John Deere Harvester Boom: Warning

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John Deere

Harvester Boom

OPERATOR’S MANUAL
John Deere CH8 Harvester Boom
OMF0669911 Issue 15JUL05 (ENGLISH)

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are


known to the State of California to cause cancer, birth
defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.

The State of California requires the above two warnings.

Worldwide Construction
And Forestry Division
LITHO IN FINLAND
Contents
Page Page

Introduction Operating
Base Machine Requirements . . . . . . . . . . . . . . . 01-1 Operating Safety Precautions . . . . . . . . . . . . . . . 06-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 General Operating Instructions . . . . . . . . . . . . . . 06-2
John Deere Contact Information . . . . . . . . . . . . . 01-2
Technical Information Feedback Form . . . . . . . . 01-3 Maintenance—General
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Warranty Servicing safety precautions . . . . . . . . . . . . . . . 7-1-1
Standard warranty . . . . . . . . . . . . . . . . . . . . . . . 02-1 General maintenance instructions. . . . . . . . . . . 7-1-2
Tightening torques for bolted joints. . . . . . . . . . 7-1-3
Fluids and lubricants . . . . . . . . . . . . . . . . . . . . 7-1-4
Safety - General Precautions
Oil capasities . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-1-1
Welding Instructions . . . . . . . . . . . . . . . . . . . . . 7-1-6
Recognize Safety Information. . . . . . . . . . . . . 03-1-1
Bleeding the Hydraulic System . . . . . . . . . . . . . 7-1-6
Understand Signal Words. . . . . . . . . . . . . . . . 03-1-2
Prepare for Emergencies . . . . . . . . . . . . . . . . 03-1-2
Maintenance
Wear Protective Clothing . . . . . . . . . . . . . . . . 03-1-3
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . 7-2-1
Handle Chemical Products Safely. . . . . . . . . . 03-1-4
Every 10 Hours or Daily . . . . . . . . . . . . . . . . . . 7-2-2
Replace Safety Signs . . . . . . . . . . . . . . . . . . . 03-1-5
Every 50 Hours or Weekly . . . . . . . . . . . . . . . . 7-2-2
Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . 7-2-4
Safety - Operating Precautions Every 1000 Hours. . . . . . . . . . . . . . . . . . . . . . . 7-2-5
Keep Danger Zone Clear . . . . . . . . . . . . . . . . 03-2-1 Every 2000 Hours. . . . . . . . . . . . . . . . . . . . . . . 7-2-5
Avoid Power Cables . . . . . . . . . . . . . . . . . . . . 03-2-2 Expander Fitting Instuctions . . . . . . . . . . . . . . . 7-2-6
Driving/Transporting on Public Roads. . . . . . . 03-2-3 Dismantling of Expander Bolts . . . . . . . . . . . . . 7-2-9

Safety - Maintenance Precautions Technical data


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-3-1 CH8 Specifications . . . . . . . . . . . . . . . . . . . . . . . 08-1
Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . 03-3-1 Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1
Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . 03-3-2
What to Do if the Machine Fires? . . . . . . . . . . 03-3-2
Avoid High Pressure Fluids . . . . . . . . . . . . . . 03-3-3
Avoid Heating near Pressurized Fluid Lines . . 03-3-4
Make Welding Repairs Safely. . . . . . . . . . . . . 03-3-4
Dispose of Waste Properly . . . . . . . . . . . . . . . 03-3-5

General
General Description of the CH8 . . . . . . . . . . . . . 04-1

Installation
Assembly instructions . . . . . . . . . . . . . . . . . . . . . 05-1
How to install the hydraulic system. . . . . . . . . . . 05-1
Requirements for the hydraulic installation . . . . . 05-2
BOOM INSTALLATION REPORT. . . . . . . . . . . . 05-3
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-4
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

i 080305
PN=1
Contents

ii 080305
PN=2
Introduction
Base Machine Requirements

This instruction manual describes the operation of your


John Deere booms. Furthermore, the operator must have
studied and understood the entire manual. The manual
provides you with information about the John Deere
boom’s function, which is necessary in order to use and
look after the machine in the proper manner. It also
serves to offer guidance during maintenance and certain
adjustment work. Please contact your nearest authorized
service workshop for more complicated maintenance and
repair work. Our service personnel have the training and
special tools that are required for such tasks. The
excavator or any other machine which is modified to be
used as the harvester boom carrier must fulfill the
following requirements:

• 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 Recuirements

-The base machine must be suitable for use in a


mechanized logging application.

JK11466,00000DE –19–01AUG03–1/1

01-1 080305
PN=4
Introduction

General

Regular servicing and proper operation is of vital


significance for long service life of the machine. The
instructions contained in this manual should therefore be
adhered to.

Experience shows that a thorough check of the boom at


regular intervals is a guarantee for favourable cost
efficiency.

Do not pollute the environment. It is imperative that you


do not allow oil to leak into the ground or water because it
only takes one liter of mineral oil to contaminate one
million liters of water. Should you see a leaky joint, fix it
immediately.

Remember fire prevention. Keep the boom clean at all


times for this reduces the risk of overheating and chance
of a fire starting.

JK11466,00000DF –19–01AUG03–1/1

John Deere Contact Information

Please, visit our web site: www.Deere.com

EL62757,000015B –19–19APR02–1/1

01-2 080305
PN=5
Introduction

Technical Information Feedback Form

We need your help to continually improve our Operator’s


Manuals please FAX or mail your comments, ideas and
improvements on this comment sheet.

SEND TO: John Deere Forestry OY


P.O. Box 474
FIN-33101 Tampere
Finland
Attn: Publications Supervisor

FAX NUMBER: +358 205 84 6160

Ideas, Comments, (Please state Page Number):

OVERALL, how would you rate the quality of "ALL" Operator’s Manuals provided to you? (Check one)
Poor Fair Good Very good Excellent
1 2 3 4 5 6 7 8 9 10

Company Name
Address
Phone
FAX No.
Dealer Acct. No.

