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Jensen A540 DiXL D-1703 E Operating Instructions Manual Download Page 41

11 

Joint 
 
Dismantling 
 

 
 
 

 
 
 
 
 
 
 
 
Assembly 

 
 
 
 
 

 
 
 

Remove retaining ring.

Place joint as shown above and use light hammer blows to drive 
up bearing bush. 

As a function of size, fix 
bearing bush into spezial 
tool SW23 or SW27 and 
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 groove is 
visible. 

Mount retaining ring. 

When mounting second 
yoke, make sure that 
tapered lubricating fitting 
is easily accessible.

Relieve joint from stress 
by applying hammer 
blows to yoke ears. 

Grease joint. 

Summary of Contents for A540 DiXL D-1703 E

Page 1: ... D 1703 E 80km h Machine Nr 561105402 Date of building 05 2011 Jensen Service GmbH D 24975 Maasbüll Tel 04634 9370 0 Fax 04634 1025 E mail info jensen service de WOODCHIPPER Operating instructions List of spare parts ...

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Page 3: ...improvements which we consider to be appropriate An obligation to any previously delivered machines and extended apparatus is ínvalid REFERENCE INSTRUCTION This instruction manual also contains descriptions of the auxiliary equipment which is not usually found in the extent of the series In accordance with the references in this service manual the enforcement of clients wishes does not generally a...

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Page 5: ...delines 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 these papers must always be handed over The instruction manual must be read and understood by every person who works with the machine e g Servicing preparation including the repair of any damage cau...

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Page 7: ...re usine 1 Kunde customer client Firma Behörde etc company société Straße Platz etc complete address adresse complète PLZ postal code Ort town Land country pays Telefon telephone 2 Übergabebestätigung acknowledgement of delivery confirmation de livraison Die unter 1 aufgeführte Maschine wurde mir in ordnungsgemäßem Zustand übergeben Ich habe die Bedienungsanleitung erhalten und wurde in Bezug auf ...

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Page 9: ...e quitte notre usine 1 Kunde customer client Firma Behörde etc company société Straße Platz etc complete address adresse complète PLZ postal code Ort town Land country pays Telefon telephone 2 Übergabebestätigung acknowledgement of delivery confirmation de livraison Die unter 1 aufgeführte Maschine wurde mir in ordnungsgemäßem Zustand übergeben Ich habe die Bedienungsanleitung erhalten und wurde i...

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Page 11: ...tte notre usine 1 Kunde customer client Firma Behörde etc company société Straße Platz etc complete address adresse complète PLZ postal code Ort town Land country pays Telefon telephone 2 Übergabebestätigung acknowledgement of delivery confirmation de livraison Die unter 1 aufgeführte Maschine wurde mir in ordnungsgemäßem Zustand übergeben Ich habe die Bedienungsanleitung erhalten und wurde in Bez...

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Page 13: ...ctive 32 BimSchV and the machine directive 98 37 EG 9 GSGV Est conforme à la directive 2000 14EG outdoor directive 32 BimSchV et à la directive machines 98 37 EG 9 GSGV Das angewandte Konformitätsbewertungsverfahren nach RL 2000 14 EG ist die interne Fertigungskontrolle nach Artikel 14 Absatz 2 in Verbindung mit Anhang V The conformity assessment procedure applied in compliance with the directive ...

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Page 15: ... Max chip capacity 190 mm Propulsion infeed rollers Hydraulic Cutting length adjustment Serial Hydraulicsystem Max 170 bar Elektric connection 12 Volt Disc revolutions per minute See type plate Diesel engine Kubota 27 5KW 37 3 PS Heights with chute 2400 mm Dimensions for transport without chute Length x width x height 3400 x 1500 x 1475 mm Weight 1200 kg Undercarriage 80 km h ...

Page 16: ...E 1 5 2 Permissible total weight 1500 kg Permitted towing hitch load 100 kg Order Nr Jockey wheel BPW 200x50 20186 Jockey wheel mounting plate LB 48 20187 Fender plastic E 2275 20748 Order Nr Wheel 175 R 13 C 20923 Rim 5Jx13H2 Air pressure 2 8 bar Diesel engine Kubota Nr AW 1030 Type D 1703 Power 27 5 KW 37 3 PS Rpm 3000 1 min Specifications A540 DiXL D 1703 E 80km h ...

