LRS 2001 & 2401 QUADSAW & HXF3300 TELEHANDLER FRAME Edition 1.1 2012
LRS 2001 & 2401 QUADSAW & HXF3300 TELEHANDLER FRAME Handbook & Parts Book Please ensure that this manual is handed to the operator before using the machine for the first time. The operator must fully understand the contents of this manual before using this machine. (If the machine is resold the Manual must be given to the new owner.) IMPORTANT NOTE The information contained in this manual is correct at the time of publication. However, in the course of constant development, changes in specification are inevitable. Should you find the information given in this book different to the machine it relates to please contact the After Sales Department for advice Spearhead Machinery Green View, Salford Priors, Evesham, Worcestershire, WR11 8SW Tel: 01789 491860 Fax: 01789 778683 www.spearheadmachinery.com enquiries@spearheadmachinery.com Spearhead Machinery Limited 2
CE Declaration of Conformity, Conforming to EU Machinery Directive 2006/42/EC We, Spearhead Machinery Ltd, Green View, Salford Priors, Evesham, Worcestershire, WR11 8SW hereby declare that: Product.. Product Code.. Serial No..... Type.. Manufactured by: Alamo Manufacturing Services (UK) Limited, Station Road, Salford Priors, Evesham, Worcestershire, WR11 8SW Complies with the required provisions of the Machinery Directive 2006/42/EC. The Machinery Directive is supported by the following harmonized standards: BS EN ISO 14121-1 (2007) Safety of Machinery Risk Assessment, Part 1: Principles Part 2: Practical Guide and Examples of Methods. BS EN ISO 12100-1 (2010) Safety of Machinery Part 1: Basic Terminology and Methodology Part 2: Technical Principles. BS EN 349 (1993) + A1 (2008) Safety of Machinery Minimum Distances to avoid the Entrapment of Human Body Parts. BS EN 953 (1998) Safety of Machinery Guards General Requirements for the Design and Construction of Fixed and Movable Guards. BS EN 982 (1996) + A1 (2008) Safety Requirements for Fluid Power Systems and their Components. Hydraulics. The EC Declaration only applies if the machine stated above is used in accordance with the operating instructions. Signed (On behalf of Spearhead Machinery Ltd) Status Date General Manager 3
CONTENTS Handbook Section 5 Mounting the Quadsaw 5 Operation & Introduction 6 Driving Recommendations 6 Maintenance 7 Belts 7 Technical Data & Description of Working Tool 9 Safety 10 HXF 3300 Mounting Frame 11 Attaching the Frame 11 Transport and Work Positions 12 Hydraulic Diagrams 13 HXF 3300 Controls (Optional Extra) 14 Diverter Valve Kit (Optional Extra) 15 HXF 3300 Maintenance 16 Troubleshooting Guide 18 Parts Section 19 Mainframe 1 19 Mainframe 2 20 Blade Shaft 21 Adjusting System 22 Piston Motor 23 Decals 24 HXF 3300 Telehandler Frame 25 HXF 3300 Telehandler Frame Valve Assembly 26 Warnings & Directions 27 4
MOUNTING THE QUADSAW The blades MUST be mounted in a downward cut rotation in relation to the tractors driving direction. The blade carrier centre bolt (M10) should be tightened to 25Nm and the (M8) outer bolts tightened to 40Nm. Mount the Quadsaw so the blades are running in the driving direction. Install and connect the hydraulic hoses so the blades are running in the correct direction. The separate drainage hose must be led directly back to the oil reservoir. Check all connections for any oil leaks. The first time the machine is used the blade speed should be measured and adjusted to achieve the optimum working speeds of: LRS 2001 (3000-3200 RPM) LRS 2401 (2700-2800 RPM) Holding this speed is important for the best optimum performance. 5