THANK YOU!

EL62757,000015C –19–19APR02–1/1

01-3 080305
PN=6
Warranty
Standard warranty

John Deere provides a warranty for the boom in


accordance with the standard conditions of the John
Deere Group.

The following prerequisites apply in relation to our


responsibility for booms that are made by us:

• The boom is exclusively operated and maintained by


experienced personnel who have been trained by John
Deere or by a dealer authorized by John Deere.
• The boom must be operated and maintained in
accordance with the instructions provided in this
manual.
• Classifications for lubricants and fluids stated in the
instructions must be adhered to.
• Genuine John Deere spare parts must be used.
• To ensure reliable operation of the boom it is essential
that thorough servicing of the boom is made after
putting it into operation

JK11466,00000E1 –19–01AUG03–1/1

02-1 080305
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Safety - General Precautions
General

If there are any information or instructions in this manual


that are not in compliance with local laws and regulations
in force in the country or region where this equipment is
operated, the local laws and regulations must take
precedence.

–UN–23AUG88
As the maintainer ensure that you become familiar with all
occupational safety regulations pertaining to forest
machinery as well as all safety instructions pertaining to

TS201
this equipment. Observe the instructions provided in this
manual and on all hazard and information decals on the Read Manual
machine.

AK12300,000003C –19–28FEB02–1/1

Recognize Safety Information

This is a safety-alert symbol. When you see this symbol


on boom or in this manual, be alert to the potential for
personal injury.

–UN–07DEC88
Follow recommended precautions and safe operating
practices.

T81389
Safety-alert symbol

AK12300,000003D –19–28FEB02–1/1

03-1-1 080305
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Safety - General Precautions

Understand Signal Words

A signal word — DANGER, WARNING, or CAUTION — is


used with the safety-alert symbol. DANGER identifies the
most serious hazards.

DANGER or WARNING safety signs are located near

–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

TS187
Signal Words

AK12300,000003E –19–28FEB02–1/1

Prepare for Emergencies

Keep a first aid kit in an easily accessible location on the


vehicle at all times. Check the first aid kit regularly and
make sure you immediately replace all items you have
used.

–UN–23AUG88
Learn to use first aid equipment and fire extinguishers.
Keep emergency numbers always available or save those
to your portable phone.

TS291
First Aid Kit

AK12300,000003F –19–28FEB02–1/1

03-1-2 080305
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Safety - General Precautions

Wear Protective Clothing

Wear close fitting clothing and safety equipment


appropriate to the job.

Prolonged exposure to loud noise can cause impairment


or loss of hearing. Wear a suitable hearing protective

–UN–23AUG88
device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.

Safety face shield, glasses, or goggles should always be

TS206
used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with tools, Wear Protective Clothing
power tools, welding equipment, and corrosive or
dangerous chemicals.

Use a rubber apron and rubber gloves when working with


corrosives and wear heavy work gloves and safety shoes
when handling large heavy and sharp objects.

AK12300,0000040 –19–28FEB02–1/1

03-1-3 080305
PN=10
Safety - General Precautions

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause


serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.

TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what Material Safety Data Sheet
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

See your authorized dealer for MSDS’s on chemical


products used with your machine.

Some advise to remember

• Keep hydraulic oil clean to eliminate possible problems


in hydraulic system. Clead the servicepoints
surroundings carefully when servicing or changing
hydraulic components.
• If possible avoid contact with oil, especially hot oil!
• Skin that has been exposed to oil or chemicals should
be washed immediately!
• wear protective gloves!
• Avoid breathing oil fumes

NOTE: See also safety instructions for base machine

CAUTION: Hydraulic oil may not exceed


recommended maximum values.

Exceeding these values may cause structural


faults and lead to injury or damage

AK12300,0000042 –19–28FEB02–1/1

03-1-4 080305
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Safety - General Precautions

Replace Safety Signs

Replace missing or damaged safety signs. See Spare


Part Book for correct safety sign placement.

–UN–23AUG88
TS201
Safety Signs

AK12300,0000043 –19–28FEB02–1/1

03-1-5 080305
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Safety - Operating Precautions
Keep Danger Zone Clear

CAUTION: A danger zone of 90 metres (300 ft)


applies when the machine is in operation. The
operator is personally responsible for
maintaining this safety rule in the absence of

–UN–06JUN01
the foreman.

When the engine is running, allow no one in the risk zone


of the machine.

T139370
Maintain a safe operating distance between the equipment
and other personnel. Never swing the boom, attachment,
or trees over the heads of bystanders.

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 accidents.

When you stop working, even temporarly, lower the boom


and set the harvester head safely to the ground so that it
cannot move.

AK12300,000010D –19–05NOV01–1/1

03-2-1 080305
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Safety - Operating Precautions

Avoid Power Cables

CAUTION: Avoid operating under overhanging


electrical powerlines for a high voltage can
’jump’ over a distance of several meters in the
air.

–UN–03OCT02
When planning the work, check with the local power
company to find out if there are any overhead cables in
the working zone and the safe distance to them.

T152796
Safety distances to electric lines

Rated voltage (kV) Min. distance under Min. distance on the


(m) side (m)
1 2 (7 ft) 2 (7 ft)
1 — 45 2 (7 ft) 3 (10 ft)
110 3 (10 ft) 5 (16 ft)
220 4 (13 ft) 5 (16 ft)
400 5 (16 ft) 5 (16 ft)

Normally stay in the cab and back up away from a


powerline.

If the engine stops and the machine comes into contact


with a powerline and you have to come out of the
machine do as follows:

Grip firmly with a bare hand on the wrist of the other hand
holding a handle while pushing the door open. Jump out
of the cab both feet together. Keep on jumping feet
together until you are at least 10 meters (33 ft) from the
machine and the powerline. If you fall earlier do not stand
up, but keep on rolling on the ground toward the same
direction.