Page 17: ...efully read operator s manual before handling the machine Observe instructions and safety rules when operating Lire le livret d entretien et les conseils de sécurité avant la mise en marche et en tenir compte pendant le fonctionnement Alvorens met de machine te werken de gebruiksaanwijzing en de veiligheidsvoorschriften lezen en in acht nehmen Schutzvorrichtungen bei laufendem Motor nicht öffnen o...

Page 18: ...à l ècarte de pièces Zich verwijderd houden van draaiende machinedelen Niemals in den Quetsch Gefahrenbereich greifen solange sich dort Teile bewegen können Never put your hand into the crushing danger area as long as parts may move Ne jamais intervenir dans une zone où il y a risque d écrasement tant que des pièces sont en mouvement Nooit de gevarenzone naderen zolang de delen draaien Während des...

Page 19: ... du châssis Chassis vooraan Z Fahrgestell vorne Chassis front Avant du châssis Chassis vooraan Gefahr durch fort schleudernde Teile bei laufendem Motor Sicherheitsabstand halten Danger flying objects keep safe distance from the machine as long as the engine is running Attention à la projection de corps étrangers Rester à bonne distance de la machine Gevaar wegslingerende delen als de motor draait ...

Page 20: ...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 Châssis à l avant Pour une axe aussi à l arrière Chassis vooraan Voor 1 as ook achteraan Z Fahrgestell vorne Bei Einachs auch hinten Chassis at the frontside For one axle at the backside Châssis à l avan...

Page 21: ...es 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 cultivation tool supplement 1 The operator alone is responsible for bringing in the machine and for its use in traffic 2 The chances of accidents occuring are significantly minimalised when the wood chipp...

Page 22: ... 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 not smoke 3 Prior to refulling stop and remove ignition keys Do not refuel in enclosed spaces Do not spill fuel make use of any help 4 Do not put the motor on high rotation speeds 5 To avoid fire haza...

Page 23: ...cautions 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 not place hands in the funnel rotating pieces 7 If someone climbs too far into the machine the control bar should be pulled to stop the machine immediately 8 The machine must only be operated when th...

Page 24: ... 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 pressure so there is a danger of being burned 7 The oil power cooling fluid batteries and filters should be stored separately Electrical construction 1 When working on the electrical construction disco...

Page 25: ...ff 7 When changing the connections ensure that they are reconnected correctly There is a danger of accidents if they are not e g Forward and backward motions and raising and lowering can be dangerous if confused 8 The hydraulic pipes should be regularly maintained and checked They should be changed at least every five years to allow for damage and age The replacement parts should be in accordance ...

Page 26: ... staff The page marked General safety and accident prevention instructions should be read carefully The safety rules for working with the machine are given by the Trade Association General attendance and inspection references There are attendance and installation references in the service instructions and also an insert from us which describe supply pieces e g motors clutches for you to take note ...

Page 27: ...the knife holder bolts are tight and check after 1 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 and that the PTO shaft is the correct length Check that the cutting disc rotates in the correct direction with your tractor Position the discharge ch...

Page 28: ...re 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 by trapping fingers even when the tractor is turned off The drawing shows correct dimensions for sharpening and repositioning knives When the knives are too thin due to repeated sharpening shims are available to enable the correct setting to be achieved...

Page 29: ... 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 for the A425 A428 60 litres for the A231 A240 64 litres for the A041 141 64 litres for the A10 Oil type HLP ISC following DIN 51524 Service procedure The filter element should be changed after 20 hours work from new and thereafter each 500 hours A ...

Page 30: ... reaches full operating rotation again then activate feeding again Check all 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 always have an inner distance of 0 5mm towards the edge of the anvil The outer distance between blades and anvil is a little ...

Page 31: ...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 the machine is back to the full rpm Necessary power with 2 knife and mixed bushes you need about 25 KW The power you really need depends on the sorting and the kind of the wood the speed of feed and th...

Page 32: ...of 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 Di 108 84 A 530 Z 103 88 ...

Page 33: ... 2 3 Retinax A If your machine is equipped with a turntable lubricate it monthly Retinax A until the grease get s out of the gap Both bearings of main shaft pos 1 are filled with lithium grease including anti corrosive of penetration class 3 On normal working conditions this is sufficient for the lifetime of the bearing The bearing must not be regreased to avoid substantiel decrease of lifetime of...

