OPERATING INSTRUCTIONS FOR FOREST SERIES TP

Transcription

1 OPERATING INSTRUCTIONS FOR FOREST SERIES TP Congratulations on your new TP wood chipper. To make sure you gain the most out of the wood chipper it is advisable to read these instructions before using the machine. When ordering spare parts, please state: 1) Model and series number. (See nameplate) 2) No. off, spare part number, description. (See spare parts catalogue) 3) Consignee name and address. 4) Method of transportation. EU DECLARATION OF CONFORMITY Manufacturer LINDDANA A/S, Ølholm Bygade 70, Ølholm, 7160 Tørring, Denmark declares that Wood chipper Model Series number is in accordance with the EU DIRECTIVE of 14 June 1989 on the approximation of the laws of the Member States relating to machinery (89/392/EEC amended by 91/368/EEC, 93/44/EEC, 93/68/EEC and 2000/14/EC) with special regard to Annex 1 of the directive on essential safety and health requirements in connection with the design and manufacture of machines. Title: Director Name: Jan Knudsen 1 April 2003 Date Signature

2 2 CONTENTS EU DECLARATION OF CONFORMITY...1 CONTENTS...2 TECHNICAL DATA...3 ETRA EQUIPMENT...4 MANUAL FEED...8 CRANE MODEL...8 SETTING...9 KNIVES AND ANVILS...11 WOOD CHIPPER...13 KNIFE REPLACEMENT...14 SLIVER BREAKER - PRESSURE PLATE 230V SAFETY RULES...16 MAINTENANCE SCHEDULE TP LUBRICATION AND OIL...18 PROBLEMS - POSSIBLE CAUSES...19 HYDRAULIC DIAGRAMS...20 NOISE LEVEL...23 ADJUSTMENT AND FAULT-FINDING ON RGC OVERLOAD PROTECTION GUARD...24

3 3 TECHNICAL DATA Type (K) 280 PH Operating principle Rotor principle Rotor disc diameter 760 mm 960 mm 960 mm Speed of PTO No. of knives Power requirement hp hp hp min./max. Tree stem diameter, max. 230 mm 270 mm 280 mm Chip length (adjustable) 9-19 mm 7-21 mm mm Weight (manual/crane) 990 kg 1370/1350 kg 1600 kg IMPORTANT! BEFORE ASSEMBLING AND STARTING THE MACHINE, IT IS ADVISABLE TO CAREFULLY READ THE OPERATING INSTRUCTIONS. See also our sales and delivery conditions at the back of this manual. When repairing and maintaining the machine, always use original spare parts. Type designations refer to the maximum tree stem diameter (mm). V : Feed at right angles to the direction of travel. P : Feed parallel with direction of travel. H : Built-in hydraulic pump station. K : Crane funnel. Must not be used for manual wood feed. No attempt must be made to use a machine (e.g. miniloader, front loader, ditch digger or similar) to feed a wood chipper with manual feed funnel. The machine is designed for chipping stems and branches from woods and hedges. Be careful when chipping branches, etc. from hedges. They can contain nails, insulators and other foreign material that must not be allowed to enter the machine. Foreign matter such as stone, iron and other metals must not be allowed to enter the wood chipper since it will damage the knives and anvils, and could present a serious hazard to persons in the vicinity of the machine. Before start-up check to make sure that there is no foreign matter inside the machine. Remove the three M12 x 50 mm bolts holding the upper and lower parts of the rotor housing together. Lift the upper part until the ejector spout rests in its own position and turn the rotor a few times manually. On delivery from the factory, the knives are set at 10 mm (280 PH:15 mm) unless otherwise agreed. The four-wheeled trolley can be towed behind the wood chipper. Total weight for type 230 V: 3000 kg. Total weight for type 270: 5000 kg. Figure 1 3-off M12x50 bolts The right to make changes in design and specifications without notice is reserved.