You run the greatest risk if you are in simultaneous


contact with the machine and the ground. Jump clear from
the machine to the ground.

AK12300,0000113 –19–05NOV01–1/1

03-2-2 080305
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Safety - Operating Precautions

Driving/Transporting on Public Roads

• Ensure that the machine is safe for driving. Adhere to


local and national traffic regulations.
• Secure the boom and harvester head in the transport
position and ensure that the boom cannot move during
the drive.
• By observant of the height of the machine when driving,
eg, tunnels, viaducts, bridges.

AK12300,000004A –19–28FEB02–1/1

03-2-3 080305
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Safety - Maintenance Precautions
General

Keep Boom in good condition and all parts properly


installed. Fix damage immediately. Replace worn or
broken parts. Remove any buildup of grease, oil, or
debris.

Adhere to the maintenance schedule in the operator’s


manual.

AK12300,0000114 –19–06NOV01–1/1

Use Proper Tools

Use appropriate and correct size tools tools. Makeshift


tools and procedures can create safety hazards or cause
machine damages.

Illuminate your work area and service points adequately.

–UN–08NOV89
Secure that portable light has a bulb enclosed by a wire
cage. The hot filament of an accidentally broken bulb can
cause a risk of fire.

TS779
Use power tools only to loosen threaded parts and
fasteners. DO NOT use U.S. measurement tools on metric
fasteners.

Keep tools clean. Avoid bodily injury caused by slipping


wrenches.

Repair or replace worn or damaged tools, before initiating


repair work on your machine.

Use only service parts meeting manufacturer’s


specifications.

AK12300,000004E –19–28FEB02–1/1

03-3-1 080305
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Safety - Maintenance Precautions

Prevent Fires

When working in a forest environment, it is impossible to


prevent combustible debris from collecting in tight corners
of the machine. This debris, in itself, may cause a fire;
however, when mixed with fuel, oil, or grease in a hot or
confined place, the danger of fire is very much increased.

–UN–23AUG88
To reduce the chance of a fire starting, observe the
following instructions:

TS227
• Remove dust and debris especially from the boom
• Clean the radiator grille and cooling ducts regularly.
• Inspect the machine daily for potential fire hazards and
make any necessary repairs immediately.
• Inspect hydraulic hose runs and fixturing to ensure they
are secure and not rubbing against other components.
• Clean up any excess grease and oil accumulation and
repair the leak immediately.
• Use only nonflamable solutions for cleaning the
machine or components.
• Store rags in a safe, fireproof location.
• Before starting repair work, such as welding, the
surrounding area should be cleaned and a fire
extinguisher should be close by.
• Maintain a charged fire extinguisher on the vehicle at all
times and know how to use it.

AK12300,000004B –19–28FEB02–1/1

What to Do if the Machine Fires?

–UN–07SEP00
• Turn the engine off.
• Turn the main switch off.
• Fight the fire by means of the fire extinguisher, if T133554

possible.
• Make sure that the fire will not spread to the
surrounding area. Fire extinguisher
• Call for help if necessary.

Hand-held fire extinguishers can be used through the


arpertures that are bordered with the extinguisher decals.

AK12300,000004C –19–28FEB02–1/1

03-3-2 080305
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Safety - Maintenance Precautions

Avoid High Pressure Fluids

–UN–23AUG88
X9811
AK12300,0000115 –19–06NOV01–1/2

CAUTION: Diesel fuel or hydraulic fluid under


pressure can penetrate the skin and cause
serious personal injury, blindness, or death. If

–UN–20SEP00
an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.

T133840
Fluid leaks under pressure may not be visible. Escaping
fluid can penetrate the skin causing serious injury. When
searching for leaks, wear work gloves and use a piece of
cardboard or wood. Never use your bare hand. Protect
body and wear safety goggles for eye protection.

Pressure can be maintained in a hydraulic system long


after the power source and pump have been shut down.

1. Lower the harvester head safely to the ground, apply


parking brake and shut off the engine.
2. Relieve trapped hydraulic pressure before performing
work on components, or disconnecting any hoses.
3. Tighten all connections before applying pressure.

NOTE: Do not change any pressure setting unless


authorized instruction has been obtained.

AK12300,0000115 –19–06NOV01–2/2

03-3-3 080305
PN=18
Safety - Maintenance Precautions

Avoid Heating near Pressurized Fluid Lines

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

Do not heat by welding, soldering, or using a torch near

–UN–15MAY90
pressurized fluid lines or other flammable materials.

TS953
AK12300,0000056 –19–28FEB02–1/1

Make Welding Repairs Safely

Before starting welding work:

1. Switch off the power with the main switch


2. Disconnect the ground wire from the batteries.

–UN–06JUN01
3. Disconnect all connectors at the under side of the cab

Before starting any welding ensure that the area to be


repaired is cleaned of debris and combustible material.

T139381
Have a charged fire extinguisher available and know how
to use it.

Do all work outside or in a well ventilated area. Dispose of


paint and solvent properly.

Avoid breadhing hazardous fumes. Remove paint before


welding or heating:

• If you sand or grind paint, avoid breathing the dust.


Wear respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.

AK12300,0000059 –19–28FEB02–1/1

03-3-4 080305
PN=19
Safety - Maintenance Precautions

Dispose of Waste Properly

Improperly disposing of waste can threaten the


environment and ecology. Potentially harmful waste used
with equipment include such items as oil, fuel, coolant,
brake fluid, filters, and batteries.

–UN–26NOV90
Use leakproof containers when draining fluids. Do not
pour waste onto the ground or down a drain.

TS1133
Government regulations may require a certified air
conditioning service center to recover and recycle used air
conditioning refrigerants. Recycle Waste

Inquire on the proper way to recycle or dispose of waste


from your local environmental or recycling center, or from
your authorized dealer.