OPERATION & INTRODUCTION The Spearhead Quadsaw encompasses a range of hydraulic arm mounted 4 blade saw units used for cutting branches and small trees. The LRS 2001 is fitted with four 500mm saw blades with a cutting capacity of up to 120mm diameter. Branches thicker than 80mm should be cut one at a time. The LRS 2401 is fitted with four 600mm saw blades with a cutting capacity of up to 160mm. Branches thicker than 120mm should be cut one at a time. Best performance is achieved by cutting in an upright or vertical cutting position and angled at no more than 45 degrees from this position. Horizontal cutting is possible on hedges with a width up to 1.2m and a branch diameter up to 40mm, thicker branches might stall the blades and or cause the blades to get stuck. DRIVING RECOMMENDATIONS It is recommended to travel at a slow forward speed when starting work in order to retain the recommended rpm of the blades. The angle of the saw should be adjusted to approximately 90 degrees in relation to the branches. If a thick branch is approaching the branch reflectors, the working position must be adjusted for the branch to hit the saw blades straight on. If small branches or other unwanted material gets stuck in the blades, the machine and tractor must be stopped and the debris cleared. Always try to keep the blades running vertical in relation to the direction of travel, this will prevent the blades from flexing too much during operation. An optional skid can be mounted at the bottom of the Quadsaw to prevent the saw blades from hitting the ground. 6
MAINTENANCE Initial Maintenance After an initial 2 hours work all taper-locks must be retightened to 31Nm. After 10 hours work all bolts, screws and taper-lock bushes must be retightened. If the bushes loosen at a later time they may be secured with Loctite or equivalent. Regular Maintenance All bolts must be retightened on a regular basis. The plastic strips are adjusted down to 1mm clearance from the blades. The plastic strips must be replaced if the clearance distance exceeds 5mm. The branch deflectors must be adjusted as close as possible to the blades without touching. Dismount the belt guard to clean the housing. Inspect and if necessary adjust the belts (see belt diagram here or under belt guard). After inspection or service ALL protection plates and guards must be replaced before using the machine. BELTS It is important that belts are kept in good condition and are correctly tensioned at all times. The correct tensions are as follows: LRS 2001: Short Belt 550 Nm and Long Belts 650 Nm LRS 2401: Short Belt 900 Nm and Long Belts 1100 Nm 7
Tensioning the Belts CAUTION! Care must be adopted when servicing this part of the machine as there is risk of trapping hands or fingers in the belts, pulleys and blades. WARNING: Ensure cover is replaced and all bolts are re-tightened before using the machine. 8
TECHNICAL DATA & DESCRIPTION OF WORKING TOOL Quadsaw for mounting on hydraulic hedgecutters or specified HXF3300 Telehandler Frame. Model LRS 2001 LRS2401 Working Width 2000mm 2380mm Blade Speed 3000 3200 RPM 2700 2800 RPM Blade Diameter 500mm 600mm Teeth per Blade 72 Teeth 78 Teeth Material Hardened Steel with Special Teeth HM Precision Blade Hardened Steel with Special Teeth HM Precision Blade Performance 1-120mm Branch Diameter 1-160mm Branch Diameter Application Vertical Vertical Oil Flow 15.0 CC Oil Flow 28.0 CC 50 Litres Relief Valve 170 Bar 85 Litres Relief Valve 140 Bar 45 Litres Relief Valve 170 Bar 80 Litres Relief Valve 140 Bar 9