4 4 ETRA EQUIPMENT TP 270 Manual feed To avoid overloading the tractor, PTO and wood chipper, a rotor speed monitor can be mounted to automatically start and stop the feed rollers on the manual feed model. Figure 2 HC960 Rotor speed monitor The rotor speed monitor is standard on TP 270K

5 5 ASSEMBLY INSTRUCTIONS The machine is designed for connection to the tractor three-point linkage. The three-point linkage connection is formed in accordance with ISO 730-1:1994(E) Category 2. The PTO shaft is 1 3/8" - 6 splines on the tractor side. On some types of tractor where a speed of 1000 r/min is used, the shaft specification is 1 3/8" - 21 splines. On the machine side, the PTO shaft is 1 3/4" - 6 splines with freewheel. This does not apply to the 280 PH PTO shaft. See operating instructions for the PTO shaft. These are in a plastic bag attached to new shafts. Length adaptation With the shortest operating length, hold the two halves of the shaft by the side of each other and make a mark. The inner and outer protection tubes must be shortened to the same length. The inner and outer shaft profiles must also be shortened to the same length as the protection tubes. It is important to make sure that sharp edges left by cutting are rounded off and that all swarf has been removed. The shaft profiles must be greased. Additional changes to power take-off shaft and protection tubes are not permissible. The shaft tube connection must never be drawn out too far. The minimum overlap is half the length of the profile tubes. In respect of the PTO shaft it is also important to make sure that the lift arm stabilisers are adapted correctly. On some types of tractors, where the lift arm is longer or shorter, stabilisers must be adjusted to give the correct angle on the PTO shaft. The aim must be to make the shaft angle the minimum possible. See instructions attached to the PTO shaft. When uncoupling the machine three-point linkage, place the PTO shaft in the support integrated with the upper link bolt. During operation, the machine must be suspended in the tractor lift arm - provided the lift arm can be locked. For manual feed models TP230 and TP270, the machine must not be used if the funnel bottom is more than 600 mm above the ground. Figure 3 Funnel dimensions

6 6 IMPORTANT Because of the very heavy rotor, the PTO shaft must be coupled in very gently. A coupling-in time of 10 seconds is recommended. This will ease the load on the tractor, PTO shaft and wood chipper. The speed of the PTO shaft (rotor) unloaded must be a minimum of 540 r/min. and a max. of 1000 r/min. TP 230 TP 270 TP270K TP280PHK Angle between wood chipper and /(10 ) tractor PTO shaft with wide angle No No No Yes Angle (wide angle) Feed angle From side 45 from rear 45 from rear Parallel with direction of travel PTO shaft, Walterscheid type 2400 / PJ / PJ / PJ / PJ500 Belt drive for main shaft none none none Ø250/Ø250 or direct 10 Belt none none none 8xPB1340 or none Gear ratio for hydraulic pump Ø140/Ø90 none none Ø64/Ø48 Pump drive 2xPA950 Dog clutch Dog clutch 1xGates GT 8MGT-800

7 7 PICTOGRAMS Read the operating instructions before use! Warning - moving belts! Warning - rotor! Warning - rotating rollers! Safety distance Crane only: Warning - do not feed the machine manually! Ear and eye protection obligatory! Safety footwear obligatory!

8 8 MANUAL FEED IMPORTANT Only machines with manual feed funnel and safety bar may be used for manual feed. The safety bar must be in its stop position (0) before start-up. After starting up, pull the safety bar back (A). The rollers will then rotate. The finger screw on the flow valve under the guard can be used to set roller speed so that it corresponds to the knife setting. See section, SETTING page9 Never run the rollers too fast, otherwise the material being fed in will act as a brake on the rotor. See Figure 5 Setting of roller speed, TP 270. Pulling the safety bar as far back as possible (B) redirects the oil flow in the control valve so that the rollers reverse. When the saftybar has been used it is necessary to activate the handle on the bar to restart the rollers. TP270 Transport position Figure 4 Manual feed funnel and safety bar TP270 Work position CRANE MODEL Manual feed of the crane model is not permitted. During operation, no persons must be allowed within the crane danger zone. See manual for the crane concerned, or warning signs on the crane.