Page 34: ...xial 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 the shaft seal For better mounting and to avoid freeting corrosion grease the shaft end Heat the drive component to 80 C if necessary Contact areas of shrink discs must be free of grease Mount the dr...

Page 35: ...00 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 draining tighten the drain plug fill the gear box with lubricant up to the check plug Tighten the fill plug Never mix mineral and synthetic oil A choice of gear oils from different manufacturers is state...

Page 36: ...ngagement 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 performed taking into account safety first Please make sure to disengage the power pack before you perform your work at the clamping set Protect the power pack against unintentional engagement e g by p...

Page 37: ...nt pressure 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 that the slots of component 1 2 and 3 are flush with each other A T T E N T I O N Plan a free space between the pressure ring in the back and the hub shaft for a later disassembly picture 2 free spa...

Page 38: ...read 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 screws used for the fixing and screw them into the threads of the back pressure ring Slightly tighten the clamping screws manually and align the clamping set with hub part At KTR 400 please make su...

Page 39: ...osswise 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 external ring component 3 see picture 6 Tighten the clamping screws evenly and crosswise Increase the impression torque step by step until the back pressure ring component 2 and the external ring comp...

Page 40: ...t 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 range Provide for adequate shielding on tractor and implement Work with fully guarded shafts only Lubrication Apply grease to inside of outer telescopic section Swing joint sideways for greasing Fre...

Page 41: ...d 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 groove is visible Mount retaining ring When mounting second yoke make sure that tapered lubricating fitting is easily accessible Relieve joint from stress by applying hammer blows to yoke ears Grease ...

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Page 73: ...Service Schedule ...

Page 74: ...il change of the 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 change of the gear box if existing X Check the level the batterie liquid Check the level the batterie liquid X Check the fuel tubes and brackets X Check the springs of the infeed and c...

Page 75: ...il of the gear box if existing X Check the clearance of the valve X Change hydraulic oil X X Change fuel filter X Check oil level of the free wheel and top up if necessary if existing Check oil level of the free wheel and top up if necessary if existing X Check the injection pressure of the fuel injector X Oil change of the free wheel if existing Oil change of the free wheel if existing X Check th...

Page 76: ...Jensen Service GmbH Bahnhofstraße 20 22 D 24975 Maasbüll Tel 04634 9370 0 Telefax 04634 1025 eMail info jensen service de http www jensen service de ...

Page 77: ...Original Ersatzteile Original spare parts Pièces de rechange d origine ...

Page 78: ...rcuit hydraulique Die mit einem gekennzeichneten Teile sind nicht abgebildet Hydraulikanlage Hydraulic system Parts marked are not shown in figures Les positons précédées du signe ne sont pas représentées ...

Page 79: ...hlauch tube tuyeau 1 15 9731 Schlauch tube tuyeau 2 16 19341 Schlauch tube tuyeau 1 17 19181 Schlauch tube tuyeau 1 18 21252 Schlauch tube tuyeau 1 19 19176 Steuerblock valve soupape de controle 1 20 9373 Motor motor moteur 1 21 19442 Hydraulikfilter hydraulic filter filtre de pression 1 19443 Filterpatrone einzeln cartridge for filter cartouche pour filtre 1 22 21201 Saugfilter suction filter fil...

Page 80: ...apter pulley adapter adapteur pour poulie 1 2 3054 Schnorrsicherung washer rondelle 6 3 16191 Inbusschraube cylinder screw vis à téte cylindrique 6 4 14728 Keilscheibe pulley poulie 1 5 3054 Schnorrsicherung washer rondelle 6 6 16231 Sechskantschraube hexagon screw vis hexagonale 6 Motorantrieb Engine drive Propulsion moteur ...

Page 81: ... fenêtres 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 2154 Keilriemen V belt courroie 3 8 3229 Sechskantmutter hexagon nut ecrou 3 9 2230 Inbusschraube cylinder screw vis à téte cylindrique 3 10 9157 Unterlegscheibe washer rondelle 4 11 22070 Inbusschraube cylinder screw vis à téte cylindr...

