Timberjack 745 Installation instructions

Timberjack
Harvester Head
F062419
Operator’s and Maintenance
Manual
Serial number 00FY0462...00FY0468
and WH0745X000469-
ENG

OPERATOR’S AND
MAINTENANCE MANUAL
Timberjack
745
1
2
3
4
5
6
7
8
9
10
11
12
INTRODUCTION
WARRANTY
SAFETY INSTRUCTIONS
PLANNING YOUR WORK
MAINTENANCE
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM
TECHNICAL DATA
OPTIONAL EQUIPMENT

The information contained in this manual is comprised
of regulations and instructions which will assist the
operator to operate the machine in a safe and efficient
manner. Make sure this manual is always close at hand
andavailabletoallwhoworkonthemachine.
Should this manual be lost or should it deteriorate to
an unintelligible state, contact Timberjack or your nea-
rest Timberjack dealer for a replacement manual.
If you sell the machine, be sure to give this manual to
the new owners.
Continuing product improvement made by Timber-
jack may result in changes to the machine which are
not covered in this manual. Shoulf you need up-to-date
information about your machine or should you have
questions in regards to this manual, please contact
Timberjack or your Timberjack dealer.
WARNING
Only persons whose training has been
approvedbyTimberjackarepermittedto
operate Timberjack machinery.
Improper operation and maintenance of
this machine can be hazardous and
could result in serious injury or death.
Therefore,itisofparamountimportance
that all the instructions given in this
manual and during training be followed
when the machine is operated or servi-
ced.
The safety rules are given in chapter 3.

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Timberjack 745
1. Introduction 1-1.............................................
1.1 General 1-2.....................................................
1.2 Single-grip harvester head 1-3.....................................
1.2.1 Main components 1-4.......................................
2. Warranty 2-1................................................
2.1 Warranty service 2-1.............................................
3. Safety instructions 3-1........................................
3.1 Warning Symbol 3-1.............................................
3.1.1 Meaning of warnings 3-2....................................
3.2 General safety rules 3-3...........................................
3.3 Operating safety precautions 3-4...................................
3.3.1 Before a new shift 3-5.......................................
3.3.2 Transport by road 3-5........................................
3.4 Servicing safety precautions 3-6....................................
3.5 Working with oils and chemicals 3-8................................
5. Planning Your Work 5-1.......................................
5.1 General 5-1.....................................................
5.2 Example of how a map sketch may look 5-2.........................
5.3 Thinning 5-3....................................................
5.4 Regeneration harvesting 5-5.......................................
5.5 Working technique for regeneration harvesting 5-6...................
5.5.1 Felling into trees 5-6.........................................
5.5.2 Felling outwards from the stand 5-7...........................
5.5.3 Felling in both directions 5-8..................................
5.6 Working technique for thinning 5-9................................
5.6.1 Thinning with a harvester alone 5-9............................
5.6.2 Thinning with a harvester and chain saw 5-10....................
5.6.3 Thinning between logging roads 5-11...........................
5.7 Felling 5-12......................................................
5.7.1 Stump height 5-12...........................................
5.7.2 Felling stage 5-12............................................
5.7.3 When felling on sloping ground 5-14............................
5.7.4 Felling trees with large roots 5-15...............................
5.8 Delimbing, Crosscutting 5-16.......................................