9 9 SETTING To achieve good, uniform chip quality the machine must be correctly set up. The knives must be perfectly sharp, the clearance between knives and anvils must be correctly set, and the speed of the feed rollers in relation to the knife cut-off distance must be checked and reset if necessary. See Figure 10 Fitting the knives, page 12. The table below recommends feed roller speeds for required chip lengths. The speed varies with the speed of the PTO shaft. The speed can be regulated with the flow regulation valve built into the wood chipper. Speeds for feed rollers, on types 230, 270 and 280 TP 230 VH (3 knives) * = flow regulation valve max. open Knife at 1000 at 540 theoretical theoretical clearance r/min r/min m/min m/min Chip length 12 (88)* (47)* TP 270 (3 knives) Knife clearance at 1000 r/min at 540 r/min theoretical m/min theoretical m/min Chip length TP 280 PH (3 knives) Knife clearance at 1000 r/min at 540 r/min theoretical m/min theoretical m/min Chip length

10 10 Extra equipment Rotor speed monitor HC960 Regulation of roller speed Figure 5 Setting of roller speed, TP 270 The throttle check valve maintains pressure on the pressure roller cylinder! Operation: Close (1/3 of turn to open). Service: Open valve to release pressure roller. Remember to close it again! Figure 6 Setting pressure on cylinder, TP 270 Regulation of pressure on cylinder. Max. 70 bar. Remember to tighten the locknut! Regulation of roller speed Remember to tighten the locknut! Regulation of pressure on cylinder. Max. 70 bar. Remember to tighten the locknut! Figure 7 Setting of roller speed, TP 270K

11 11 KNIVES AND ANVILS The quantity of material the machine is able to deal with before the knives need sharpening will depend on chip lengths, type of wood, and on how clean the material happens to be. The machine is equipped with a vertical anvil that can be turned three times and a horizontal anvil that can be turned once. The anvils must be ground 90. Anvil settings can be adjusted. If, for example, the knives must be set from 10 mm to 12 mm, the anvil bolts must be loosened so that the anvils can be drawn back. The knives can then be set at 12 mm and anvils with a clearance between anvils and knife edges of 0.5 mm mm. See Figure 10 Fitting the knives page 12. The tightening torque for anvil bolts is 200 Nm. When mounting knives, make sure they are orientated correctly; it is possible to fit them the wrong way round! See Figure 10 Fitting the knives. The knives must be sharp to ensure good chip quality. Inspect them daily and trim them with a carborundum stone if necessary. This will maintain the sharpness of the knives and prolong the period until they have to be ground properly. The knives must be ground at an angle of 30. Knives may be ground down to min. 106 mm. See Figure 8 Knife. Figure 8 Knife Figure 9 Wet grinder Grinding must be performe d with a wet grindstone. See Figure 9 Wet grinder. N ever use a right-angle grinder or similar on the knives. When grinding knives, make sure that widths (weights) are identical in order to ensure good rotor balance.

12 Figure 10 Fitting the knives 12

13 13 WOOD CHIPPER When starting the wood chipper, check to make sure that the rotor speed/pto shaft does not exceed 1000 r/min. (see tractor manual). Turn the ejector spout and adjust the tilting section to give the correct discharge trajectory. When transporting the wood chipper on public roads, swivel the ejector spout rearwards in relation to the direction of travel and secure it properly. Adjusting the handle on the tilting section turns the adjustment bolt against the eccentric at the end of the handle and gives the correct degree of tightness. After adjustment, tighten the locknut (types 230 and 270 only). See Figure 11 Setting of ejector spout Figure 11 Setting of ejector spout To avoid slivers when leaf-bearing trees are chipped, the internal deflector should be mounted in the top half of the rotor housing. When handling wet conifer, the deflector can be removed if the machine tends to clog. See Figure 12 Fitting/removal of deflector. The deflector in the top half of the rotor housing is secured by 3-off M12 x 20 mm setscrews. Figure 12 Fitting/removal of deflector