SAFETY Never operate the machine with other people present as it is possible for debris to be thrown from the saw blades in all directions. Always ensure all cab safety guards are in place and all tractor windows are closed. Never allow an inexperienced person to operate the machine without supervision. Never allow children to play near or around the machine at any time. Never attempt any maintenance or adjustment without first disengaging the PTO/hydraulic pump, lowering the head to the ground, stopping the tractor engine and applying the tractor parking brake. Before leaving the cab remove the ignition key. Never stop the engine with the PTO engaged. Before leaving the tractor cab always ensure that the saw head is firmly on the ground, no weight is on the tractors hydraulics and blades have stopped spinning. Never transport with the PTO engaged. Always check that all guards are properly fitted, check there are no damaged or loose parts. Always operate the blades at a speed between 2700-3200 RPM (depending on the model). Maximum oil pressure of 250 bar in the hydraulic hoses. Never transport without the blade protection guards mounted. Always inspect work area for wire, steel posts, large stones and other dangerous materials. If such items are found remove them. Never attempt to use the machine for any other purpose other than what it was designed for. Ensure all warning labels are always visible and that they are not damaged, defaced or missing. 10
HXF3300 MOUNTING FRAME The HXF3300 is a mounting frame specifically designed for attaching the Spearhead LRS 2001 or LRS 2401 Quadsaw models to Telehandlers. The HXF3300 features a reach of approximately 2.5 metres, 180 manual folding system, and hydraulic collision safety. The overall weight of the unit, without tools, is 225kg. ATTACHING THE FRAME 1) Drive up to the machine, tilt attachment bracket into the horizontal position. 2) Locate attachment bar into hooks and secure latches. 3) Tilt bracket backwards 90. 4) Detach supporting legs. DANGER Keep well clear of all overhead power lines when manoeuvring or operating this machine. 11
TRANSPORT & WORK POSITIONS Transport Position Work Position C A B The procedure for moving the machine from transport position to work position is as follows; A) Remove transport pin. B) Manually fold the arm out by 180 into the work position. C) Fit and secure the ram pin. Storage Position 12
HYDRAULIC DIAGRAMS 13
HXF3300 CONTROLS (OPTIONAL EXTRA) An optional electrical control unit is available for controlling the main functions of the HXF3300 and LRS Quadsaw. Operator Controls 1) On/Off Switch. 2) Cutting Angle Switch. 3) Tool On/Off Switch. 4) Control Unit Fuse (8 Amp). Cutting Angle Adjustment The cutting angle is adjusted hydraulically by operation of the rocker switch (2); operate the switch in the required direction to set the desired cutting angle before starting work. The angle switch may be operated during work to make minor angling adjustments, but it is recommended to halt work before making major adjustments to the cutting angle. Valve Unit (Part of Optional Electrical Control Unit) 1) Flow Adjustment. 2) Manual Override. 3) Pressure Relief Valve (200 bar). A) Flow for Tool (regulated). B) N/A C) Cutting Angle D) Cutting Angle P) Pressure (flow from pump). T) Tank Connection (pressureless + T from motor). 14
Electrical Diagram DIVERTER VALVE KIT (OPTIONAL EXTRA) P) Pressure from pump (Max. 150L/min). R) Regulated oil flow (Max. 90L/min). T1) Return from motor. T) Tank connection. M) Manometer test plug. P / R / T1 / T = ¾ Thread M = ¼ Thread 15
HXF3300 MAINTENANCE Lubrication Grease the lubrication points on machine on the following basis; Daily prior to use. Always prior to storage. Always after it has been washed. NOTE: Never use grease that contains Molybdenum Disulfide on nylon bushes. Hydraulic Hoses Inspect hydraulic hoses and fittings on a daily basis prior to using the machine; ensure they are free from damage or leaks and that the hoses are not rubbing on machine components. Any damaged hoses or fittings should be repaired or replaced immediately. Run new hoses alongside the old ones prior to removal to ensure the correct routing is retained. When replacing a hose avoid twisting it, use 2 spanners to tighten it. Ensure hoses bend with machine movements and that they do not twist or strain. All hose connections are of a