AK12300,000005A –19–28FEB02–1/1

03-3-5 080305
PN=20
General
General Description of the CH8

5
4

3
9
7 6
8

10 2

–UN–27OCT03
1

T195708
1—Base 4—Main boom cylinder 7—Outer boom 9—Rotator link
2—Slewing cylinders 5—Outer boom cylinder 8—Extension boom 10—Rotator
3—Pillar 6—Main boom

AK12300,00000D8 –19–22OCT01–1/1

04-1 080305
PN=21
Installation
Assembly instructions

IMPORTANT: When removing joint pins or other


load-bearing structures bear in mind the
following:

• The lifting capacity of the crane or pulley must be


adequate.
• The hoisting equipment must be reliable and in good
working order.
• The booms must be properly supported in every
direction
• If the hydraulic system has been serviced or repaired,
air must be eliminated from the system before the
machine is put to use again. (See section 7, bleeding
the hydraulic system or base machine operator‘s
manual for more information)

NOTE: The lifting moments of the booms can be seen on


the Section 8 Technical data.

JK11466,00000E5 –19–01AUG03–1/1

How to install the hydraulic system

Pump Recommendation for boom


Boom type Max. working Pressure Oil Flow L/min Power Input
MPa KW
CH883 / CH811 / VH810 25 300 150

Cylinder pressures (bar)


Boom type Slewing Cylinder Lifting Cylinder Jib cylinder Extension cylinder
+ Piston side + - + - + - + -
(-)Rod side
CH883 175 175 250 80 160 240 240 240
CH811 175 175 250 80 160 240 240 240
CH810 175 175 250 80 160 240 115 240

JK11466,00000E6 –19–01AUG03–1/1

05-1 080305
PN=22
Installation

Requirements for the hydraulic installation

The pressure category of the hoses must be high enough


and the working area of the hoses must be from -50°C to
+100°C. The main rule is that the hydraulic system have
to be filled always with the same oil type which already is
in the system.

NOTE: Before oil filling make sure that hydraulic oil is


right type.

Strict cleanness should always be observed during


installation and contaminants should be prevented from
getting into the hydraulic system. Contamination of the
system can be avoided with the help of the following
measures:

• installation must be carried out in a clean environment


• welding and rubbing must not be carried out during
installation
• tube and hose ends must always be protected -hoses
and tubes must be rinsed and cleaned with pressurized
air before installation

When the hydraulic system has been installed, air must


be eliminated from the system.

Bleeding can be done so that all the cylinders will be


operated carefully all the way to the end limiters at least
two times.

NOTE: While bleeding the hydraulic system, make sure


that THERE IS NOBODY WITHIN THE REACH
OF THE Boom, because air can result in sudden,
unintended movements.

JK11466,00000E7 –19–01AUG03–1/1

05-2 080305
PN=23
Installation

BOOM INSTALLATION REPORT


Boom Type Serial Number
Base machine Serial Number
Installation Date Contact Person
Company (Owner) Telephone
Address Mobile phone
Fax number E-Mail

Checklist for Boom installation


OK NOTE
1. Bolts, Tightening torque
2. Hydr. hoses and tubes, installed
3. Any leaks
4. Rating plate
5. Outreach / Loading diagram
6. Warning signs
7. Declaration of incorporation
8. Bleeding the hydraulic system
9. Test--run
10. Operator’s and Maintenance manual
11. Warranty terms

Place and Date


___________________________ ____ /____ _________
Signature
Company(owner) Representative
_____________________________ ___________________________

JK11466,00000EA –19–01AUG03–1/1

05-3 080305
PN=24
Installation

Couplings
1. Main boom cylinder couplings
Lifting cylinder Piece CH8
Piston side 1 JIC 1 1/16-12 UNF
Rod side 1 JIC 1 1/16-12 UNF

2. Outer boom cylinder couplings


Lifting cylinder Piece CH8
Piston side 1 JIC 1 1/16-12 UNF
Rod side 1 JIC 1 1/16-12 UNF

3. Slewing
Lifting cylinder Piece CH8
Base piping 2 JIC 1 1/16-12 UNF

Continued on next page JK11466,00000EB –19–01AUG03–1/5

05-4 080305
PN=25
Installation

–UN–27APR05
T210888

Continued on next page JK11466,00000EB –19–01AUG03–2/5

05-5 080305
PN=26
Installation

4. Lifting boom couplings


Lifting boomr Piece CH8
A) Return 1 ORFS 1 11/16-12
UNF
B) Leak 1 JIC 1 5/16-12 UNF
C) Rotator right 1 JIC 1 1/16-12UNF
D) Extension in 1 JIC 1 1/16-12UNF
E) Extension out 1 JIC 1 1/16-12UNF
F) Rotator left 1 JIC 1 1/16-12UNF
G) Pressure 1 ORFS 1 11/16-12
UNF

Continued on next page JK11466,00000EB –19–01AUG03–3/5

05-6 080305
PN=27
Installation

–UN–02AUG05
T213183

Continued on next page JK11466,00000EB –19–01AUG03–4/5

05-7 080305
PN=28
Installation

5. Outer Boom Couplings


Lifting cylinder Piece CH8
A) Return 1 ORFS 1 11/16-12
B) Leak 1 JIC 1 1/16-12 UNF
C) Rotator right 1 JIC 3/4-16 UNF
F) Rotator left 1 JIC 3/4-16 UNF
G) Pressure 1 ORFS 1 11/16-12

JK11466,00000EB –19–01AUG03–5/5

05-8 080305
PN=29
Operating
Operating Safety Precautions

• Observe the lifting ratings given on the boom decal,


IMPORTANT: Make sure that you have been do not overload the system.
provided with enough guidance in • Do not force the cylinders to their extreme positions
the use of the boom since it is the at full speed.
operator of the machine who is
primarily responsible for safety in IMPORTANT: Do not use the boom for towing.
operation.
• Exercise great caution particularly when operating
• Adhere strictly to all safety regulations stipulated by the boom near the cabin.
law at the work site pertaining to the operation of • Bear in mind the overall height of the machine.
this equipment. Approach an area where overhanging electrical
powerlines are present with extreme caution.
CAUTION: Before starting the engine ensure
that there is nobody within the reach of the CAUTION: Approach an area where
boom. overhanging electrical powerlines are
present with extreme caution.
• Make sure that you have good visibility of the
working area. • Maintain the safety distances required between the
• If you are still learning to operate the boom, slow machine and power lines. See section 03.
down the speed of the boom functions. • For transport, the boom and the harvester head
• Keep an eye on the machine stability during must be properly secured in the appropriate position.
operation. • Do not leave the cab before you have securely
placed the boom down.
CAUTION: During operation no other people
are allowed in the cab or within the danger
zone of 90 meters (300 ft).

