®

Satco
SAT630H
SAT630H Auto Saw
SAT420
Hydraulic Felling Grapple
Test and Service
Manual

A01368-001 1
 IMPORTANT

Due to SATCO®Ltd policy of continuous product improvement the information

contained in this manual was correct at the time of latest revision (refer footer.)
Any changes after the below revision will only be included in the next update to this manual.

Illustrations in this manual are pictorial representations of components and

are not drawn to scale.

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 Contents

Page Number

Pressures and speeds 4

Dump Valve 5

Centre Joint 6

Connection to carrier 7

Grapple 8

Saw Motor Manifold 9

Accumulator 11

Tilt 12

Trouble Shooting 13

Service Plan 18

Schematic 630 20

Schematic 420 21

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Satco Felling Grapple
Pressures and speeds
Some of the pressures will need to be tested
at the base machine work ports and set at
the base machine. (these cannot be set at
the pump pressure as there may be a differ-
ential between pump and work port)
This will require the help and support of the
service dealer for the base machine.

Component Function Specification

Rotator Left and Right 82bar 1189 psi
25 l/m 6.6gpm

Grapple closed between 280-380bar 4351-5511 psi

open 230-350bar 3481-5511 psi

(it is vital the speed on the open is not to
fast as it will damage the link and cylinder
pins)

Saw 320-350bar 4351-5511 psi

(saw speed 4800rpm to 5000rpm)
Flow required 200 l/m 53gpm
Dump Valve The dump valve is pre-set at the factory
but may need to be fine tuned to the base
machine and felling grapple.
Refer to page 5 for more information

Accumulator Accumulator charged to Between 508 - 580 psi

35 - 40 bar

A01368-001 4
Dump Valve Adjustment for Tilt up pressure (200bar for the 630
Felling Grapple, 160bar for the 420 Felling Grapple)
Depending on the base machine will deter-
mine where the dump valve is mounted on Tank return Adjustment for Tilt up speed
the base machine. “C”
It is important to understand why the dump
valve is used and what its job is in relation to
the Felling Grapple.
1) Tilt Up-when Tilt Up is activated the hy-
draulic oil from the base machine valve
is pushed through the “X” port on the “X” Port
dump valve.
2) The Dump Valve Solenoid needs to be
powered up for the tilt up to work. When Hydraulic oil from the
base machine
powered up the Tank port ’C’ is blocked
and the oil is redirected down the saw
return line to the Felling Grapple which “A” Port is both where the saw
then tilts the Felling Grapple into the return oil comes to from the
Felling Grapple and the Tilt Up
standing position.
oil goes from here to the Felling
3) The adjustment for Tilt up has both Grapple
speed and pressure that can be adjust-
ed . You need to set the Tilt up pres-
sure first before changing the speed. Dump Valve Solenoid
The factory setting for this is 200bar for
the 630 Felling Grapple and 160bar for
the 420 Felling Grapple. The pressure
cartage is set at the factory on a test
bench, there is no test port for the Tilt
Up on the Dump Valve or the Felling
Grapple so a test port would need to be
added to the ’A’ port while this test is
being made. Another way to test the
pressure is to Tee a –6JIC gauge into
the rod end of the tilt up cylinder. Check
pressure and adjust if needed.
To much speed and the Felling Grapple
slams into the Tilt up stops and to little
speed it will take to long to stand up.
Saw Return-Once the saw is activated the
Dump Valve Solenoid is turned off (and will
not be activated until the Tilt Up is activated
again)
The return oil from the saw comes in “A” port
and out the “C” port returning through the
machine cooler then to the tank.

A01368-001 5
Centre Joint SATCO Centre Joint
There are two types of centre joints that the
630/420 Felling Grapple have.

The first is the old SATCO centre joint V1

Refer to SATCO Parts Manual for a parts
break down.

Case Drain
The second (V2) is being used in all new H
series felling grapples.
Refer to SATCO Parts Manual for a parts
break down.

Hose connection:
“S” SAW
“C” CLOSE GRAPPLE
“H” HARVESTER TILT/SAW RETURN
“O” OPEN GRAPPLE

A01368-001 6
 CENTER JOINT V2
CONNECTING TO CARRIER
Open
HOSE CONNECTIONS Close
Saw R1 R2

It is very important to correctly connect the

Felling Grapple hoses to the carrier's hydrau-
lic system so the Felling Grapple correctly
responds to the movement of the controls.

