Jensen A540 DiXL D-1703 Track, Operating Instructions Manual

Page 1: ...D 1703 Track Machine Nr 561305770 Date of building 05 2013 Jensen Service GmbH D 24975 Maasb ll Tel 04634 9370 0 Fax 04634 1025 E mail info jensen service de WOODCHIPPER Operating instructions List o...

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Page 3: ...mprovements which we consider to be appropriate An obligation to any previously delivered machines and extended apparatus is nvalid REFERENCE INSTRUCTION This instruction manual also contains descript...

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Page 5: ...elines According to legal provisions the work agreement and the service manual must remain with the machine at all times and must always be available for use When buying renting or borrowing a machine...

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Page 7: ...ne quitte notre usine 1 Kunde customer client Firma Beh rde etc company soci t Stra e Platz etc complete address adresse compl te PLZ postal code Ort town Land country pays Telefon telephone 2 bergabe...

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Page 9: ...que la machine quitte notre usine 1 Kunde customer client Firma Beh rde etc company soci t Stra e Platz etc complete address adresse compl te PLZ postal code Ort town Land country pays Telefon telepho...

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Page 11: ...machine quitte notre usine 1 Kunde customer client Firma Beh rde etc company soci t Stra e Platz etc complete address adresse compl te PLZ postal code Ort town Land country pays Telefon telephone 2 b...

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Page 13: ...ective 32 BimSchV and the machine directive 98 37 EG 9 GSGV Est conforme la directive 2006 42 EG outdoor directive 32 BimSchV et la directive machines 98 37 EG 9 GSGV Das angewandte Konformit tsbewert...

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Page 15: ...l Hydraulicsystem Max 180 bar Elektric connection 12 Volt Disc revolutions per minute See type plate Diesel engine Kubota 27 5KW 37 3 PS Motornumber 7 DD 1015 Track Hinowa Hinowa Number BD 0615 Track...

Page 16: ...lly read operator s manual before handling the machine Observe instructions and safety rules when operating Lire le livret d entretien et les conseils de s curit avant la mise en marche et en tenir co...

Page 17: ...r l carte de pi ces Zich verwijderd houden van draaiende machinedelen Niemals in den Quetsch Gefahrenbereich greifen solange sich dort Teile bewegen k nnen Never put your hand into the crushing danger...

Page 18: ...du ch ssis Chassis vooraan Z Fahrgestell vorne Chassis front Avant du ch ssis Chassis vooraan Gefahr durch fort schleudernde Teile bei laufendem Motor Sicherheitsabstand halten Danger flying objects...

Page 19: ...de wielen aanspannen Alle andere moeren en schroeven regelmatig controleren en desnoods aanpannen Di Fahrgestell vorne Bei Einachs auch hinten Chassis at the frontside For one axle at the backside Ch...

Page 20: ...nes ensure that they are unable to roll away and are protected from unauthorised usage firm brakes activated under wedge in place power source switched off ignition key removed The Wood chipper as cul...

Page 21: ...down 2 Caution is demanded when in the vicinity of fuel as there is an increased risk of fire Never replenish fuel when near unguarded flames ignition sparks or hot pieces of metal When refulling do...

Page 22: ...autions Respect the other parts as well as they may also be not completely safe 4 Never leave the Wood chipper unattended when in use 5 Only operate the machine in good light and good visibility 6 Do...

Page 23: ...and ensure that they are kept only in approved containers 5 Take care when pouring hot oil as there is a danger of being burnt 6 Take care when removing the cool lid The cooling fluid is kept under pr...

Page 24: ...7 When changing the connections ensure that they are reconnected correctly There is a danger of accidents if they are not e g For ward and backward motions and raising and lowering can be dangerous i...

Page 25: ...staff The page marked General safety and accident prevention instructions should be read carefully The safety rules for working with the machine are giv en by the Trade Association General attendance...

Page 26: ...hour s work with new or re sharpened knives Before the first use lubricate the feed roller bearings and repeat according to the instructions Ensure that the machine is securely coupled to the tractor...

Page 27: ...e of the machine is quickly affected if the knives are blunt or damaged Take great care when removing knives from the machine as the weight of the flywheel can create enough movement to cause injury b...

Page 28: ...ch oil change Note Required oil viscosity is 30 50 cSt at 40 C Reservoir capacity 18 litres for the A518 20 litres for the A521 A528 A530 28 litres for the A540 23 litres for the A328 A340 27 litres f...

Page 29: ...l screws and nuts for tightening V belts Check suspense regularly and re tighten if necessary Knives and counter knife In order to achieve an easy cut always keep a sharp edge The blades edges should...

Page 30: ...cm A528 15cm A530 15cm A518 12cm A521 13cm On heavy feed please watch the rpm of the chipper disk In case the rpm drops you should disengage the hydraulic feed rollers and do not engage again before t...