CAUTION: It is forbidden to use the boom


for lifting people.

AK12300,00000D9 –19–22OCT01–1/1

06-1 080305
PN=30
Operating

General Operating Instructions

1. After start
First, operate the boom smoothly without load in order
to allow the grease to warm up and a coherent
lubrication film to be formed in boom joints.
2. During Operation:
• Observe the lifting ratings given on the boom decal.
The weight of the harvester head is included in the
load to be lifted.
• When handling a maximum load, exercise great
caution.
• Operate the control levers smoothly; avoid jerky
movements.
• Always exercise extra caution when a boom or the
booms are in their extreme positions.
• Keep an eye on the machine stability.
Constant alertness is required, particularly when
operating on sloping ground.
If necessary, decrease loads or drive the machine
closer.
When you notice that the machine is about to fall
over, pull extension in, move the outer boom in, and
lower the load smoothly onto the ground.
• It is possible that you exceed the lifting capacity of
the boom (the booms will go over relief) if you pick
up a load that is close to the machine and then
move this load away from the machine. When this
happens you must bring the load closer to the
machine by pulling the outer boom or extension
inwards. This is necessary because otherwise the
power of the main boom cylinder will not be sufficient
to handle the load.
• Bear in mind the potential operation of the frame
brake, should you move the machine while also
operating the boom.
• Always when possible move the extension boom in
before processing a stem to avoid excessive strain
on the outer boom.

Continued on next page AK12300,00000DA –19–22OCT01–1/2

06-2 080305
PN=31
Operating

3. When operation is over:


• Carry out the last movements unloaded.
• When you drive the machine make sure that the
boom does not make any sudden movements. Move
the harvester head close to the machine when
driving.

–UN–19APR05
• Never leave the boom unsupported by relying on the
hydraulic system only.
Secure the harvester head by means of a chain for
long drives to other working sites. Lock the harvester

T153883
head tilt if needed. Bring the booms down as
displayed in the figure.
Position the harvester head on the ground even for Boom after operation
short breaks, and always before leaving the cab.

AK12300,00000DA –19–22OCT01–2/2

06-3 080305
PN=32
Maintenance—General
General

IMPORTANT: This maintenance section contains a


number of servicing and checking
procedures that are performed
regularly. Some of these are carried out
by the operator. When it comes to
maintenance and repairs that require
special skills and tools, contact the
nearest authorized repair shop. Any
defect or shortcoming that
compromises the operational safety
must be remedied immediately. If the
aim is a reliable and safe operation, the
most important (and the most
inexpensive) contribution is regular
boom checks and maintenance.

NOTE: The operator and service personnel must be


familiar with the safety rules and regulations
provided in this service manual and in the decals
of the boom, as well as with those related to
national road traffic and occupational safety.

All safety rules and regulations in effect pertaining


to the boom and workplace must be obeyed.

This Maintenance program is for the following boom


models

• CH883 / 8,3m
• CH810 / 9,7m
• CH811 / 10,7m

JK11466,00000E9 –19–01AUG03–1/1

Servicing safety precautions

Carefully study the safety instructions before starting


maintenance work.

JK11466,00000EC –19–01AUG03–1/1

7-1-1 080305
PN=33
Maintenance—General

General maintenance instructions

General instructions for checking oil levels and fill-ups:

• The machine must stand on level ground when you


check boom slew oil level.
• Check the oil level in the morning for that is when the
oil is cold and it has seeped down into the lower parts
of the component.
• Avoid direct contact with oil, particularly heated oil.
• Oil on the skin should be washed off immediately

Before servicing machine:

Prepare service properly:

• Clean work area and machine.


• Make sure you have all necessary tools and right parts
on hand

NOTE: Understand service procedure before doing work.


Read all instructions thoroughly; do not attempt
shortcuts.

Keep eye on bolted joints daily between the boom and the
frame. Keep tightening until the bolts maintain their
tightness. Check the hose joints, too. During ordinary
operation, the joints should be frequently checked in
addition to scheduled maintenance.

Grease the machine while it is still warm after a work shift.


Before you grease lower the boom to the ground in order
to eliminate pressure from the cylinders. This will also
help the grease to be better spread on bearing surfaces.

NOTE: The operator and service personnel are


responsible for safety on and around the machine.

