Service training
Service training
1
Safety regulations
2
Technical data
3
Electrical equipment
4
Adjustment and service instructions
5
Testing instructions
6
Hydraulics
7
Pressure adjustments
8
Extra equipments
9
Scheduled maintenance
10
Service training
Safety regulations
Safety while servicing and repairing: 1.
Use caution and patience when servicing the harvester head.
2.
Immediately report any malfunctions in the head to your foreman or the person responsible for servicing.
3.
The engine should be shut off during servicing.
4.
Avoid working alone. Keep a mobile phone near you when you service the harvester outside the cab. Store an emergency alarm number in one of the quick select phone numbers.
5.
Service the harvesting head according to the manufacturers service schedule.
6.
If you are not familiar with the construction of the machine, ask the manufacturer for instructions before beginning to service or repair it.
7.
000 04052000
Danger to life! Never attempt to service the head near the range of movement of the saw, the delimbing knives or the feed rollers when the engine is running.
8.
Danger to life! When servicing the head, make definitely sure that nobody starts the harvester! If the harvester is started, the knives and rollers will close, the saw will return to its home position and the head will return to a horizontal position!
9.
Manual control: Each directional valve is equipped with a precontrol solenoid which allows the directional valve to be controlled manually by pressing the end spindle.
9.1
Danger to life! Avoid using the manual control when troubleshooting or repairing the harvester head. If maual control is absolutely necessary be extremely caution.
9.2
Do not use the manual control to tilt the harvester head or operate the rotator.
9.3
Be sure of the correct valve. Beware of the spinning motion of the feed rollers and the movement of the delimbing knives and the saw bar. 1.1
Service training
10.
Safety regulations
When testing the functioning of the saw: - The harvester head must be in a horizontal position - Nobody is to be in line with the saw - Keep the harvester head as near to the ground as possible
17.
Be aware of the danger of slipping when working on top of the harvester head.
18.
If oil gets on your skin, remember to clean it off. Take care of cuts and scratches immediately.
19.
Use safety goggles in service and repair jobs.
11.
Never raise the harvester head near the cab windows while testing the saw.
20.
12.
When servicing indoors, the saw must only be tested with the chain removed.
Do not change the pressure settings without the approval by the manufacturer.
21.
13.
Remove the pressure from the hydraulic system before beginning to service or repair jobs.
Use only sound tools and approved lifting equipment, abandon / repair damaged tools.
22.
Danger! Be careful when removing hot liquids or oils from the machine. Hot liquid or oil can cause serious burn injuries.
23.
Disposal of liquids, oil or other problem wastes:
14.
15. 16.
000 04052000
Do not clean or lubricate the machine while the engine is running. Always wear protective gloves when handling the saw chain. Pay special attention to cleaning and inspecting the limit switches, saw bar, saw chain and delimbing knives. Do not slit yourself to the cutting edge of the delimbing knives. Always wear protective gloves when handling the delimbing knives.
- Do not pour into ground or water - Find out the proper ways to dispose of them - Note the local environmental regulations
1.2
H73001
Technical data
Service training
16 12 5
13
6 8 5 4 18
7
3 15 9 3
14 11 2
17
1
10
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
000 28022000
Chain lubricating oil container Saw bar Feed rollers Reaction bar Delimbing knives (front) Delimbing knife cylinder (front) Feed roller cylinder Cradle Tilt cylinder Saw bar cylinder
11. 12. 13.
14. 15. 16. 17. 18.
Saw motor Rotator Serial number (Give the serial number when ordering spare parts or otherwise contacting the manufacturer) Delimbing knives (rear) Delimbing knife cylinder (rear) Swing coupling Feeding motor (upper side) Feeding motor, 2 pcs (lower side) 2.1
Service training
Technical data
Weight Height Width:open Power consumption Operating pressure Oil flow requirement Rotator
950 kg 1515 mm 1440 mm 70-90 kW 20-24 Mpa 200-300 l/min SISU MR10AMF
Saw unit: Power Sawbar length Chain speed Chain pitch Cutting diameter
hydraulic chain saw (F11-19) 45 kW 750 mm 44 m/s 0.404" 640 mm
Feeding unit: Feeding type Feeding force Feeding speed
3 spiked steel rollers 26 kN 0-4 m/s
Delimbing unit: Delimbing diameter
H73001
One fixed ond four movable knives. 670 mm Delimbing knives and feed rollers separately controllable
Measuring and control automation: PONSSE 1000 or PONSSE OPTI system Automatic volume measurement with data storage and printer output.