Page 31: ...machine Load running No load running A 141 Di 105 88 A 141 Z 105 92 A 231 Di 108 90 A 231 Z 106 81 A 328 Di 114 92 A 328 Z 104 80 A 328 ZUX 103 81 A 425 Di 107 92 A 425 Z 104 92 A 540 Di 107 88 A 530...

Page 32: ...Operating instructions infeed rollers First touch on the button is reverse and the second touch is forward STOP STOP...

Page 33: ...ft weekly 2 2 3 Retinax A 4 Bearing guidance of the bearing from the upper roller shaft daily 1 2 3 Retinax A 5 Roller bearing in the bearing housing of the upper roller shaft free of maintenance 1 6...

Page 34: ...t forward Pull both levers backward to go reverse Right left steering To steer right push the left lever forward To steer left push the right lever forward Steering on the axis Push one lever foreward...

Page 35: ...more than 2 700 kg The winch has a lever which releases the rope clutch Simply pull the lever and rotate it 90 As soon as the rope is released it can be pulled out manually To reengage the rope clutch...

Page 36: ...Avoid crossing slopes since there s always the overturn danger Parking and stopping on inclined grounds Caution parking and stopping on inclined grounds is very dangerous If you can t help parking or...

Page 37: ...ld not exceed an incline of 20 Above 20 the machine can to overbalance Only for tracks with tilting mechanism Using the tilting mechanism on sloping ground Caution The recommended limit of operation f...

Page 38: ...angerous IMPORTANT During cold seasons warm the machine up sufficiently before loading unloading the machine IMPORTANT 1 Avoid steering when going up or down ramps since this can be extremely dangerou...

Page 39: ...and uneven surfaces such as streambed rock gravel etc 2 Do not keep the rubber tracks in direct sunlight for more than 3 months 3 Avoid improper steering maneuvers on asphalt and cement since these ca...

Page 40: ...n grease valve 1 for more than one turn If the valve is loosened too much you risk expelling grease under pressure and possible serious injury to the machine operator Also never loosen grease nipple 2...

Page 41: ...They are made on the bottom part that rests on the ground The wheel guides located on the inside of the track prevent the track from sliding off the guide rollers Causes of damage A Breakage of steel...

Page 42: ...ation on sandy terrain or repeated sudden changes in direction 4 Abrasion of the carved profile may be caused in particular by rotation on concrete or gravel surfaces or hard surfaces Damage as indica...

Page 43: ...at gives access to the adjustment system 3 To loosen a track slowly unscrew valve 1 counter clockwise for no more than 1 turn One turn of valve 1 is sufficient for loosening the track 4 If grease does...

Page 44: ...ng wheel 4 4 Rotate the driving gear in erverse 7 and pull the track soles inside the frame 8 5 Position the track using a steel tube and turn the driving gear again 6 Make sure track links mesh corre...

Page 45: ...5min 5 C 40 C IV 95min 30 C 50 C IV 95min 30 C 65 C IV 165min Every 100 hours check the oil level in the reduction unit gearbox Stop the hydraulic geared motor with plugs aligned horizontal Remove the...

Page 46: ...ial shaft loads are not exceeded To mount drive components remove anti corrosion paint from shaft extension by means of a suitable solvent This should be done carefully because the solvent may damage...

Page 47: ...0 h 12 000 h max 5 years Under hard ambient conditions the oil should be changed more often For changing the oil should be warm Position a can under the drain and remove drain and fill plug After drai...

Page 48: ...gagement You can be seriously hurt by rotating parts Please make absolutely sure to read through and observe the following safety instructions All operations on and with the clamping set have to be pe...

Page 49: ...ressure ring slotted 2 1 back pressure ring slotted 3 1 external ring slotted 4 see catalogue cap screw DIN 912 picture 1 CLAMPEX KTR 400 C A U T I O N Check the clamping set before the assembly so th...

Page 50: ...d by 2 clamping screws see picture 3 and 4 Insert clamping set KTR 400 between shaft and hub picture 3 fixing of the front pressure ring picture 4 fixing of the back pressure ring Remove the clamping...

Page 51: ...swise Increase the impression torque step by step until the front pressure ring component 1 and the external ring component 3 are separated Screw the clamping screws into the forcing threads of the ex...

Page 52: ...off inner and outer guard tubes 3 Shorten inner and outer telescopic sections to same extent as guard tubes 4 De burr tubes and remove chips Guards Attach safety chain loosely Pay attention to swivel...

Page 53: ...remove bearing bush by light hammer blows onto the yoke or by rotating it Mount cross into yoke Use cross journals to guide bearing needles when inserting bushes Drive in bearing bush until annular g...