Connect the hydraulic hoses to the Felling

Grapple Saw as detailed.

Case Harvester / Saw return

• R1 = Rotate
• R2 = Rotate
• O = Grapple Open
• C = Grapple Close
• S = Saw Base Machine
• H = Harvester / Saw Return

HOSE SIZES When connecting Felling Grapple position rotate on the

right side when looking from the cab

The hydraulic pipes and hoses that connect

the Felling Grapple to the carrier have the
following minimum requirements:

HOSE Hose Size Centre Hose Size Centre

Joint V1 Joint V2
R1 1/2” 1/2”

R1 1/2” 1/2”

O 3/4” or 1/2” 1/2”

C 3/4” or 1/2” 1/2”

S 3/4” 3/4”

H 3/4” 3/4”

A01368-001 7
 Felling Grapple Main Manifold
Grapple Block (on Felling Grapple)

The grapple arms / cylinder are built to a high Open

standard and are built to handle high hydrau-
lic pressure, heavy work loading.
The Grapple closed pressure needs to be set
at 300-350bar. This pressure is set at the
base machine and the base machine dealer
will need to set this. The grapple closed
speed is not an issue.
The Grapple open pressure should be set at
230-350bar. This may need to be change as
the speed of the Grapple open is very im-
portant. If the open speed is to fast, damage
will happen to the cylinder and link pins.
Close
IT IS VITAL THAT THE OPEN SPEED IS
SET NO FASTER THAN 2.5 SECONDS
FROM CLOSE TO COMPLETELY OPEN.

The Grapple Open speed is set at the base

machine and may need to be carried out by
the base machine dealer.

A01368-001 8
 Felling Grapple Main Manifold Block
(on Felling Grapple)
SAW
The saw pressure is set at the base machine Saw (from centre
and the pressure should be between 320- joint)
350bar
The saw flow requirement is controlled by the
compensator (Flow control valve) refer to
SATCO Parts Manual for parts.
The flow to the saw is limited to 200l/m (53g/
m) by the Flow Control Valve on the main
manifold block on the Felling Grapple.
When the saw is activated the pressure in the
saw line needs to be more than 200bar as
this pressure charges the accumulator.
With the correct flow and pressure the saw
motor will run at between 4800-5000rpm.
Saw (to Saw Manifold
The correct saw motor speed needs to be
Block on Saw Motor)
achieved before the saw bar out speed is set.

Pressure reducing valve

NOTE:
Felling Grapple
THE SAW MUST NOT BE RUN FOR
Main Manifold Block (on Felling
MORE THAN 5 SECOUNDS
CONSTANT WHEN TESTING
Saw Return
Check Valve

Flow Control Valve

Saw Return
Check Valve
Schematic Main Manifold Block

A01368-001 9
Saw Motor Manifold Test and repeat if problem persists

The saw manifold block is located in the saw When saw bar is extending correctly Stand
box and is bolted onto the saw motor. head up.

Saw Bar Speed If bar extends when standing head up the

sequence valve has been set incorrectly.
The saw bar speed is altered here. The saw
bar speed has been set at the factory but Turn sequence valve adjuster in 1/8 of a turn
may need to be altered because of the appli- and test (repeat if saw bar still extends )
cation that it is working in (i.e. soft or hard
wood applications). It is recommended the
saw bar takes 2-3 seconds to complete its full
travel.
NOTE:
If the bar speed is to fast damage can be
caused to the saw cylinder spigot, saw
bar and tip and premature saw motor fail-
ure.

Saw Sequence Valve.

The saw sequence valve switches the bar
return to case drain and blocks of the oil that
is coming from the accumulator when saw is
run and switches back to the accumulator oil Saw Bar Speed
going to the bar return side of the cylinder
and case drain blocked of when saw is not
running.
The factory setting for the sequence valve is
unscrew the adjuster all the way out
(anticlockwise) then 2 full turns in (clockwise)
and lock of.
Note: If saw motor is running and the bar
is not extending. First check the saw Saw Sequence Valve
speed is correct and there is good pres-
sure in the saw supply line before adjust-
ing the sequence valve.
Remove the sequence valve and check that
the seals are not damaged.
Re install, Test, if same issue exists.
Re set the valve as per above (wind fully out
then 2 full turns in)
Test, if same issue exists
Turn sequence valve adjuster 1/8 of a turn
anticlockwise.