000 28022000
2.2
Service training
Electrical equipment Electrical harness / sensoring
Harvester connector Valve connectors
Saw sensor Length measure sensor Diameter sensor Tilt sensor
Colour marking connectors
000 28022000
3.1
Service training
Electrical equipment Optinet
To pivot frame
Computer
To crane
000 02052000
3.2
Service training
Electric diagram (IPS) Directional valve solenoids+diodes
Location number of pin connector box Saw rotation Saw feed Slow forward Slow reverse Rollers open Front knives open Fast forward Fast reverse black
brown blue
black
brown blue
Saw limit A
Saw limit B
black brown black Feed current length sensor
yellow
brown blue
Tilt limit
red
green blue
Length sensor
Diameter sensor
blue yellow Tilt up Rear knives open Rear knives open extra pressure Color 1 (blue) Color 2 (red) Urea valve Rotator right Rotator left
Front knives open extra pressure GND
000 28022000
3.3
Service training
Electric diagram, Knutsson Location number of pin connector box
Directional valve solenoids+diodes
Saw rotation Saw feed Slow forward Slow reverse Rollers open Front knives open Fast forward Fast reverse Lubrication oil pump black
brown blue
black
brown blue
Saw limit A
Saw limit B
black brown black
brown
Feed current length sensor blue
yellow
Tilt limit
red
green blue
Length sensor
Diameter sensor
blue yellow Tilt up Rear knives open Feed rollers 2-power system Color 1 (blue) Color 2 (red) Urea valve Rotator right + (KGK-) Rotator left+(KGK-) Front and rear knives extra pressure KNUTSSON GND
000 28022000
3.4
Service training
Adjustment and service instructions Length measuring device
Sensor casing
Sensor
Metering wheel
000 29022000
Rubber coupling
4.1
Service training
Adjustment and service instructions Length measuring device Testing the length measurement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Lift the harvester head so that you can rotate the measuring roller. Shut the engine off. Turn on the measurement system, switch on the power to the harvester head by pulling the knob out on the main switch (moto-switch). Go to the length calibration programming mode. Write down the original value of the length correction. Set the length correction of pine to zero. In the Handling mode, select pine for the tree sort. Press the ENTER key to zero the length. Mark the zero point on the measuring roller and on the measuring roller housing. Be careful not to move the roller. Check that the length on the display is zero. Rotate the measuring roller with force e.g., by kicking it. Rotate the measuring roller so the zero mark on the measuring roller is inline with the zero mark on the measuring roller housing. Check the length on the display. It should be divisible by 50 without a remainder. E.g., 50, 100, 150, 200, 250, 300, etc.
If the display shows some other length, the measuring system is not functioning correctly at high speeds.
ATTENTION! After testing, change the length correction to the original value.
Repair: Adjust the gap between the sensor and code roller again. If this does not help, replace the sensor.
000 29022000
4.2
Service training
Adjustment and service instructions Diameter measuring
B
A
Before calibrating of the diameter, you should check the following:
000 29022000
1.
The tree travels in the centre of the harvester head. If necessary, adjust the tree (a round one) to the centre using the reaction brace .
2.
Check that the measurements A and B are equal. If the difference is greater than 5 mm, an adjustment has to be made. A half revolution of the reaction brace is equivalent to a 5 mm change in the difference between measurements A and B. Recheck the measurements.
3.
When the feeding rollers are closed, the sensor reading must be 30. If the reading is something else, it can be adjusted by turning the sensorbody.
4.3
Service training
Adjustment and service instructions Saw sensor replacement
1 mm C
000 29022000
B
A
1.
Turn the engine off and make sure no one is able to start the machine.
2.
Turn the saw bar to its upper position and remove the old sensors.
3.
Use a thin-bladed screwdriver or similat tool to check that the detector holes do not coincide with the sensor locations (A, B).
4.
Lightly screw the new sensors into place until they are seated.
5.
Unscrew the sensors one revolution to obtain a 1 mm gap.
6.
Tighten the locking nut C. 4.4
Service training
Adjustment and service instructions Saw sensor replacement Adjustment of sensors
Sensors Adjustment plate
000 29022000
4.5
Service training
Adjustment and service instructions, saw Adjustment of sensors
Saw bar limit screw
000 29022000
4.6
Service training
Adjustment and service instructions Delimbing knife sharpening
The condition of the delimbing knives has a major effect on the pruning result and pruning resistance (especially in the summer). The recommended shape of the delimbing knives is shown in the following diagram. Sharpen the top side of the blade to a 45° angle. Do not sharpen the bottom side.