14 14 KNIFE REPLACEMENT Carefully clean the rotor and knife bolting surfaces before mounting. They must be absolutely clean. Mount the knife up under the retainer plate against the adjustment bolts. Then finger-tighten the nuts, turn the rotor and check the clearance between knife and anvil. To increase the distance the knife protrudes, use the two adjustment bolts to press it forward. When adjusting knives, use one of the gauge blocks supplied. 230: mm. 270: mm. 280: mm. Place the selected gauge block at the side of the rotor, then press the knife forward with the adjustment bolts until the knifeedge registers on the block surface. This setting must be performed at both ends of the knife. Figure 13 Fitting the knives When the knife has been set, tighten the four nuts. Finally, tighten the locknuts on the adjustment bolts. See Figure 13 Fitting the knives The tightening torque for the stud bolt nuts is 200 Nm.

15 15 SLIVER BREAKER - PRESSURE PLATE 230V To understand the significance of the sliver breaker, the condition of the wood to be processed must be evaluated. A distinction is made between hard, dried wood with less than 25% water and soft wood with more than 25% water. On delivery, the machine is fitted with a type A long-fingered sliver breaker, with the pressure plate turned away from the sliver breaker as shown in Figure 10 Fitting the knives on page 11, Pos. 1. This setup is used for soft wood, branches, etc. With hard, dried wood, the short-fingered type B sliver breaker should be used with the pressure plate turned 180 as shown in Figure 10 Fitting the knives on page 11, Pos. 2. The pressure plate is pressed against the sliver breaker when fastening the knives. Figure 14 Sliver breaker, type A The pressure plate can be turned as desired after evaluating the condition of the wood. The short-fingered type B sliver breaker is available as extra equipment. When using the short-fingered type B sliver breaker, the knife clearance must be max. 8 mm. Sliver breakers are very effective and should only be used to achieve a particular chip quality.

16 16 SAFETY RULES General 1. The upper part of the machine must not be opened until the rotor has come to a complete standstill. 2. Always stop the machine and tractor before inspection, service or repair work is performed. 3. After maintenance and/or repairs have been carried out, the machine must not be started until all bolts are tightened and all protection devices have been refitted. 4. Before starting, make sure that the protection devices on the machine operate correctly. This applies particularly to the safety bar stop-return function. 5. The maximum speed of the machine must not be exceeded. 6. No one under the age of 18 may be allowed to operate the machine. However, persons over the age of 16 may be allowed to do so under supervision. The working environment rules currently in force in the country concerned must be observed. 7. Never use the machine without the guards being correctly fitted and bolts properly tightened. 8. Knife replacement and setting anvils/knives must only be performed by instructed personnel. Operation and transportation rules 9. The PTO shaft guard and shielding must always be intact. Safety chains must be fitted. 10. Use ear protection, safety glasses, and close-fitting protective clothing and footwear. 11. During operation, all parts of the body must be kept clear of machine openings and moving parts. Never touch the inside of the funnel. 12. Always stand by the side of the feed funnel when operating the machine. Take note of the surface on which the machine is operating. Falling near the machine can be dangerous! 13. Models with crane feed funnel must not be fed manually. 14. When chipping short lengths of wood, use a tool, e.g. a stout stick or staff, to push the material into the feed rollers. 15. During operation, the ejector spout must not point towards the feed funnel area. 16. No persons must be allowed in the discharge area while the machine is running. IN EMERGENCY SITUATIONS: THROW THE SAFETY BAR INTO ITS NEUTRAL OR RETURN POSITION! 17. During operation, set the machine height so that the bottom edge of the funnel is at least 30 cm above the ground and that the best working position for the operator(s) is achieved. 18. During transport or when not in use, place the PTO shaft in its holder on the machine. 19. For road transport, swivel the ejector spout rearwards in relation to the direction of travel. 20. For transport where normal traffic regulations apply, requirements as regards lights, stop lights, flashing indicators, etc. must be observed. 21. Before cleaning the machine, IT MUST BE STOPPED and the rotor must be at a standstill.