JK11466,00000ED –19–01AUG03–1/1

7-1-2 080305
PN=34
Maintenance—General

Tightening torques for bolted joints


Joint Qty Size Grade Torque Nm Torque lb-ft
Locking screws, boom pillar pivot 2 M16 x 40 8.8 222 164
Slew bearing cover, boom pillar 8 M12 x 20 12.9 137 101
Slew bearing cover, slew housing 9 M12 x 35 12.9 137 101
Slewing cylinder, piston 32 M12 x 60 8.8 85 63
Slewing cylinder 96 M12 x 70 12.9 110 81
Main boom ram 1 M78 x 6 1580 1165
Outer boom ram 1 M58 x 2 710 524
Extension ram 1 M35 x 2 500 369
Expander, boom pillar-main boom 1 M30 x 2 8.8 600 443
cylinder
Expander, main boom cylinder top 1 M30 x 2 8.8 600 443
end
Expander, rotator link 1 M20 x 1,5 8.8 400 295
Expander, parallel link 1 M24-8 600 443

JK11466,000002C –19–30OCT03–1/1

7-1-3 080305
PN=35
Maintenance—General

Fluids and lubricants

General instructions for checking oil levels and fill-ups:

• The machine must stand on level ground when you


check any of the oil levels.
• Check the oil level in the morning for that is when the
oil is cold and it has seeped down into the lower parts
of the component.
• Renew the oil while the engine is warm. Thus it is
easier to remove the old oil.
• To even the pressure at the oil space, open a plug
located above the oil level (e.g. filling plug) before
opening the drain plug.
• Avoid direct contact with oil, particularly heated oil.
• Oil on the skin should be washed off immediately.

Basic rules when changing oil and filters, checking


hydraulic pressures, repairing etc:

• Clean thoroughly the area around the components to be


opened to ensure that no dirt enters the system.
• Keep the hydraulic hoses plugged as well as the filters
in their packs until they are installed to the machine.
• Plug removed components.
• Ensure that all parts are clean before assembly.

Grease

Apply lithium grease, some examples:

• Neste Yleisrasva EP 2
• Esso Beacon EP2
• Shell Retinax LX Lithium
• Mobilgrease
• Castrol LM Grease
• Texaco Molytex Grease EP 2
• BP Energrease

NOTE: Use enough grease!

Hydraulic fluid

If you use mineral oil:

• Comply with SH 68 (SMR classification) in summer.


• Comply with SHS 32 (SMR classification) in winter.

Continued on next page JK11466,000002F –19–31OCT03–1/2

7-1-4 080305
PN=36
Maintenance—General

• Comply with SHS 46 (SMR classification) for year-round


usage.

If you use synthetic biodegradeable oil:

• Neste Biohydrauli SE 46
• BP BIOHYD SE 46

IMPORTANT: Do not mix different types of oils as this


will cause degradation of their
properties when mixed. When in doubt,
contact the manufacturer. Abuse will
result in the revocation of the warranty.

Gear oil

• Boom slew housing

Use hypoid oil that complies with the classification: API


GL-5 or MIL-L-2105 B or D.

The following viscosity categories can be used: SAE 90,


SAE 85W/90, SAE 80W/90, SAE 75W/90.

JK11466,000002F –19–31OCT03–2/2

Oil capasities

Boom slew housing oil capacity


Boom model Liters Gallons
CH885 / CH810 and CH811 30 l 7,9 gal

JK11466,0000030 –19–31OCT03–1/1

7-1-5 080305
PN=37
Maintenance—General

Welding Instructions

Before you start welding the machine bear in mind the • castings
following: • boom ends
• cylinder fastening lugs
1. Before starting welding work: • corners of box girders
a. Switch off the power with the main switch.
b. Detach the ground wire from the batteries. 6. Welding
Weld inside, if possible, in facilities reserved for this
2. Ground connection: purpose where the temperature is at least 10°C
• Connect the ground wire as close to the welding (50°F). If welding in other places, pay attention to
point as possible. local regulations and to circumstances as well as to
• The welding current must never pass through the environment before you start welding.
bearings, joints, electrical equipment, or hydraulic The welder must possess adequate skills and the
systems. permits required.

3. The parts that must never be welded: 7. Assessment of damage


• boom fastening bolts In case a component or structure has been
• control valves damaged as a result of an accident, excessive load,
• hydraulic pipes or fatigue, it is first necessary to determine whether
the structure requires reinforcements or is ordinary
4. The parts that must not be welded without the repair sufficient.
manufacturer’s instructions: 8. Instructions
• castings Before you start welding you can also contact the
• cylinder loops manufacturer who has detailed instructions for each
case.
5. The points and components to which it is Possibility of major damage is reduced by regularly
forbidden to attach other parts by welding: cleaning and checking the machine and the boom.

AK12300,0000059 –19–12OCT01–1/1

Bleeding the Hydraulic System

If the hydraulic system has been serviced or repaired, air


must be eliminated from the system before the machine is
put to use again

If not eliminated from the system the presence of air will


result in the following problems:

• Sudden, unintended movements


• Damage to gaskets. When compressed, air heats up
quickly and burns the packing material.

NOTE: See basemachine manual for detailed instructions


for bleeding the hydraulic system.

EL62757,00001C8 –19–22APR02–1/1

7-1-6 080305
PN=38
Maintenance
Maintenance Intervals
Every 10 Hours or Daily
❒ Check boom structures visually
Every 50 Hours or Weekly
❒ Check boom shafts, circlips and joints ❒ Drain the water deposited in the base
❒ Check the boom slew housing oil level ❒ Grease the rocker and cylinder bearings and the slewing system
bearing of the boom
Every 250 Hours
❒ Clean the boom ❒ Check boom structures
❒ Check the extension boom for vertical and horizontal clearance ❒ Check the tightness of screw joints
❒ Drain water from the boom slewing system ❒ Check the tightness of expander pins
Every 1000 Hours
❒ Clean the magnetic plug of the rotator
Every 2000 Hours
❒ Change the boom slewing system oil

IMPORTANT: Expander pivot pin joints of the new


machine must be tightened after first
working day. Keep tightening until the
bolts maintain their tightness.

Grease the machine while it is still warm after a work shift.


Before you grease lower the boom to the ground in order
to eliminate pressure from the cylinders. This will also
help the grease to be better spread on bearing surfaces.

AK12300,0000095 –19–16OCT01–1/1

7-2-1 080305
PN=39
Maintenance

Every 10 Hours or Daily

1. Check boom structures visually.


Check hoses, joints, and cylinders for tightness. Make
sure that the booms are not lowered by themselves.
Should you locate a defective component or a
malfunctioning operation, repair it immediately. Check
the hydraulic system for potential damage visible from
the outside in order to make sure that such damage
will not result in a sudden leakage. All oil leaks must
be repaired immediately.