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Page 55: ...istribution and copying of this document together with use and communication of its contents are not permitted except by express prior permission Infringements are actionable for damages All rights in...

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Page 57: ...detailed front view Function of the keys Display of the chosen operating values confirmation key for parameterisation Function key F2 Next display increase value and number Function key F1 Previous di...

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Page 59: ...e settings on the HMCflex 8 3 1 Service overview diagram 11 3 2 Security overview diagram 11 3 3 Daily operating hours meter overview diagram 13 3 4 Operating hours meter overview diagram 13 3 5 Chipp...

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Page 61: ...s operating hours Further parameters can be displayed in the framework of customised software 1 2 Target group This documentation is aimed at the service staff of equipment where the HMCflex is incor...

Page 62: ...rvice Department in identifying the fault so the HMCflex can be more quickly repaired and returned NOTE Ehb electronics GmbH accepts liability exclusively for the correct execution of the work it perf...

Page 63: ...e CAN bus SAE J1939 Low power contacts ehb cable code 1 oil pressure green 1 mm 2 D terminal excitation white 1 mm 3 temperature brown 1mm 4 tank level switch grey 1 mm 5 terminal 31 GND earth blue 1...

Page 64: ...xt The display changes between error display and representation of the operating parameters The equipment must be attached to continuous plus clamp 30 so that the data and attitudes are duly stored Af...

Page 65: ...ngs factory code PIN Nr 1000 2 Service factory code PIN Nr 1884 3 security factory code PIN Nr 1884 4 Day hours factory code PIN Nr 0000 5 total hours factory code PIN Nr 1884 6 chipper factory code P...

Page 66: ...s oil pressure SET 0 2bar 0 3bar 0 5bar 0 10bar 0 16bar 0 25bar SET options temperature SET KTY PT100 PT1000 92 027 004 92 027 006 92 027 016 92 027 022 92 027 064 92 027 081 SET options pulses rev SE...

Page 67: ...press SET In seconds 1 5 SET input temp max SET In seconds 1 5 SET input gen SET In seconds 1 5 SET input Diverse SET In seconds 1 5 SET input min speed SET In seconds 1 5 SET input max speed SET In s...

Page 68: ...interval SET 50 100 150 200 250 SET options EngHour 50 service occured SET service is occured SET exit SET display returns to the main menu SET 2 Saved Errors No 1 no 10 exit SET Display returns to t...

Page 69: ...y SET SET options 8 error delay SET SET options 9 limit values SET SET options 10 in outputs SET SET options exit SET Display returns to the main menu SET 2 PIN number delete SET 0000 9999 SET input s...

Page 70: ...display jumps back into the main menue 4 day hours Settings Sub menu Options Input Note 1 day hours clear SET yes no SET options Display returns directly to the main menu 3 4 Operating hours meter ove...

Page 71: ...Cursor stops blinking Top Speed SET 0000 9999 U min SET input SET until Cursor stops blinking Norm Speed SET 0000 9999 U min SET input SET until Cursor stops blinking Ret Speed SET 0000 9999 U min SE...

Page 72: ...gised during operation of the engine Switch off magnet ETS A switch off magnet ETS energise to stop means a lifting magnet which requires voltage to stop the engine None Magnet without pull coil ETR H...

Page 73: ...e switched on or off When no auto boot is pro grammed the signal output is on contact no 7 of the connecting plug Signal output and auto boot cannot be operated in parallel The autostart input is posi...

Page 74: ...The setting gives the time period for how long an alternator charging error is suppressed by the management system After this time period expires the alarm event programmed under 7 comes into play va...

Page 75: ...a sensor NC NO or without query It is not possible to connect the temperature sensor and the temperature switch When a temperature switch is connected no temperature dependent preheat possible D Moni...

Page 76: ...The pickup must be in the right corner of a rotating metal part which is directly connected to the crankshaft of the engine This can for instance be a belt pulley or the engine s flywheel Holes and el...

Page 77: ...e HMCflex Several buttons can be switched parallel Another pushbutton is connected to terminal 4 Diverse If the button is pressed the feeder will stop Only by pressing the button return automatic the...

Page 78: ...idity 48 h 95 As per SAE J1378 Vibration 6 h 10 80 Hz 20 g As per SAE J1378 Shock 72 x 9 13 ms 44 g 55 g As per SAE J1378 LCD 2 x 16 lines Alphanumeric Dimensions housing 80 x 120 x 100 mm Fixing On v...

Page 79: ...HMCflex Operating instructions 22 23 ehb errors and omissions excepted Operating instruction 10 Diagram...

Page 80: ...and software adaptation new wiring diagram 07 10 2008 Blume Appen 0 2 Additions and software adaptation new wiring diagram Te 15 and alarm output 25 02 2009 Blume Appen 1 9 Adaption to new SW Level 2...