A01368-001 10
Three Way Ball Valve (630)
Two Way Ball Valve (420)
Position 1 accumulator is charged when saw
is used providing pressure for the bar to re-
turn home.
Position 2 depressurises the accumulator al-
lowing the bar to be manually pulled out from
the bar home position. This allows easy
maintenance of the saw bar and saw unit.
Four way Ball Valve (630 Auto Adjust Saw)
Four way ball valve
Position 1 accumulator is charged when saw
is used providing pressure for the saw bar to
return home and pressure to the bar tension
system.
Position 2 removes pressure from the bar
clamp pistons and retracts the bar. Also re-
moves pressure from the bar return allowing
the bar to be manually pulled out for bar and Three way ball valve
chain maintenance

Two way ball valve

A01368-001 11
Pressurising Accumulator
The line going to the accumulator first goes
through a pressure reducing valve (set to
120 - 150 bar) then a check valve.
NOTE: DRAIN ACCUMULTOR FIRST Accumulator charged to 35 - 40bar
BY SWITCHING BALL VALVE 4-5
TIMES or more if needed

Accumulator
The accumulator is to provide pressure for
the bar return after a saw cut. The accumula-
tor is to be charged to 35 - MAX 40bar with
nitrogen. When new this may not have been
carried due to transport restraints and needs
to be tested regularly.

Add Test Port

Checking Accumulator hydraulic

charge pressure.

This can be tested by putting a test point at

Main Manifold
the accumulator (Tee into hose).
Accumulator Check Valve
Note: this test is the same on the
SAT420 / SAT630H Standard / SAT630H
Auto saw
With the Ball Valve set in the operate posi-
tion run the saw and note the pressure on
the gauge.
Note: The saw needs to be running at full
rpm to test (Base Machine at full rpm) there
needs to be 180bar or more as standby
Pressure reducing
pressure in the saw line when the saw is run-
valve
ning to be able to test.
NOTE: THE SAW MUST NOT BE RUN
FOR MORE THAN 3 SECOUNDS
CONSTANT WHEN TESTING.

A01368-001 12
The charge pressure with the saw running
should be between 120 - 150 bar
To adjust turn the pressure reducing valve
adjuster clockwise for more pressure or anti-
clockwise for less pressure.
The pressure reducing valve can be found on
Add Test Port
the main inlet block.
Note: the accumulator charge pressure is dif-
ferent to the standby pressure.
Standby Pressure
Once the charge pressure has been set
check the stand by pressure (the pressure
showing on the pressure gauge when the
saw bar has returned to the home position)
The pressure showing should remain con-
stant (This pressure should be 48 bar +/- 2
percent)
This pressure should remain constant (on an
older felling head it may drop over 10 to 20
minutes)
If pressure drops quickly then there is an is-
sue that will need fixing
1) check that the ball valve is in the correct
position (recheck as per above) If pres-
sure drops go to 2
2) Cap the saw cylinder hoses and re-
check. If pressure is stable the saw cyl-
inder will need resealing.
3) Cap bar oiler Hydraulic hose and re-
check. If pressure is stable reseal
4) Cap the Auto tension and clamp lines
for the auto saw. If pressure is stable.
Reseal the tension pistons, if clamp pis-
tons have oil leaking out they will need
resealing (seal kit A01300)

If problem persists contact SATCO product

support
support@satco.co.nz

A01368-001 13
Tilt Up
The tilt up is controlled by the Dump Valve
(see page 5).
The oil for the tilt up comes down the saw
return line into the main manifold, the check
valve is then blocked (as shown) and the oil
goes to the tilt cylinders.

Tilt oil from the base machine

A01368-001 14
 TROUBLESHOOTING

1. Remember to always check the simple

things first, e.g. oil in hydraulic tank,
power in the control box, damaged or
squashed hoses.

FAULT FINDING
2. The following details the fault, cause
and remedy of the Felling Grapple, the
list is not definitive.