Saw chain lubricating pump adjustment
1. 2. 3. 4.
2 4 1
3
Oil volume adjustment Lubricating pump Check valve Lock nut
NOTE! If the adjusting screw is overtightened, the pump will not function, because the piston will not be able to move.
Oil volume adjustment: Oil volume should be adjusted according to the type of oil used and the lubricating need. Open lock nut no. 4. Turn adjusting screw no. 1 to obtain a suitable oil flow volume. Turning the screw clockwise will decrease the volume. Tighten the lock nut. 000 29022000
4.7
Service training
Testing instructions Pulse sensor testing
1. Turn on the power by turning the switch to the ON position. 2. Switch the NPN/PNP switch to the correct position, depending on which type of inductive sensor you are going to test. In the new harvester heads all inductive sensors are NPN type. In the older harvester heads the saw sensor is PNP type if the saw sensors diameter is 8 mm. 3. Connect the conductors as follows: - Brown conductor to + - Blue conductor to - Black conductor to IN NOTE! If you are going to test two sensors at the same time, connect as follows: - The brown conductors to + - The blue conductors to - The black conductors to different IN poles. 4. Put a piece of metal in front of the sensor. If a red or yellow lamp lights on the tester, the sensor is in good condition, otherwise the sensor is faulty. 5. Turn off the power of the test device when you have finished testing the sensors. If the BATT.OK lamp does not light when the power has been turned on, the batteries are empty. Replace the batteries.
000 04052000
5.1
Service training
Testing instructions Using a digital multimeter
Resistance measurement E.g., Checking the diameter sensor:
NOTE! The measured object has to be without a voltage.
1. Connect the wires as in the adjacent figure. 2. Slowly turn the the gear of the diameter sensor and watch the display of the digital multimeter. The value should vary between 1.5 and 11.5 kW (kilo-ohm) (±10 %) depending on the rotating direction.
10.0 V
A
By connecting black and blue wires to the multimeter, reading must be 10 kW (±10 %). Rotating of the gear wheel may not affect the reading.
Short-circuit measurement Select the measuring unit by turning the switch as shown in the adjacent figure. By putting both ends of the black and red measuring cables together you should hear an audible signal from the digital multimeter.
W
Yellow
Blue
NOTE! The wire that you are going to measure has to be without voltage.
V
A
000 04052000
V
W
5.2
Service training
Testing instructions Using a digital multimeter
Voltage measurement Connect the black measuring cable to the COM terminal and the frame of the machine. Connect the red measuring cable to the V terminal and the other end to the wire or connector you want to check. Then the digital multimeter will show the actual voltage at that moment at that point.
Diode test When the digital multimeter is connected as shown in the adjacent figure and the switch on the digital multimeter is turned to the diode measuring mode, the multimeter show a value between 0.5 - 0.7. Swapping the measuring cables on the diode should change the reading on the multimeter to 1.
NOTE! AC/DC switch in position DC
24.0 V
V
A
W
NOTE! To check a diode, it has to be without a voltage.
0.600 V
A
000 04052000
V
W
5.3
Service training
Feed hydraulics
Restrictors Feed valve (fast) Feed valve (slow) Feed pressure relief valve
Restrictor
000 29022000
6.1
Service training
Saw rotation hydraulics
Saw valve
Saw motor Anticavitation valve Casing line check valve
000 29022000
6.2
Service training
Saw motor hydraulics Cooling option
Tank line
Resistor check valve
000 29022000
6.3
Service training
Saw rotation hydraulics F12-30
Casing line check valve
Restrictor
Main spindle
Pilot -operated valve
F12-30
Anticavitation valve
000 29022000
6.4
Service training
Saw feed hydraulics
Directional valve
Pressure reducer T-line check valve
Resistor check valve
Saw cylinder
000 29022000
6.5
Service training
Lubrication pump
Screen + check valve
Check valve Lubrication oil pump
000 29022000
6.6
Service training
Lubrication pump Opti oil control
Lubrication pump
Directional valve From measuring device
Lubrication pump valve
Adapter block T-line check valve
Pressure reducer
000 29022000
6.7
Hydraulic diagram
Service training
Saw
H73001-H73202
2-power, F11-19
Feed (fast)
Feed (slow)
Rear knives Feed rollers pressing
Saw feed
Front knives
Tilting
Rotator
Saw feed
000 20032000
6.8
Hydraulic diagram
Service training
Saw
H73203
1-power, F11-19 Feed (fast)
Feed (slow)
Rear knives
Feed rollers pressing
Saw feed
Front knives
Tilting
Rotator
Saw feed
000 20032000
6.9
Hydraulic diagram
Service training
Saw
H73203
1-power, cooling, F11-19 Feed (fast)
Feed (slow)
Rear knives
Feed rollers pressing
Saw feed
Front knives
Tilting
Rotator
Saw feed
000 20032000
6.10
Hydraulic diagram
Service training
Saw
H73211
1-power, F12-30 Feed (fast)
Feed (slow)
Rear knives
Feed rollers pressing
Saw feed
Front knives
Tilting
Rotator
Saw feed
000 20032000
6.11
Hydraulic diagram
Service training
Saw
Excavator, 1-power Feed (fast)