Page 81: ...u n k t i o n e n T e s t 2 V o r s c h u b m a n a u s T e s t 1 R c k l a u f m a n R c k l a u f H a u b e n s c h a l t e r 2 n d e r u n g 3 n d e r u n g e h b 2 1 9 8 a 1 K a b e l b a u m H M...

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Page 83: ...r l a g e n G e r t e K a b e l b a u m H M C f l e x _ K _ e h b 2 1 9 8 a _ J e n s e n _ K u b o t a 2 6 0 5 2 0 1 0 S t a 1 n d e r u n g Z u s t z l i c h e F u n k t i o n e n T e s t 2 V o r s...

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Page 85: ...em jeweiligen Pendant aufgeklemmt Verkabelung elektrische Einzugssteuerung an HMC Flex braun 0 5mm blau 0 5mm Drehzahl Sensor Typ PSC von Balluff oder IGA3008 BPKG von IFM schwarz 0 5mm braun 0 75mm b...

Page 86: ...raun 0 5mm braun 0 75mm schwarz 0 5mm braun 0 75mm schwarz 1mm rot 1mm 4x blau 5x bei Hatz grau Klemme 15 Magnetventil Vorschub Sensor Drehzahl Magnetventil r ckw rts Sensortaster gr n vor r ck Sensor...

Page 87: ...Service Schedule...

Page 88: ...free wheel if existing Oil change of the free wheel if existing X Change hydraulic filter cartridge X Check main bearing X Check the condition of the cutting parts and change them if necessary X Oil c...

Page 89: ...f the gear box if existing X Check the clearance of the valve X Change hydraulic oil X Change fuel filter X Check oil level of the free wheel and top up if necessary if existing Check oil level of the...

Page 90: ...Jensen Service GmbH Bahnhofstra e 20 22 D 24975 Maasb ll Tel 04634 9370 0 Telefax 04634 1025 eMail info jensen service de http www jensen service de...

Page 91: ...Original Ersatzteile Original spare parts Pi ces de rechange d origine...

Page 92: ...Hydraulikanlage Hydraulic system Circuit hydraulique...

Page 93: ...lide joint de mesure 1 25 9948 Kombinationsverschraubung screwing joint de tuyeau 1 26 19203 Kombinationsverschraubung screwing joint de tuyeau 1 27 9916 Winkelverschraubung screwing joint de tuyeau 2...

Page 94: ...apter pulley adapter adapteur pour poulie 1 2 3054 Schnorrsicherung washer rondelle 6 3 16191 Inbusschraube cylinder screw vis t te cylindrique 6 4 14728 Keilscheibe pulley poulie 1 5 3054 Schnorrsich...

Page 95: ...t fen tres 1 4 29008 Stehlager flage bearing roulement a flange 2 5 2377 Spannsatz KTR clamping set KTR bague de serrage KTR 1 6 14729 Keilscheibe pulley poulie 1 7 Keilriemen V belt courroie 3 8 3229...

Page 96: ...78 Messerunterlage 2 0mm knife s washer 2 0mm rondelle pour couteau 2 0mm 2 5 2679 Messerunterlage 2 5mm knife s washer 2 5mm rondelle pour couteau 2 5mm 2 6 22070 Messerschrauben knife screw vis pour...

Page 97: ...nnpratze fixing device griffe d arret 1 3 22022 Scheibe washer rondelle 1 4 5158 Sechskantschraube hexagon screw vis hexagonale 1 5 65009 Mundst ckeinlage inlay Bout de debit horicontal 1 6 9320 Senkr...

Page 98: ...osring Nilos ring rondelle Nilos 1 11 2121 Sicherungsring lock ring joint d arret 1 12 66206 Buchse bushing douille 1 13 541 Stellring adjusting ring collier r glable 1 14 40124 Flanschlager flange be...

Page 99: ...otte 1 3 16538 Verstellstange adjustment lever levier d articulation 1 4 20021 Unterlegscheibe washer rondelle 2 5 2324 Stopmutter hexagon nut ecrou 1 6 22026 Sechskantschraube nut crou 1 7 40142 Glei...

Page 100: ...Einf hrtrichter klappbar Infeed chute Tremie d alimentation...

Page 101: ...r n green sensor capteur vert 2 5 40509 Sensortaster rot re sensor capteur rouge 2 40511 Kabeldose 2m Kabel 2m cabel 2m c ble 4 6 40404 Sensor N herungsschalter sensor capteur 1 7 40393 Gasfeder dampe...

Page 102: ...Jensen Service GmbH Bahnhofstra e 20 22 D 24975 Maasb ll Tel 04634 9370 0 Telefax 04634 1025 eMail info jensen service de http www jensen service de...