soft seal type and should only be turned a further 1/2 turn more than hand tight in order to be leak-proof (see table below). Machine Oil Supply BSP Nm (size) ¼ 24 Nm 18 lbs/ft ⅜ 33 Nm 24 lbs/ft ½ 44 Nm 35 lbs/ft ¾ 84 Nm 62 lbs/ft 1 115 Nm 85 lbs/ft Check oil level in the tank each day prior to starting work - it is good practice to constantly keep an eye on the sight glass level as a ruptured pipeline can empty a system within minutes; a pump or motor that runs out of oil will be damaged beyond repair very quickly. The oil must be changed if there are signs that it is contaminated (discolored). Ensure cleanliness when replacing or topping up the oil by; Carefully cleaning around the filler neck prior to opening. Always using clean containers for refilling the system. Regular inspection of the filtration system. Never letting the oil level fall below the level in the sight glass. 16
Check daily that all hydraulic connections and fittings are in good condition. Any defect or leak must be immediately repaired, it is part of the daily maintenance that will reduce costs and prolong machine life. If fittings require retightening always use 2 spanners and avoid over tightening. If the fitting continues to leak, replace it. Regular Maintenance Tasks After every 4 hours of use the following maintenance task should be observed; Check bolts for tightness and retighten if required. Check valve block, hoses and fittings for signs of leaks retighten or replace seals if required. Bolts and bushes should be greased and retightened. Bolts and Bushes All major pivot points are equipped with replaceable bushings, if they show signs of wear, replace them. NOTE: Never use grease that contains Molybdenum Disulfide on nylon bushes. Machine Storage Before the machine is placed into storage, it should be thoroughly washed. Remove all traces of grass, leaves and dirt. Take care if using high pressure jet hoses or steam cleaners as these can quickly damage paintwork and decals. Remove all cleaning products thoroughly to avoid them from staining or damaging the paint. Grease lubrication points until fresh grease comes out. Where applicable, drive belts should be loosened to remove tension and relax the belts. Ideally, the machine should be stored in a clean dry environment where it is protected from the elements; if the machine has to be stored outside it is advisable to keep it covered over to protect it from rain and sunlight. Control units should be stored clear of the ground and protected from the damp. It is recommended that canvas tarpaulin or similar coverings are used to cover the machine rather than plastic sheeting which would harbor condensation and promote rapid corrosion. 17
TROUBLESHOOTING GUIDE Problem Possible Cause Solution Valve or motor leak. Oil pressure too high. Hose incorrectly fitted or Check pressure. Replace gasket. Refit and tighten correctly. loose. Overheating. Tool speed incorrect. Incorrect oil level. Wrong oil type. Electrical failure. Hydraulic failure. Irregular arm movements. Electric valve not responding. Blades clogged. Air temperature too high. Wrong supply from tractor. Contacts exposed to water. Oil level too low. Pressure hose kinked. Oil leak in pressure hose. Oil pump suction filter blocked. Broken spring in the PVG valve. Defective ram seals. Faulty wiring. Dirt in valve. Valve stuck. Insufficient voltage. Check PTO speed. Check oil level. Empty tank and fill with correct oil. Stop machine and clear blades. Reduce operating speed/install fan. Check fuse and supply from tractor. Always store protected from water. Top up oil to correct level. Check pump rotates / check hoses. Check machine for leaks. Replace filter element. Check spring replace if required. Check seals replace if required. Check wiring and switches. Check and clean valve. Replace valve. Check for bad connection. 18
