Vicon Extra 532 User manual

1
Technical Service Manual
Trailed plain mower
Extra 532-540

Date 08-08-2018
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
Additional Information

Table of contents
3
1.0 General information
1.1 Machine specification 4
1.2 Machine dimensions 5
1.3 Safety symbols 6
1.4 Changing RPM 13
2.0 Attachment
2.1 Stetting of 540 o 1000 pm fo PTO 14
2.2 Attaching the machine to the t acto 15
2.3 Bleeding PTO 18
2.4 Fi st sta t up of machine 19
2.5 Adjusting g ound p essu e 20
2.6 Setting stubble height 21
3.0 Maintenance
3.1 Basic inst uctions 24
3.2 To ques 25
3.3 Maintenance inte vals 26
4.0 Components
4.1 PTO's - clutch 27
4.2.1 Lifting cylinde s 33
4.2.2 Replacement cylinde (s) 36
4.3 Stee ing cylinde 38
4.4 P ess elieve valve 39
4.5 Hyd aulic diag ams with functions 40
4.6 Swivel gea box incl. epai inst uctions 43
4.7 Bevel gea box incl. epai inst uctions 51
4.8 Cutte ba details 58
4.8.1 Cutte ba epai inst uctions 65
4.8.2 Cutte ba maintenance 75
4.8.3 Cutte ba ; changing oil 78
4.9 Bevel gea box; changing oil 79
4.9 Swivel gea box; changing oil 80
4.1 Lub ication 81
4.1 Wheel info incl. to que and hub info 83
5.0 Options 84
6.0 Troubleshootin 88

Kubota
1.1 Machine specifications
4

Machine dimensions Machine dimensions
Extra 532 Extra540
1.1 Machine specifications
5

Safety symbols for the US and Canada
On the machine you will find labels relatin to your safety. These
labels must not be removed. If the labels become ille ible or detached,
new labels can be ordered and affixed to the relevant areas.
1.3 Safety labels US and Canada
6

Safety symbols for the US and Canada
1.3 Safety labels US and Canada
7

Safety symbols for the US and Canada
1.3 Safety labels US and Canada
8

Lighting and reflective devices - USA
The machine is equipped with lighting and reflective devices as
a standard, which serve to ensure safety on the roads. Lighting
and reflective equipment shall be in good and sound condition
at all times. Lights and labels must not be removed from the
machine. Illegible or missing labels must be 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 machine, so
that it is clearly visible at all times when the
machine is in the transport position. This sign
is for machines that are being transported at
speeds of less than 40 km/h (25 mph) on
public roads.
This machine must be transported on public roads at speeds
of less than 40 km/h (25 mph) only.
1.3 Safety labels US and Canada
9

Safety symbols
On the machine you will find labels relatin to your safety. These
labels must not be removed. If the labels become ille ible or detached,
new labels can be ordered and affixed to the relevant areas.
1.3 Safety labels
10

Safety symbols
1.3 Safety labels
11

Safety symbols Safety symbols
1.3 Safety labels
12

Changing the rpm
Changing the rpm
Checking the rpm
Checking the rpm
Checking the rpm
Checking the rpm
Checking the rpm
Checking the rpm
• The swivel gear can be
switched to 2 modes, 540 rpm
or 1000 rpm.
From the factory the
machine is adapted to
tractors that run at 540 RPM
on the PTO.
• The swivel gear is factory-
fitted with a sign that gives the
tractor's PTO shaft rpm.
• If the sign shows 1000 rpm,
the machine must run at a
rotational speed of 1000 rpm.
• If the sign shows 540 rpm, the
machine must run at a
rotational speed of 540 rpm.
• 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.
• For 1000 rpm. 3 turns for the
disc. makes one turn on
tractors PTO outlet.
• If the swivel gear's profile on
the lower part of the swivel
gear is narrow, the machine
should be run at a rotational
speed of 540 rpm.
• For 540 rpm.; ± 6 turns for
the disc will make one turn on
tractors PTO outlet
In case the RPM need to be
changed;
• Disassemble the gearbox
from the drawbar.
• Remove the air release plug
and the oil plug and switch
them over by using a suitable
sealant on the tapered
threads of the plugs.
• Remove the adapter for the
PTO shaft and switch it over
to the other side.
2.1 Setting 540 or 1000 rpm for PTO
13

Changing the rpm
Changing the rpm
Changing the rpm
Changing the rpm
Changing the rpm
Changing the rpm
Changing the rpm
Changing the rpm
• Rotate the transmission 180
degrees
• Fit the transmission.
• Do not forget the lock plate’s .
• Fit the bolts on both sides of
the transmission
• Tighten all bolts to a torque of
225 Nm. (165 ft/lb.).
• Fit the bracket.
• Fit the bolts on both sides of
the transmission.
• Tighten all bolts 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 around!
• Reason for that;
*The level plugs have the same
position in both gearboxes but
the bottom part = ex top part
will have less oil volume
because before the gearwheel
was in that position in the oil.
*The top part = ex bottom part
with more oil volume as the
gearwheel was not in the oil,
has now the gearwheel in the
bottom so in the oil resulting in
a too high level!
14
2.1 Setting 540 or 1000 rpm for PTO