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Timberjack 745
5.9 Checklist 5-18....................................................
5.9.1 Felling/Crosscutting 5-18......................................
5.9.2 Delimbing 5-19..............................................
5.9.3 Feeding 5-20................................................
6. Maintenance 6-1.............................................
6.1 Servicing safety precautions 6-2....................................
6.2 Saw unit safety 6-4..............................................
6.2.1 When replacing the saw chain 6-4.............................
6.3 Instructions for greasing 6-5.......................................
6.4 Oil recommendations 6-6.........................................
6.4.1 Grease 6-6.................................................
6.4.2 Hydraulic oil 6-6............................................
6.4.3 Saw chain oil 6-7............................................
6.4.4 Greasing the diameter and lenght measurement sensors 6-7.......
6.5 Tightening torques for bolt fastenings 6-7...........................
6.6 Daily maintenance or after every 10 hours 6-8.......................
6.7 Weekly maintenance or after every 50 hours 6-9.....................
6.8 Service after every 250 hours 6-9..................................
6.9 Chain saw maintenance 6-10.......................................
6.9.1 Tightening the saw chain 6-11.................................
6.10 The feeding system 6-12...........................................
6.10.1 Feeding rollers 6-12..........................................
6.10.2 Tightening the feeding roller chains 6-13........................
6.10.3 Feeding roller motors 6-14.....................................
6.10.4 The feeding roller hubs at the bevel shaft 6-14...................
6.11 Saw components 6-15.............................................
6.11.1 Saw unit 6-15...............................................
6.11.2 Replacing the tip sprocket 6-17.................................
6.11.3 Replacing the guide bar and saw chain 6-17......................
6.11.4 Sharpening the saw chain (.404 chain pitch) 6-18.................
6.11.5 Saw guide bar maintenance 6-20...............................
6.11.6 Checking/Replacing the tip sprocket 6-21........................
6.12 Length measurement system 6-22...................................
6.13 Diameter measurement system 6-24.................................
6.13.1 Checking the TJ 3000 / TimbermaticZ300 set values 6-24.........
6.13.2 Checking the diameter potentiometer, TimbermaticZ10 6-25......
6.13.3 Checking the diameter potentiometer, Lokomatic 6-25.............

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Timberjack 745
6.13.4 Adjustment 6-26.............................................
6.13.5 Mounting the diameter sensors 6-29............................
6.14 Sharpening the delimbing knives 6-30................................
6.15 Installation of inductive switches 6-31................................
6.15.1 The adjustment of the “Saw bar home” sensor 6-31...............
6.15.2 The adjustment of the positional sensor of the saw bar 6-31........
6.16 Troubleshooting 6-34..............................................
7. Hydraulic system 7-1.........................................
7.1 Hydraulic components 7-3........................................
7.2 Hydraulic diagram 7-3............................................
7.3 Checking and adjusting pressures 7-9...............................
7.3.1 Adjusting the main pressure relief valve (13) 7-10.................
7.3.2 Checking the adjustment of the main pressure relief valve (13) 7-11.
7.3.3 Checking/Adjusting the pressure reducing valve for the upper
pressure of the delimbing knives (Upper knives; 41) 7-11...........
7.3.4 Checking/Adjusting the pressure relief valve for the lower
pressure of the delimbing knives (Upper knives; 34) 7-12...........
7.3.5 Checking/Adjusting the pressure relief valve (28) for the lower
squeeze pressure of the feeding rollers 7-13......................
7.3.6 Checking/Adjusting the pressure relief valve (29) for the increased
squeeze pressure of the feeding rollers 7-14......................
7.3.7 Checking/Adjusting the pressure reducing valve (31) of
the harvester head lift 7-15....................................
7.3.8 Adjusting the pressing power on the saw 7-16....................
7.3.9 Adjusting the flow control check valve (70) 7-16..................
7.3.10 Adjusting the pilot pressure 7-17...............................
8. Electrical system 8-1..........................................
8.1 Control and measuring system 8-2.................................
8.2 Connectors 8-3..................................................
8.2.1 HHM 8-3..................................................
8.2.2 HM, attachment 8-7.........................................
8.3 Wiring diagram 8-9..............................................

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Timberjack 745
11. Optional equipment 11-1......................................
11.1 Dye marking system 11-1..........................................
11.1.1 Putting the system into use 11-1...............................
11.1.2 Maintenance 11-2............................................
11.1.3 Useful tips 11-4..............................................
11.1.4 Technical specifications of color pump 11-4......................
11.2 Saw equipment 11-5..............................................
11.2.1 Saw components 11-5........................................
11.2.2 Hydraulic pressures and volyme flows 11-6.......................
11.2.3 Tightening torques for bolt fastenings 11-6......................
11.2.4 Maintenance 11-6............................................
11.2.5 Description of operation 11-7..................................
11.2.6 Special tools 11-8............................................
11.2.7 Chain lubrication system 11-9..................................
11.2.8 Chain tensioning in conjunction with sawing 11-10.................
11.2.9 Bleeding the chain tensioning system 11-11.......................
11.2.10 Adjusting the pressure of the chain tensioner 11-12................
11.2.11 Changing the saw chain 11-13..................................
11.2.12 Changing the saw bar 11-14....................................
11.2.13 Changing the bar holder 11-15..................................
11.2.14 Bleeding the chain lubrication system 11-16.......................
11.2.15 Adjusting the sensors 11-17.....................................
11.2.16 Hydraulic diagram, SuperCut 11-17..............................
12. Technical data 12-1............................................