PARTS SECTION MAIN FRAME 1 Pos LRS 2001 LRS 2401 Description Number 1 200101.0 Mounting arm with splines 1 1 200101.1 240201.0 Mounting arm from 2005 onwards 1 10 + 40 Bolt 4 16 + 40 Bolt 1 2 240147.0 240147.0 Welding kit for arm 1 3 200170.H 240170H Skid EU model 1 3 200170V 240170V Skid for left use/gb model 1 4 200112.0 240112.0 Branch carried fits on L & R hand machines 3 5 200141.0 240141.0 Belt/Short 1 6 200140.0 340140.0 Belt/Long 2 7 200142.0 200142.0 Rubber protection 1 19
MAIN FRAME 2 Pos LRS 2001 LRS 2401 Description Number 1 200111.1 240111.0 BLADE 4 2 200110.0 200110.0 PLASTIC STRIP 1 3 240168.0 WEAR PLATE - LONG 4 4 200157.0 200157.0 WEAR PLATE SHORT JUNE 2007 4 4 200153.0 200153.0 WEAR PLATE SHORT - JULY 2007 4 5 200162.0 200162.0 TRAFFIC PROTECTION 1 20
BLADE SHAFT Pos LRS 2001 LRS 2401 Description Number 1 200114.0 200114.0 MOUNTING PLATE 4 2 200115.0 CENTRE BOLT - CONICALLY 4 200115.1 200115.1 CENTRE BOLT STD ALLEN 4 3 200116.0 200116.0 BOLT 4 X 6 4 200117.0 200117.0 BLADE SHAFT 4 5 200118.0 200118.0 SEAL 4 6 200119.0 200119.0 CIRCLIP 4 X 2 7 200120.0 200120.0 BEARING 4 X 2 8 200121.0 200121.0 CIRCLIP 4 9 200122.0 200122.0 PULLEY 4 10 200123.0 200123.0 TAPER LOCK CLAMPING ELEMENT 4 21
ADJUSTING SYSTEM Pos LRS 2001 LRS 2401 Description Number 1 200121.0 200121.0 LOCK RING 2 2 200119.0 200119.0 LOCK RING 2 X 2 3 200120.0 200120.0 BEARING 2 X 2 4 200124.0 200124.0 TENSION PULLEY 1 5 200125.0 200125.0 ADJUSTABLE TIGHTENING PLATE 1 6 200126.0 200126.0 PULLEY DOUBLE 1 7 200127.0 200127.0 ADJUSTMENT BOLT 2 8 200128R 200128R ADJUSTMENT BOX 1 8 200128L 200128L ADJUSTMENT BOX 1 9 200129.0 200129.0 WASHER 4 10 200108.0 200108.0 SPRING WASHER 5 11 200109.0 200109.0 BOLT 5 12 200107.0 200107.0 WASHER 1 22
PISTON MOTOR Pos LRS 2001 LRS 2401 Description Number 1 200230.0 200230.0 PISTON MOTOR 15CC 1 200231.0 200231.0 PISTON MOTOR 28CC 1 1A 200130A 200130A SEAL + O RING (OUTPUT SHAFT) 1 1B 200130B 200130B SEAL KIT COMPLETE 1 2 200235.0 200235.0 MOUNTING PLATE 1 3 200237.0 200237.0 PULLEY 1 4 200234.0 200234.0 KEY 1 5 200129.0 200129.0 WASHER 2 6 200108.0 200108.0 SPRING WASHER 2 7 200109.0 200109.0 BOLT 2 8 200138.0 200138.0 WASHER 1 9 200156.0 200156.0 SPRING WASHER 1 10 200139.0 200139.0 BOLT 1 200158.0 200158.0 ¾ HYDRAULIC HOSE 2 200159.0 200159.0 3/8 HYDRAULIC HOSE 1 3870500 3870500 PROTECTION HOSE 1.6M 23
DECALS KEEP BOLTS TIGHT Check bolt tightness after 1 hour, 4 hours, 10 hours & there after daily 1 2 3 4 Pos LRS 2001 LRS 2401 Description Number 1 8770360 8770360 ROTATION PARTS 1 2 8770359 8770359 ELECTRICAL WIRE KEEP DISTANCE 1 3 8770357 8770357 KEEP DISTANCE TO MACHINE 1 4 8770362 8770362 READ SERVICE BOOK 1 5 8770363 8770363 READ HANDBOOK GB+D+F+NL 1 8770340 8770340 READ HANDBOOK DK+N+S+SF 6 8770306 8770306 KEEP BOLTS TIGHT 1 7 8770301 8770301 SPEARHEAD 50CM 1 24
HXF3300 TELEHANDLER FRAME Pos HXF3300 Description Number 1 481177182 RAM 1 2 8334001.0 BUSH 4 3 482677062 RAM 1 4 3041935 ACCUMULATOR 1 5 8331506 ARM 1 6 8331503 PIN 1 7 8331502 PIN 1 8 8331501 PIN 1 9 8331504 BRACKET L/H 1 8331505 BRACKET R/H 1 10 8331508 MAINFRAME 1 11 833050HF0 GUARD 1 NS S49306 TOP LINK 1 25
HXF3300 TELEHANDLER FRAME VALVE ASSEMBLY Pos HXF3300 Description Number 1 157B6709 PRIORITY VALVE 1 157B6200 MOTOR VALVE 1 157B6100 TOOL VALVE 1 2 157B2018 END COVER 1 3 157B5010 END COVER - PRESSURE 1 4 157B3999 SEAL KIT FOR LEVER 1 5 157B4997 O RING KIT ELECTRIC VALVE 1 6 157B8003 SEAL KIT SANDWICH 1 7 157B3173 LEVER HOUSING C/W SEAL KIT 157B3999 1 8 157B4216 ELECTRIC VALVE C/W O RING KIT 157B4997 1 NS 157B7000 SPOOL 10l NS 157B7103 SPOOL 65l 26
WARNINGS & DIRECTIONS Never attempt any maintenance or adjustment without first disengaging the PTO/Hydraulic pump Only authorised personal must do maintenance work on the equipment Read this manual carefully before using the machine 27
28
29