Page 82: ...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 cauteau 6 7 9183 Schnorrsicherung washer rondelle elastique 6 8 22109 Sechskantmutter hexagon nut ecrou 6 2553 Messerschrauben kpl Pos 6 7 8 knife screw cpl Fig Nr 6 7 8 boulon pour cauteau cplt Fig ...

Page 83: ...Spannpratze fixing device griffe d arret 1 3 22022 Scheibe washer rondelle 1 4 5158 Sechskantschraube hexagon screw vis hexagonale 1 5 65009 Mundstückeinlage inlay Bout de debit horicontal 1 6 9320 Senkr Schneidkante Vertical counter Bout de debit vertical 1 7 1817 Inbusschraube cylinder screw vis à téte cylindrique 5 Gegenmesser Counter knife Contre couteau ...

Page 84: ...s 1 11 2121 Sicherungsring lock ring joint d arret 1 12 66046 Buchse bushing Douille 1 13 541 Stellring adjusting ring collier réglable 1 14 40124 Flanschlager flange bearing palier flange 2 15 66030 Zwischenblech intermediate plate intermédiaire tôle 2 16 66022 Gelenk komplett joint complete fourche d articulation cpl 1 17 5047 Spannstift strain pin tige de tension 1 18 66023 Gelenk komplett join...

Page 85: ...xagon bolt vis 1 7 40142 Gleitlager slide bearing roulement coulissant 1 8 16536 Klemme clamp pince 1 9 16537 Knebelmutter handel poignée 1 10 65045 Knebelschraube toggle srew écrou 2 11 65041 Klemmplatte mit Begrenzung clamping plate with stop bolt plaque de serrage avec butée 1 12 65042 Klemmplatte clamping plate plaque de serrage 1 13 1972 Zylinderstift cylinder pin goupille 2 14 16223 Sechskan...

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Page 87: ... Beleuchtungseinheit rechts Illuminator right Unité d éclairage droite 1 40096 Lichtscheibe rechts Light lens right Verre lumineux droite 1 4 20306 Seitenrückstrahler Reflektor Catadioptre 1 5 15941 Umrißleuchte Light Éclairage 1 6 20798 Positionsleuchte mit 4m Kabel Light with 6m cable Éclairage avec 4m câble 1 40194 Hauptkabel 5m Main cable 5m Set de câbles 5m 1 40100 Kabel 6m ohne Pos 5 Cable 6...

Page 88: ... 462 20941 Gewindebolzen mit Anschlagpuffer Thread bolt with stop buffer Boulon fileté avec butée caoutchouc 463 20942 Sicherungsmutter Locking nut Ecrou de sûreté 465 20943 Anzugsdämpfer Tightening damper Amortisseur de serrage 483 20944 Sicherungsscheibe Locking washer Rondelle de sécurité Zugvorrichtung ZAF 1 5 2 Differences between construction and picture are possible Die mit einem gekennzeic...

Page 89: ...et 522 20880 Kegelschmiernippel Grease nipple Graisseur 523 20950 Sischerungsscheibe Locking washer Rondelle de sécurité 524 20951 Gabelkopf Yoke Chape 526 20910 Bolzen Bolt Boulon 527 20911 Sicherung Lock Pièce de sûreté Frein á inertie ZAF 1 5 2 Bauartbedingte Bildabweichungen möglich De légéres différences clûes á la construction peuctent apparaitre sur l image Overrunning brake ZAF 1 5 2 Zugvo...

Page 90: ... construction and picture are possible Radbremse S 2005 7 RASK Frein S 2005 7 RASK Brake S 2005 7 RASK Bauartbedingte Bildabweichungen möglich De légéres différences clûes á la construction peuctent apparaitre sur l image ...

Page 91: ...anger 58 20529 Sicherungsklammer Parenthèse de protection Fuse clip 20530 ab Baujahr 06 98 Dès l année de construction 06 98 From year of construction 06 98 60 20531 Nachstellbolzen Boulons de règlage Adjusting bolt 61 20532 Schraube M12x22 Vis M12x22 Screw M12x22 62 20533 Nachstellmutter écrou de règlage Adjusing nut 63 20534 Sicherung Protection Fuse 67 20642 Zugfeder Ressort de traction tension...

Page 92: ...Jensen Service GmbH Bahnhofstraße 20 22 D 24975 Maasbüll Tel 04634 9370 0 Telefax 04634 1025 eMail info jensen service de http www jensen service de ...

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