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PageIssueSerial no 08/01-0800FY0462-
Timberjack 745
1. Introduction
This operator’s manual describes the operation
of your Timberjack 745 harvester head.
This machine may only be operated by those
who have successfully completed a Timberjack
course for 745 operators.
The operator must also have read and under-
stood the entire operator’s manual.
This manual will provide you with information
about the construction and operation of the ma-
chine that is essential in order to use and look af-
ter the machine correctly. It will also serve as
guidance for maintenance and certain adjust-
ments.
For more complicated maintenance or repairs
you should contact your nearest authorized ser-
vice workshop. Our service personnel have the
experience and specialist tools that are necessary
for more complicated work.
The excavator or any other machine and the
boom which are modified to be used as the har-
vester head carrier must fulfill the following re-
quirements:
- The machine must be CE-certified when
working in an European Union country.
- EU machine directive 89/392/EEG
- EMC directive
- The machine must fulfill all other national
and international regulations.
NOTE
Make sure that the carrier fullfills all
above mentioned requirements.
- The base machine and the boom must be suit-
able for use in a mechanized logging applica-
tion.

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Timberjack 745
1.1 General
This head is designed to fell, delimb and cross-
cut trees.
Regular servicing and correct operation are vital
to ensure a long service life. You should there-
fore follow carefully the instructions in this
manual.
Experience shows that a thorough inspection of
the machine at regular intervals is a guarantee
for favourable cost efficiency. The combination
of your care and experience and the high quality
of construction will ensure minimum downtime
and high performance throughout the life of the
machine.

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Timberjack 745
1.2 Single-grip harvester head
The Timberjack 745 is a compact harvester head
designed for felling, limbing and cross-cutting
trees.
The head is mounted on the tip of a boom to fa-
cilitate simple and efficient sorting and high-
level stacking.
The Timberjack 745 can also be used for early
thinning and regeneration harvesting of trees up
to the maximum diameter specified in the Tech-
nical Data. Because it can handle fallen trees the
745 can also be used as a processor.

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Timberjack 745
1.2.1 Main components
13
10
1211
1
2
3
4
5
6
7
8
9
10
1. Rotator.
2. Fixed delimbing knife.
3. Moving delimbing knife (left).
4. Motor for left feeding roller 500 cubic cm.
5. Saw guide bar and motor, standard
(SuperCut saw unit as option)
6. Moving delimbing knife
(lower; optional equipment).
7. Equipment for measuring of length.
8. Motor for right feeding roller 500 cubic cm.
9. Serial number of harvester head.
10. Two diameter sensors (on upper delimbing
knives).
11. Valve block for harvester head control (not
shown).
12. Upper feeding roller (left).
13. Motor for left upper feeding roller 315 cubic cm.

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PageIssueSerial no 08/01-0800FY0462-
Timberjack 745
2. Warranty
Timberjack guarantees its machine in com-
pliance with the standard warranty conditions of
the Timberjack group.
Our responsibility for machines manufactured
by us requires that:
- the machine is used and maintained by skilled
and trained persons only.
- the machine is used and maintained in com-
pliance with this operator’s manual and the
service manual for this machine.
- the fuel and oil specifications stated in this
manual are adhered to.
- only Original Timberjack Spare Parts are
used.
2.1 Warranty service
The machine was checked and test driven before
delivery, and it can be put to use immediately.
However, to ensure good reliability it is very im-
portant to thoroughly service the machine once
it has been put to use.
The warranty given by Timberjack will be valid
provided that the machine is handed over for af-
ter sales maintenance after appr. 250 running ho-
urs, the service shop being one authorized by
Timberjack .
CAUTION
The harvester head may be
badly damaged if you work
on trees that are oversize!
Do not use the harvester for
the processing of trees that
exceed maximum ratings!