17 17 MAINTENANCE SCHEDULE TP Interval=> m 3 10,000m 3 PTO shaft lubrication 1 Knife and anvil inspection 2. All nuts and bolts 3 Main bearings for rotor 4 PTO shaft telescopic connection 5 Fixed roller bearings 6 Pressure roller and chain wheel 7 Return filter TP Pressure filter TP280 9 Hydraulic oil change 10. Anvil turn/replacement 11. Ejector blades 12 Deflector in upper rotor housing 13 Triangular and square strippers 14 Grinding of flats on feed rollers 15 Shell in rotor housing 16 1 Removal and lubrication of PTO shaft. 2 See section, KNIVES AND ANVILS, page 11 3 Tighten nuts and bolts. Important: The 4-off M16 mm Allen screws that fasten the rotor and main shaft must not be tightened; the screws are locked with adhesive and extra-tightened at the factory. 4 Lubricate with Uniway Ep2 or similar. 5 Dismantle PTO, clean and grease. Inspect protection tubes. 6 Lubricate pressure roller and fixed roller bearing. Remember fixed roller bearing under the feed. 7 Clean chain and lubricate with chain oil or chain grease. 8 Change filter. 9 Change filter. 10 Drain off oil and take it to an authorised disposal point. Fill with new oil. See page See section KNIVES AND ANVILS, page Replace ejector blades and bolts. 13 Replace deflector (if fitted) in upper rotor housing. 14 Turn or replace. 15 Sharp-grind feed rollers. 16 Replace removable shell in upper rotor housing.

18 18 LUBRICATION AND OIL Mineral oils: We recommend the use of mineral-based hydraulic oil containing sufficient anti-wear additives of a type that remain effective under marginal lubrication conditions at low temperatures, i.e. below 60 C. Normal working temperature +30 C to +60 C. Minimum working temperature -30 C. Maximum working temperature +90 C. Within the working temperature range the viscosity should be cst. The lowest permissible viscosity is approx. 20 cst. The filling and vent plugs fitted to the machine must not become blocked in a way that makes pressure equalisation in the hydraulic tank impossible. Prior to long standstill periods: Clean the machine thoroughly. Remove the knives, then grease the anvils and knives. Spray the remainder of the machine with thin oil. Grease all lubrication points. TP 230 TP 270 TP 280 Hydraulic oil: Statoil HydraWay HM litres 51 litres 88 litres Pressure lubricant: Statoil UniWay EP 2 Number Number Number PTO shaft Main shaft bearings Fixed roller bearings Pressure roller bearings Pressure cylinder Hydraulic oil: Statoil HydraWay HM 32 Pressure lubricant: Statoil UniWay EP 2 or corresponding lubricant recommended for grease nipples and chain. For lubrication intervals, see MAINTENANCE SCHEDULE TP , page 17

19 19 PROBLEMS - POSSIBLE CAUSES Problem Possible cause Rollers do not rotate Insufficient oil in hydraulic system. Sensor and sensor clearance need checking. Flow valve closed. Pump V-belt drive defective. Rotor speed too low (speed monitor). Hydraulic pump defective. Hydraulic motor defect. Insufficient or no pull-in on feed Pressure relief valve defective. rollers Hydraulic pump defective. Feed rollers need grinding. Hydraulic motor defect. Poor chip quality Knives need grinding. Anvils should be inspected/adjusted/ground. Safety bar not fitted. See Figure 12 Fitting/removal of deflector. Poor chip ejection Tractor PTO speed needs checking. Ejector blades worn. Shell in lower rotor housing needs replacing. Deflector in upper rotor housing should be removed (wet conifer). Machine difficult to feed Feed rollers running too fast. See SETTING, page 9 Investigate possible causes before contacting supplier. When contacting Linddana A/S always have the type designation, year of manufacture and machine number to hand.