Feed (slow) Rear knives Feed rollers Saw feed pressing
Front knives
Tilting
Rotator
Saw feed
000 20032000
6.12
Service training
Pressure adjustments
A. B. C. D. E. F. G. T. P. 2. 3. 4. 5. 6. 7. 8. 9.
SAW (rotate) SAW (feed) TRUNK FEED ROLLERS FRONT DELIMBING KNIVES TILT ROTATOR REAR DELIMBING KNIVES Tank line Pressure line Fast feed direction valve Slow feed direction valve Rear delimbing knife pressure reducer valve Rear delimbing knife pressure relief valve Rear delimbing knife check valve Rear delimbing knife direction valve Tilt pressure reducer valve Tilt direction valve
000 04052000
10. Saw check valve 11. Saw pressure reducer valve 12. Saw direction valve 13. Front delimbing knife pressure reducer valve 14. Front delimbing knife pressure relief valve 15. Front delimbing knife check valve 16. Front delimbing knife direction valve 17. Feed roller pressure reducer valve 18. Feed roller direction valve 19. Main pressure relief valve 20. Rotator direction valve 21. Feed roller check valve
7.1
Service training
Pressure adjustments Harvester head pressure relief valve adjustment
26
THE PRESSURE OF THE BASE MACHINE MUST BE ADJUSTED BEFORE THE FOLLOWING ADJUSTMENTS ARE MADE. The measurement connector is on the opposite side of the pressure reducing valve. BE EXTREMELY CAREFUL WHEN ADJUSTING THE PRESSURE 1. 2.
3. 4. 5.
000 04052000
6. 7.
Disconnect the electric cable from the harvester head. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Have a helper press the forward feed button (fast feed). Open the locking screw and close the pressure relief valve by turning adjustment screw 26 clockwise (no oil flow). Turn adjustment screw 26 counterclockwise. As soon as the sound of oil flowing can be heard, turn the adjustment screw clockwise until the sound of oil flowing stops. Turn the adjustment screw 26 clockwise one full turn. Lock the adjustment screw and connect the electric cable.
7.2
Service training
Pressure adjustments Saw cylinder feed pressure
23
1. 2. 3.
4.
5.
000 04052000
Disconnect the electric cable from the harvester head. Connect a pressure gauge to the measurement connector. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Open the lock and adjust the pressure reducer valve by turning adjustment screw no. 23 to obtain 30 bar / 435 psi. (25-30 bar / 363-435 psi.). Lock the adjustment screw and connect the electric cable.
7.3
Service training
Pressure adjustments Feed roller cylinder pinch pressure
25
NOTE! BE ESPECIALLY CAREFUL NOT TO ADJUST THE PINCH PRESSURE TOO HIGH.
1. 2. 3.
4.
5.
000 04052000
Disconnect the electric cable from the harvester head. Connect a pressure gauge to measurement connector. Start the motor and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Open the lock and adjust the pressure reducer valve by turning adjustment screw no. 25 to obtain 120 bar / 1740 psi. (110-130 bar / 1595-1885 psi.). Lock the adjustment screw and connect the electric cable.
7.4
Service training
Pressure adjustments Front delimbing knife cylinder pressure adjustment
27
24
1. 2. 3.
4. 5.
6. 7. 000 04052000
Disconnect the electric cable from the harvester head. Connect a pressure gauge to the measurement connector. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Open the lock and adjust the pressure reducer valve by turning adjustment screw no. 24 to obtain 120 bar / 1740 psi. (120-140 bar / 1740-2031 psi.). Open the lock and turn adjustment screw 27 clockwise (no oil flow), then turn adjustment screw 27 counterclockwise until the sound of oil flowing can be heard. Turn the adjustment screw clockwise until the sound of oil flowing stops. The pressure relief valve is now at 120 bar / 1740 psi. (120-140 bar / 1740-2031 psi.). Adjust the pressure reducer valve by turning adjustment screw no. 24 to obtain 50 bar / 725 psi. (50-70 bar / 725-1015 psi). Lock the adjustment screw and connect the electric cable. 7.5
Service training
Pressure adjustments Rear delimbing knife cylinder pressure adjustment
28
21
1. 2. 3.