CAUTION: Never attempt to locate or plug an oil


leak with your hand because it only takes fluid
injected at a pressure of 30 bar to penetrate
your skin and possibly cause serious personal
injury, even death.

AK12300,0000096 –19–16OCT01–1/1

Every 50 Hours or Weekly

1. Check boom shafts, circlips and joints.


Tighten expander pivot pin joints. See group Tightening
Torque for Bolted Joints.
2. Check the boom slew housing oil level.
The boom slew system and the lower bearing of the
boom pillar are immersed in oil. The oil level is
checked in the measuring glass. If the boom stands
still for a long period of time, the oil level must exceed
the upper mark on the measuring glass. This is to
ensure that the slewing cylinder pipes will not corrode.
Filling plug (A).
–UN–21APR05
T195701

Continued on next page AK12300,0000097 –19–16OCT01–1/2

7-2-2 080305
PN=40
Maintenance

2 3

4 3
5

–UN–26APR05
T195702
3. Grease the rocker and cylinder bearings of the boom
and the slewing system bearing. See the figure.

1—Main boom cylinder, 2 nipples.


2—Outer boom cylinder, 1 nipple.
3—Main boom and outer boom bearings and
linkages, 3 nipples + 2 nipple, central.
4—Rotator link, 2 nipples.
5—Slew housing bearing, 2 nipples. Following
instructions are for optimum greasing of the upper
slew housing bearing: Tilt the boom towards the
cab and extend the boom. Swing the boom to its
full extent on one side and grease, swing to the
other side and grease.
6—Grease bearings of the boom tilt. There are two
nipples in the boom pillar pivot and two in both

–UN–26APR05
cylinders.

5
6
T210853

6
–UN–26APR05

6
T195703

AK12300,0000097 –19–16OCT01–2/2

7-2-3 080305
PN=41
Maintenance

Every 250 Hours

1. Clean the boom.

NOTE: When washing the machine with a pressure


washer avoid directing the stream of water at the

–UN–27OCT03
point where the boom pillar and base meet (A).

2. Check boom structures.


• Load-bearing structures. A

T195704
• Boom bearings, pins, and links.
• Hydraulic system.
• Rotator linkage and rotator.

3. Check the extension boom for vertical and horizontal


clearance.
If necessary, make the adjustment by inserting 1
additional adjustment plates (1) under the slide pieces 2
(2).
The aggregate thickness of the fitting plates under the
slider parts must not exceed 3 mm (0,12 in). This is to
make sure that the slider parts will stay in place. The
top of the slider part must exceed the edges of the
bearing housing by at least 2 mm (0,08 in).
4. Check the tightness of the boom fastening bolts,
hydraulic cylinder covers, and other screw joints.
For nut and bolt torque values,

–UN–27OCT03
5. Drain water from the boom slewing system.

T195705
1

2
–UN–27OCT03
T195706

AK12300,000009A –19–16OCT01–1/1

7-2-4 080305
PN=42
Maintenance

Every 1000 Hours

1. Clean the magnetic plug of the rotator.


Position the unit so that the magnetic plug is at the
lowest point. Place a receptacle below the plug.
Unscrew the plug, clean it and suitably allow two litres

–UN–08MAR02
of oil to drain. Screw in the magnetic plug and tighten
with a torque of about 60 Nm (44 lb-ft).

T152547
AK12300,000009F –19–16OCT01–1/1

Every 2000 Hours

1. Change the boom slewing system oil.


Open the plug at the end of the drain hose (1). Drain
oil completely into a basin. Clean the drain plug. Close 1
and tighten the plug.
The oil must be changed after every 2000 running
hours or once a year.

–UN–20APR05
T195707
AK12300,00000A1 –19–16OCT01–1/1

7-2-5 080305
PN=43
Maintenance

Expander Fitting Instuctions

1. The expander system consists of a pin, which is


tapered at both ends, expansion cones, pressure
washers and fastening elements. Lubricate expansion
cones slightly before installing.

–UN–28OCT03
T195762
Expander fitting picture A

JK11466,0000002 –19–07OCT03–1/6

2. Picture B: Check the lughole visually. If necessary,


grind the lughole slightly for better fitting. Do not grind
more than 1 mm. Drop small amount of proper
lubricant to the lughole. Install the assembly tool on
expander pin.

–UN–28OCT03
T195763

Expander fitting picture B

Continued on next page JK11466,0000002 –19–07OCT03–2/6

7-2-6 080305
PN=44
Maintenance

3. Picture C: Remove assembly tool. Install fasteners


properly

–UN–28OCT03
T195764
JK11466,0000002 –19–07OCT03–3/6

The fasteners should be tightened in certain order as


seen on picture C. When the fasteners are tightened,
the slitted sleeves are pushed down over the tapered
ends of the pin, expanding parallel to lock the
Expander System in the pivot.

Table1
Tihghtening torques
Bolt size M12 M14 M16 M20 M24 M30 M36 M40
(mm)
Torque 80 130 180 400 500 600 700 900
(Nm)

Table2
–UN–28OCT03

Tihghtening torques
Sleeve M17 M25 M35 M45 M55 M65 M75 M85
size(mm)
Torque 30 90 195 265 340 460 630 700
T195765

(Nm)

Expander tightening torques

1—See table 1 for tighetning torques


2—See table 2for tighetning torques

Continued on next page JK11466,0000002 –19–07OCT03–4/6

7-2-7 080305
PN=45
Maintenance

4. Picture D: Notice that there should be little clearance


between washer and the pivot

–UN–28OCT03
T195766
Expander fitting picture D

Continued on next page JK11466,0000002 –19–07OCT03–5/6

7-2-8 080305
PN=46
Maintenance

IMPORTANT: Retighten until the joint is secured. The


first hours of operation are particulary
important. Thereafter at regular service
intervals.