Fault Possible Cause Remedy

Saw Bar comes out when the Sequence valve set too low Increase pressure by turning the se-
head stands up quence valve clockwise

Saw supply line not draining to Tilt supply and Saw cut must be on the
tank correctly with Tilt up function same spool on the carrier valve

Saw Bar does not return
Accumulator Failure Replace the accumulator (see pages
12-13
(check by removing the hose, with a
good accumulator you cannot insert a
blunt screw driver into length of the ac-
cumulator)
Hose’s are not connected to the Check the 3/8 hose’s on the saw motor
correct ports block if they have been removed.

Ball valve in the wrong position Adjust handle to ‘up’ position

Sequence valve set too low Increase pressure by turning the se-
quence valve clockwise

Bar does not come out
Accumulator charge valve pres-
sure too low
Sequence valve set too high
Check the pressure with saw motor
running at the accumulator (120 - 150
bar) See pages 12 - 13
Decrease pressure by turning the se-
quence valve anti-clockwise

Leaking piston seal on saw cylin- Replace piston seal

der

A01368-001 15
Grapple jaws not holding Leaking piston seal on grapple cyl-
inder
Fault in check valve between saw
and grapple close on the main
manifold
Faulty relief valve on carrier valve
Leaking Centre-Joint seal
Saw Chain does not turn Saw bar tip seized
Saw motor failed
Saw switch faulty
Saw relay faulty
Saw solenoid on carrier faulty
Saw bar comes out slowly Incorrect bar speed valve
adjustment
Low saw motor supply flow
Low saw motor supply pressure
Leaking piston seal on saw
cylinder
Head does not stand up Faulty dump valve solenoid coil
Faulty dump valve
Tilt up switch fault
Tilt up solenoid on carrier faulty
Saw bar tip seized. Will not allow
the saw to turn backwards.
Head falls over Leaking tilt cylinder piston seals
Saw return check valve in the main
manifold faulty
Dump valve bypassing on the
carrier
Fault in the tilt up relief valve on
the carrier
Leaking Centre-joint seals
Oiler does not function No oil in the tank
Screen blocked
Failed oiler seals
A01368-001
Reseal cylinder
Replace O-Rings or check valve
Check the pressure and adjust or the re-
place valve
Reseal the Centre joint
Fit a new bar
Check if motor turns by hand
Replace saw motor if seized
Replace switch
Replace relay
Replace Solenoid
(Swap with the tilt up solenoid to check op-
eration.)
Turn the bar speed valve anti-clockwise to
speed up
Check you have 2 pump flow for saw cut
Check saw valve relief pressure
Reseal saw cylinder
Replace the coil
Replace dump valve
(don’t over tighten the coil nut)
Replace the switch
Replace the solenoid valve or coil
Replace saw bar tip
Reseal the tilt cylinders
(the leak barrel will get hot first when check-
ing operation)
Clean out valve
Replace the O-ring or check valve
Clean out valve
Replace the O-Ring or dump valve
Check the pressure, 200bar
Replace the valve
Reseal the Centre joint
Fill with oil and bleed the oiler
Clean screen and bleed the oiler
Replace seals in the saw oiler
16
 Main Manifold

A01368-001 17
 Saw Manifold

A01368-001 18
A01368-001 19
 Service Plan

Service interval
CHECK OVER FOR ANY CRACKS daily
CHECK FOR HOSE WEAR daily
CHECK HOSE PROTECTION FOR CORRECT POSITION daily
GREASE ALL GREASE POINTS daily
TOP UP CHAIN BAR OIL daily
CHECK SAW UNIT (INCLUDING CHAIN SHOT GUARD CATCHER) daily

CHECK CYLINDER SEALS FOR LEAKAGE weekly

CHECK THE SPEED OF ARMS, SAW BAR, AND TILT UP weekly
CHECK ROTATOR SLEW RING BOLTS weekly
CLEAN UNDER COVERS weekly
CHECK SAW SPROCKET WEAR weekly

CHECK PIVIOT PIN AND BUSH WEAR 250 hr

CHECK SWIVEL LINK BUSHES AND REPLACE IF NEEDED 250 hr

HYDRAULIC CYLINDERS - (service and replace seals) 2500 hr

REMOVE PINS AND BUSHES - (inspect for wear and damage) 5000 hr
REMOVE AND SERVICE ROTATOR MOTOR 5000 hr

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