4. 5.
6. 7. 000 04052000
Disconnect the electric cable from the harvester head. Connect a pressure gauge to the measurement connector. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Open the lock and adjust the pressure reducer valve by turning adjustment screw no. 21 to obtain 120 bar / 1740 psi. (120-140 bar / 1740-2031 psi). Open the locking screw and turn adjustment screw 28 clockwise (no oil flow), then turn adjustment screw 28 counterclockwise until the sound of oil flowing can be heard. Turn the adjustment screw clockwise until the sound of oil flowing stops. The pressure relief valve ís now at 120 bar / 1740 psi. (120-140 bar / 1740-2031 psi). Adjust the pressure reducer valve by turning adjustment screw no. 21 to obtain 50 bar / 725 psi. (50-70 bar / 725-1015 psi). Lock the adjustment screw and connect the electric cable. 7.6
Service training
Pressure adjustments Harvester head tilt cylinder pressure adjustment (tilt)
22
1. 2. 3. 4.
5. 6.
000 04052000
Disconnect the electric cable from harvester head. Tilt the harvester head to a horizontal position. Connect a pressure gauge to the measurement connector. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch Open the lock and adjust the pressure reducer valve by turning adjustment screw no. 22 to obtain 120 bar / 1740 psi. Lock the adjustment screw and connect the electric cable.
7.7
Service training
Pressure adjustments Rotator pressure relief valve adjustment (Indexator)
34
33
ATTENTION! MAKE SURE THAT YOUR HELPER IS FAMILIAR WITH THE MACHINE AND KNOWS HOW TO OPERATE IT. 1. 2. 3.
4. 5. 6. 000 04052000
Disconnect the rotator hoses and connect pressure gauges to them. Tilt the harvester head to a horizontal position. Start the engine and set the constant pressure: - engage the working brake and constant rpms - turn on the harvester head main switch While your assistant activates the rotator right function, adjust the pressure to 200 bar / 2901 psi. using adjustment screw no. 33. While your assistant activates the rotator left function, adjust the pressure to 200 bar / 2901 psi. using adjustment screw no. 34. Disconnect the gauges and reconnect the rotator hoses. 7.8
Service training
Extra equipments Color marking device
Crane
Shut-off cock
Electric valve
Nozzles 000 22032000
8.1
Service training
Extra equipments Stump treatment system
Electric valve
Crane boom head
000 22032000
8.2
SCHEDULED MAINTENANCE, NEW HARVESTER HEADS Service training
I = Inspect or check R = Replace C = Clean
G = Greasing
VI = Visual inspection T = Tightening A = Adjustment
Maintenance interval (hours)
N:o Item
50
200
1000
HARVESTER HEAD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Rotator mounting bolts Hydraulic motor mountings Feed roller mounting Measurement roller mounting Valve block mounting Bearing pin tightness and locking Hydraulic leaks visual inspection Valve blocks mounting Function of chain lubricating unit Valve group main safety (relief valve) Feed roller cylinder pinch pressure (pressure reducer valve) Pressure relief valve of feed roller cylinder (H60) Pressure reducer valve of saw feed Pressure relief valve of front knives Pressure reducer valve of front knives Pressure reducer valve of rear knives (H53, H73) Pressure relief valve of rear knives (H53, H73) Tilt cylinder pressure of multi-function unit Adjusment of rotator pressure relief valve (Only the Indexator rotator) Pressure of rear knive (H60) Speed of saw feed Speed of saw low-feed Speed of saw high-feed Greasings, according to the owner´s manual
20 21 22 23 24 25 Please, check that all labels are in good condition and in right places. If not, change them.
I, T I, T VI I, T I, T VI VI I, T VI
I, T I, T I, T I, T I, T I, T VI I, T VI I
I, T I, T I, T I, T I, T I, T VI I, T VI I
I
I
I I I I I I I I
I I I I I I I I
VI VI VI
I VI VI VI
I VI VI VI
I
I
I
Notes:
Place and date: Signature of service dealer WHITE - END USER
Signature of client RED - DEALER
BLUE - PONSSE OYJ