–UN–28OCT03
T195767
Expander Tightening instruction

JK11466,0000002 –19–07OCT03–6/6

Dismantling of Expander Bolts

Pictures G to J describes dismantling alternative 1 and


picture K describes the second alternative. The alternative
depends on which kind of expansion pin is used To
dismantle expander bolt you will need special tools as
seen on picture.

1—Dismantling tools

–UN–28OCT03
T195768

Continued on next page JK11466,0000003 –19–07OCT03–1/7

7-2-9 080305
PN=47
Maintenance

Picture F: Unscrew the bolts and remove washers

–UN–28OCT03
T195769
Expander dismantling picture F

JK11466,0000003 –19–07OCT03–2/7

Picture G: Screw the dismantling tool on lughole

–UN–28OCT03
T195770

Expander dismantling picture G

Continued on next page JK11466,0000003 –19–07OCT03–3/7

7-2-10 080305
PN=48
Maintenance

Picture H: Unscrew the locking screw.

–UN–28OCT03
T195771
Expander dismantling picture H

JK11466,0000003 –19–07OCT03–4/7

Picture I: Remove assembly tool and expansion cone from


the pivot lug

–UN–28OCT03
T195772
Expander dismantling picture I

Continued on next page JK11466,0000003 –19–07OCT03–5/7

7-2-11 080305
PN=49
Maintenance

Picture J: Dismounting alternative two. Install the


assembly tool on bolt and peen lightly so that the
expansion cone removes

Repeat G - K if necessary.

–UN–28OCT03
T195773
Expander dismantling picture J

JK11466,0000003 –19–07OCT03–6/7

Same as in picture J but use a different tool

–UN–28OCT03
T195774

Expander dismantling, tool alternative 2

JK11466,0000003 –19–07OCT03–7/7

7-2-12 080305
PN=50
Technical data
CH8 Specifications
Technical data CH8
Lifting capacity, gross 210 kNm (147510 lb-ft)
Slewing torque, gross 60 kNm (44250 lb-ft)
Slewing angle 220°
Tilting angle -15°...+25°

CH885
Outreach, max 8250 mm 27 ft 1 in
Stroke of boom extension 800 mm 2 ft 7 in
Weight, without oil 2850 kg 6280 lbs

CH810
Outreach, max 9700 mm 31 ft 8 in
Stroke of boom extension 1250 mm 4 ft 1 in
Weight, without oil 3250 kg 7165 lbs

CH811
Outreach, max 10700 mm 35 ft 1 in
Stroke of boom extension 2250 mm 7 ft 5 in
Weight, without oil 3300 kg 7275 lbs

JK11466,000002B –19–30OCT03–1/1

Rotators
Rotator CH8
AV12S AV14S H122
Weight 56 kg 56 kg 57kg
(123 lbs) (123 lbs)
Slewing 2,1 kNm 3,3 kNm 2,2 kNm
torque (1550 lb-ft) (2435 lb-ft)
Slewing unlimited unlimited unlimited
angle (±180° with (±180° with (±180° with
harvester harvester head) harvester head)
head)

AK12300,00000DE –19–22OCT01–1/1

08-1 080305
PN=51
Technical data

08-2 080305
PN=52
Index
Page Page

B Safety, general precautions . . . . . . . . . . . . . . 03-1-1


Safety, invisible fluid leaks . . . . . . . . . . . . . . . 03-3-3
Bleeding Safety, power cables . . . . . . . . . . . . . . . . . . . 03-2-2
Hydraulic system, Boom . . . . . . . . . . . . . . . . 7-1-6 Safety, prepairing for emergencies . . . . . . . . . 03-1-2
Boom CH8, Specification . . . . . . . . . . . . . . . . . . 08-1 Safety, pressurized fluid lines . . . . . . . . . . . . . 03-3-4
Boom, general description . . . . . . . . . . . . . . . . . 04-1 Safety, proper tools . . . . . . . . . . . . . . . . . . . . 03-3-1
Boom, general operating instructions . . . . . . . . . 06-2 Safety, protective clothing. . . . . . . . . . . . . . . . 03-1-3
Boom, maintenance every 10 hours or daily. . . 7-2-2 Safety, public roads . . . . . . . . . . . . . . . . . . . . 03-2-3
Boom, maintenance every 1000 hours . . . . . . . 7-2-5 Safety, understanding signal words . . . . . . . . 03-1-2
Boom, maintenance every 2000 hours . . . . . . . 7-2-5 Safety, welding repairs . . . . . . . . . . . . . . . . . . 03-3-4
Boom, maintenance every 250 hours . . . . . . . . 7-2-4
Boom, maintenance every 50 hours or
weekly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-2
W
Boom, operating safety precautions . . . . . . . . . . 06-1
Welding instructions . . . . . . . . . . . . . . . . . . . . . 7-1-6

CH811 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1
CH883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1

Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . 03-3-2


Fire, what to do . . . . . . . . . . . . . . . . . . . . . . . 03-3-2

Maintenance intervals, boom . . . . . . . . . . . . . . 7-2-1


Maintenance, boom . . . . . . . . . . . . . . . . . . . . . 7-2-1

Rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-1

Safety information. . . . . . . . . . . . . . . . . . . . . . 03-1-1


Safety signs, replacing . . . . . . . . . . . . . . . . . . 03-1-5
Safety, before servicing . . . . . . . . . . . . . . . . . 03-3-1
Safety, chemical products. . . . . . . . . . . . . . . . 03-1-4
Safety, danger zone . . . . . . . . . . . . . . . . . . . . 03-2-1
Safety, disposing waste . . . . . . . . . . . . . . . . . 03-3-5
Safety, fire . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-3-2
Safety, fire prevention. . . . . . . . . . . . . . . . . . . 03-3-2

Index-1 080305
PN=1
Index

Index-2 080305
PN=2

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