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Timberjack 745

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Timberjack 745
3. Safety instructions
If any information or instructions in this manual
does not agree with local legislation you should
follow the local legislation.
The head may only be used and maintained by
personnel who have undergone training ap-
proved by Timberjack.
Make sure you are familiar with local occupa-
tional safety legislation on working with forest-
ry machinery, as well as the safety precautions
that apply to operation of the Timberjack har-
vester head. You can read about them later in this
manual and on decals affixed to the machine.
3.1 Warning Symbol
This warning symbol is used throughout the
manual wherever there is a risk of personal inju-
ry or damage to the machine if you do not follow
the instructions.

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Timberjack 745
3.1.1 Meaning of warnings
DANGER indicates a risk of fatal injury. There
is a risk of serious or fatal injury if the necessary
measures are not taken.
WARNING indicates dangerous situations.
There is a risk of accident resulting in serious or
fatal injury if the necessary measures are not
taken.
CAUTION indicates hazardous situations.
There is a risk of minor personal injury if the
necessary measures are not taken. The word
CAUTION may also be used to warn of unsafe
methods of working in situations that can lead to
personal injury, or to point out particularly im-
portant facts.
DANGER
WARNING
CAUTION

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Timberjack 745
3.2 General safety rules
CAUTION
The machine may only be used by
operators who are properly trained to
operate and use the machine.
- Check the machine for potential faults before
starting each shift.
- Before starting always ensure that no-one is
near the machine where there is risk of per-
sonal injury!
- Standing in front of or behind the chain saw
(in the longitudinal direction of the saw bar)
is absolutely prohibited. Watch especially the
area in line with the saw chain!
- Avoid crosscut felling when the cabin is on
the sawing line.
- Never stand in front of a saw chain when it is
running.
- Regularly check: Saw bar, saw chain and s-
procket wheel for secure mounting, damage,
etc.!

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Timberjack 745
3.3 Operating safety precautions
- Do not allow anyone within a risk zone of 70
metres from the machine! Stop the machine
immediately, if someone steps to this area.
Watch especially the area in line with the saw
chain!
- Never leave the machine unattended while
the engine is running.
- Keep all doors and windows closed during
operation. When you are learning to use the
machine or demonstrating it, stay in the cab.
- Notice the safety distances to electric lines.
- Notice the weakness and inclination of the
ground. Follow the information package of
the stand.
- Check that no-one is in the line of the blade
during sawing. Should the saw chain break,
fragments may fly off causing a risk of acci-
dents.
- Avoid sawing above the lower edge of the
cabin window.
- Only chains, guide bars and tip sprockets
from a well-known manufacturer should be
used.
- Never saw with a damaged or worn-out guide
bar or chain.
- Follow up cut times. There is an automatic
cut time supervision in Tj 3000 / Timber-
maticZ300. Change a worn chain when
needed.
- Use as short guide bar as possible.
- Never saw with a bent or poorly aligned guide
bar.
- Check that the saw bar returns immediately
after sawing through. Avoid sawing through
too large stems. If the bar goes too far, the
chain may jump off or possibilities of sawing
to a stone grows. See additional instructions
on regulating the control system saw depth.

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Timberjack 745
3.3.1 Before a new shift
- Test all the machine functions!
3.3.2 Transport by road
In the event of transport by road, the harvester
head is suspended from chains.
The chains may be attached only by using the ap-
propriate holes (A), see illustration.
A

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Timberjack 745
3.4 Servicing safety precautions
DANGER
You must never carry out service on the
machine while the engine is running.
WARNING
Never touch pressurised cylinders orhy-
draulic hoses or stand in the vicinity of
them.Donottightenleakingconnectors
whenthemachineisrunning.Highpres-
sure jets of oil can be fatal!
- The manufacturer cannot take any responsi-
bility for conversion of the head’s construc-
tions or electrical and hydraulic systems if
these are not the same as the original.
- Never modify the hydraulic system to speed
up the chain rotation.
- Rest the harvester head firmly and safely on
the ground and release the hydraulic rams.
However, do not operate the cylinders all the
way to the end limiters.
- Lock the harvester head so that it cannot fall
over. See group 6.1.
- Stop the engine.
- You must never stand between the delimbing
tools, feed rollers or in front of the saw bar
while the engine is running!
- When washing the harvester head with pres-
surized water, be careful with the electrical
components: make sure no water gets inside.