Cutting grass on the verges of public roads
•Harvesting corn
•Clearing forest floors or other densely wooded areas
Similar use is outside the intended applications of the machine.
The manufacturer is not liable for any damages caused by incorrect
usage of the machine. The user is wholly liable for the machine.

About the machine
19
Machine
characteristics
Description of the machine
532 - 540 is a trailed mower which operates on the tractor's right-hand
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. The machine can be set in either the transport position or the
working position using the drawbar which is operated using the
tractor's hydraulic system.
The machine's cutting unit is hydraulically connected to the main
frame of the machine and can be lowered using the tractor's hydraulic
system. The cutting unit is balanced using strong springs which
secure the machine's cutterbar, following the ground precisely and
cutting the crop uniformly.
The machine's cutting discs are equipped with durable, reversible
knives, which have a high capacity when used at a high speed of
rotation, even for difficult crops.
Even at high mowing speeds, the machine is able to mow the crop
cleanly and uniformly. For safety reasons, it is recommended that the
speed does not exceed 15 km/h (9 mph).
The cutting unit is fitted with a guard, which protects it against moving
objects. The guard, or parts of the guard, must never be removed from
the machine and must always be kept in good condition.
Solid construction
Thanks to a solid construction and its flexibility, the machine is both
strong and reliable.
Quick and easy lifting of the cutterbar when turning on the
headland
The machine's cutterbar is raised hydraulically without the use of tools
on the headland.
Your safety when using the machine
To make working with the machine as safe as possible the machine
complies with EC regulations. The machine is CE marked.

About the machine
20
Synopsis
Spring
Main frame
Main gear
Cutting unit
Guard
Drawbar
Support leg
PTO shaft
Swivel hitch
Swivel hitch Hydraulic cylinder