Service training

Service training

1 2 3 4 5 6 7 8 9 10

Safety regulations

Technical data

Electrical equipment

Adjustment and service instructions

Testing instructions

Hydraulics

Pressure adjustments

Extra equipments

Scheduled maintenance

Service training

Safety regulations

Safety while servicing and repairing: 1. Use caution and patience when servicing the harvester head. Immediately report any malfunctions in the head to your foreman or the person responsible for servicing. The engine should be shut off during servicing. 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. Service the harvesting head according to the manufacturers service schedule. If you are not familiar with the construction of the machine, ask the manufacturer for instructions before beginning to service or repair it. 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. 9. 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! 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. Do not use the manual control to tilt the harvester head or operate the rotator. 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

2.

3. 4.

5.

6.

9.2

7.

9.3

000 04052000

Service training

Safety regulations 17. Be aware of the danger of slipping when working on top of the harvester head. If oil gets on your skin, remember to clean it off. Take care of cuts and scratches immediately. Use safety goggles in service and repair jobs. Do not change the pressure settings without the approval by the manufacturer. Use only sound tools and approved lifting equipment, abandon / repair damaged tools. Danger! Be careful when removing hot liquids or oils from the machine. Hot liquid or oil can cause serious burn injuries. Disposal of liquids, oil or other problem wastes: - Do not pour into ground or water - Find out the proper ways to dispose of them - Note the local environmental regulations

10.

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

18.

19. 20.

11.

Never raise the harvester head near the cab windows while testing the saw. When servicing indoors, the saw must only be tested with the chain removed. Remove the pressure from the hydraulic system before beginning to service or repair jobs. 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.

12.

21.

13.

22.

14.

15. 16.

23.

000 04052000

1.2

Service training

Technical data
16 12 5 6 8 5 4 18 3 15 9 7 13

H73001

14 11 2 10

3 1

17

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

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

000 28022000

Service training

Technical data
950 kg 1515 mm 1440 mm 70-90 kW 20-24 Mpa 200-300 l/min SISU MR10AMF hydraulic chain saw (F11-19) 45 kW 750 mm 44 m/s 0.404" 640 mm

H73001

Weight Height Width:open Power consumption Operating pressure Oil flow requirement Rotator Saw unit: Power Sawbar length Chain speed Chain pitch Cutting diameter Feeding unit: Feeding type Feeding force Feeding speed Delimbing unit: Delimbing diameter

3 spiked steel rollers 26 kN 0-4 m/s 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)

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 black brown black
Feed current length sensor

Directional valve solenoids+diodes

Saw limit A

brown blue

Saw limit B

brown blue red

Tilt limit

yellow green blue blue yellow Tilt up Rear knives open

Length sensor

Diameter sensor

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
Saw rotation Saw feed Slow forward Slow reverse Rollers open Front knives open Fast forward Fast reverse Lubrication oil pump black brown blue black black brown black yellow green blue 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 brown red Tilt limit brown blue

Directional valve solenoids+diodes

Saw limit A

Saw limit B

Feed current length sensor blue

Length sensor

Diameter sensor

000 28022000

3.4

Service training

Adjustment and service instructions

Length measuring device

Sensor casing

Sensor

Metering wheel

Rubber coupling

000 29022000

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

Before calibrating of the diameter, you should check the following: 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 . 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. 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.

2.

3.

000 29022000

4.3

Service training

Adjustment and service instructions

Saw sensor replacement

1 mm C B A

1. 2. 3.

Turn the engine off and make sure no one is able to start the machine. Turn the saw bar to its upper position and remove the old sensors. Use a thin-bladed screwdriver or similat tool to check that the detector holes do not coincide with the sensor locations (A, B). Lightly screw the new sensors into place until they are seated. Unscrew the sensors one revolution to obtain a 1 mm gap. Tighten the locking nut C.
4.4

4. 5. 6.
000 29022000

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

2 4 1

1. 2. 3. 4.

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: 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. 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.

NOTE! The measured object has to be without a voltage.

10.0
V
V

Yellow

Blue

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.

NOTE! The wire that you are going to measure has to be without voltage.

000 04052000

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.

NOTE! AC/DC switch in position DC

24.0
V V

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! To check a diode, it has to be without a voltage.

0.600
V V

000 04052000

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

Service training

Hydraulic diagram
2-power, F11-19

H73001-H73202

Saw

Feed (fast)

Feed (slow)

Rear knives Feed rollers pressing

Saw feed

Front knives

Tilting

Rotator

Saw feed

000 20032000

6.8

Service training

Hydraulic diagram
1-power, F11-19
Feed (fast) Feed (slow) Rear knives Feed rollers pressing Saw feed Front knives Tilting Rotator

H73203

Saw

Saw feed

000 20032000

6.9

Service training

Hydraulic diagram
1-power, cooling, F11-19
Feed (fast) Feed (slow) Rear knives Feed rollers pressing Saw feed Front knives Tilting Rotator

H73203

Saw

Saw feed

000 20032000

6.10

Service training

Hydraulic diagram
1-power, F12-30
Feed (fast) Feed (slow) Rear knives Feed rollers pressing Saw feed Front knives Tilting Rotator

H73211

Saw

Saw feed

000 20032000

6.11

Service training

Hydraulic diagram
Excavator, 1-power
Feed (fast) Feed (slow) Rear knives Feed rollers Saw feed pressing Front knives Tilting Rotator

Saw

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

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

000 04052000

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. 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.

3. 4. 5.

000 04052000

6. 7.

7.2

Service training

Pressure adjustments
Saw cylinder feed pressure

23

1. 2. 3.

4.

5.

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.

000 04052000

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.

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.

000 04052000

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 s 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.

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.

000 04052000

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. 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

4. 5. 6.
000 04052000

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 N:o Item

VI = Visual inspection T = Tightening A = Adjustment

G = Greasing

Maintenance interval (hours) 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 owners manual 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 I I I I I I I I VI VI VI I I VI VI 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 VI VI VI I

20 21 22 23 24 25 Please, check that all labels are in good condition and in right places. If not, change them. Notes:

Place and date:

Signature of service dealer
WHITE - END USER RED - DEALER

Signature of client
BLUE - PONSSE OYJ