Attachment of the tractor
Attachment of the Quick
Coupler.
Attachment of the tractor
Attachment of the Quick
Coupler.
Attachment of the tractor
Attachment of the Quick
Coupler.
Attachment of the tractor
Attachment of the tractor
We have 2 standard versions;
• Quick Coupler; the one shown
on the LH side, is standard on
machines for all countries
except the US.
The Clevis 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 lower link crossbar
to the side or remove the
lower link crossbar.
• Raise or lower the tractor's lift
arms until the swivel hitch can
be mounted on the tractor's lift
arms.
• Fit the swivel hitch on the
tractor's lift arms.
• Secure the attachment with
the locking pin on both lift
arms.
• Attach the PTO shaft to the
tractor.
• The chain is an option!
2.2 Attachment to tractor
15

Attachment of the tractor
Clevis Coupler on the lower
link crossbar
Attachment of the tractor
Attachment of the Quick
Coupler.
• Adjust the tractor's lift arms to
the height shown.
• Fit the PTO.
Attachment of the tractor
In order to connect machines in
compliance with ISO 6489-3, the
following shall be observed:
• (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”).
Clevis Coupler on the lower
link crossbar
Adjust the plates to tighten the
coupling against the lower link
crossbar until you reach a play
of 0,5 mm - 1 mm (1/32“ - 1/16“ )
Attachment of the tractor
Parking stand
Connect the machine to the
tractor.
• Secure the coupling using the
locking pin.
• Remove the parking foot from
the bracket and install it on
the holder on the side of the
drawbar.
2.2 Attachment to tractor
16

Hydraulic connection to
tractor
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. The problem can be
solved by as follows:
• Activate the tractor's
hydraulics and lower the
machine's cutting unit down to
the ground.
• Continue to run the tractor's
hydraulic system for approx.
2-5 minutes. This ensures the
machine's hydraulic cylinders
are emptied of any air.
X
• The tractor must be fitted with
2 sets of double acting
hydraulic outlets, which are
connected as follows:
•Xfor the drawbar for steering
unit to the right or to the left
•Y for lifting and lowering of
the cutting 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
• For lifting and lowering of the
cutting unit use always double
acting and be sure that the
cylinder is extended
completely = bolt half way in
the slot hole.
Only then the unit is free to
float up and down
Never use float position!
Working position lifting cylinders
PTO length
PTO length
It is important that the P.T.O.
shaft between the tractor and the
machine is horizontal. If the
P.T.O. shaft is not horizontal, the
universal joint in the shaft may be
damaged. Check the length of
the PTO.
When inspecting and shortening
the P.T.O shaft, please refer to
the manufacturer's description
pertaining to the P.T.O shaft.
• Check to see that the halves
of the shafts have a minimum
overlap of 200 mm (8") [b].
• Check to see that the P.T.O.
shaft has a minimum
clearance of 20 mm (7/8") [a].
2.2 Attachment to tractor
17

Bleeding of the clutch.
Bleeding of the clutch
Bleeding of the clutch.
Bleeding of the clutch
Bleeding of the clutch.
Bleeding of the clutch.
The friction clutch is bled in the
following way:
• Open the guard and remove
the PTO shaft with the friction
clutch.
• Tighten all bolts on the friction
clutch.
• Fit and fasten the friction
clutch on the machine.
• Block the cutter bar by placing
a wooden block 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 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.
• Disconnect the PTO outlet
and stop the tractor.
• Remove the friction clutch
from the machine.
• Loosen all the bolts on the
friction clutch.
• Fit and fasten the friction
clutch on the machine.
• Remove the wooden block
from the cutter bar.
2.3 Bleeding of slip clutch
18

First start-up of machine
First start-up of machine
First start-up of machine
First start-up of machine
• The side guard for the cutting
unit must be correctly
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 runs
smoothly without any
vibrations.
• Return the PTO shaft to idle
speed.
• Activate all the hydraulic
functions of the machine, one
by one.
2.4 First start up
19

Balancing the cutting unit
Spring dimensions
Balancing the cutting unit
Balancing the cutting unit
Balancing the cutting unit
Balancing the cutting unit
• The balancing of the machine's
cutting unit should be adjusted
so that the downward pressure
on the machine's cutting unit is
about 40-60 kg (90-130 lb).
• Undo the counter nuts from
both springs
• 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 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 lifting the cutting
unit by hand, gripping both
sides of the cutting unit in the
places shown.
• 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) .
Extra 532;
RH side; N = 42,5 – Ø10 mm.
LH side; N = 41,5 – Ø12 mm.
Extra 540;
RH side; N = 45,5 – Ø12 mm.
LH side; N = 45,5 – Ø13 mm.
Note; N = number of turns
Ø = wire diameter.
Counter nut
2.5 Adjusting ground pressure
20