20 20 HYDRAULIC DIAGRAMS Figur 15 Hydraulic diagram TP 230 Figur 16 Hydraulic diagram TP 230 with HC960 speed monitor

21 21 Figure 17 Hydraulic diagram TP270 Figure 18 Hydraulic diagram TP270 with HC960 speed monitor Figure 19 Hydraulic diagram TP270K

22 22 Figur 20 Hydraulicdiagram TP 280PHK Figur 21 Hydraulicdiagram Crane

23 23 NOISE LEVEL The noise level from the wood chippers has been measured during operation with a rotor speed of 1000 r/min, driven by a tractor. The measurements were taken in accordance with current test directives. Directive 2000/14/EC, 3 July 2000 EN ISO 3744, 1995 ISO 11094, December 1993 ISO 4871, 19 March 1997 The guaranteed noise levels that must be stated by the manufacturer in accordance with Directive 2000/14/EC are as follows: TP 230 wood chipper: 123 db(a) re.1pw. TP 270 wood chipper: 127 db(a) re.1pw. TP 280 wood chipper: 130 db(a) re.1pw. The above values cover a common uncertainty of measuring method and an estimated variation arising from a product series of this type of machine. Further information about measurements, results and the estimation of uncertainty is available in a detailed report.

24 24 ADJUSTMENT AND FAULT-FINDING ON RGC OVERLOAD PROTECTION GUARD. ADJUSTMENT OF OVERLOAD PROTECTION GUARD: Unless anything else has been agreed, the overload protection guard has been set by the factory to start at 1000 revolutions and stop at 800 revolutions. If other start and stop setting are required, then carry out the following procedure: Remove the cover of the control box and turn it as shown in the assembly instructions. Follow the assembly instruction. If for instance it is set to start at 1000 revolutions and to stop at 800 revolutions and you want it to start at 900 and stop at 750 revolutions, then the stop position is set first by turning trimmer no 1 clockwise. After that the start position is to be adjusted by turning trimmer no. 2 clockwise. Trimmer no. 3 (only RGC) is for adjustment of the reverse time. If you want the in-feed rollers to reverse less, turn trimmer no. 3 clockwise. The difference between stop and start should be minimum 100 revolutions.

25 25 FAULT-FINDING: In case the overload protection guar does not work please check the following: 1. Is there a supply voltage of 12 volt. When the switch is set on Auto the Power lamp should light, if not check the fuse. 2. Check the number of revolutions. Is it within the pre-set area. 3. Check the oil pressure. 4. Are the cable connections intact. Please notice that the male plug and female plug are correctly plugged together. If once male and female plug er plugged wrong together can especially the ground contact o the plugs be damaged. 5.Is the connection correct +12 volt + brown blue. 6. Are sensor and key intact, correctly adjusted and is the distance between them in the area between 0,5 and 1,0 mm? For checking the sensor you need a voltmeter and the woodchipper is to be stopped and the voltage drop needs to be between 2 and 4 in the circuit board. For checking the sensor you need to stop the woodchipper. Measure the voltage drop with a voltmeter. It needs to be between 2 and 4 in the circuit board. A. When the sensor and the track are facing each other (activ) the voltage drop has to be between 5 and 7 volt. B. When the sensor and track are not facing each other (inactiv) the voltage drop has to be between 1,5 and 2 volt. If item A and B are a fact the sensor and the printed circuit board are OK. 7. Is the control box defect? If no fault found according to the above-mentioned please contact Linddana A/S.