M A N U A L

High Yield User Manual • Contact Information

Key Knife Contact Information

If you have any questions, please consult an authorized Key Knife® representative at:

Key Knife Western Canada Key Knife Europe

Key Knife - Western US 2740 Burrard St. Gewerbegebiet West/Siedlung 79
(Corporate Office) Vanderhoof, BC V0J 3A0 A-4843 Ampflwang
CANADA AUSTRIA
19100 SW 125th Court Tel.: (1) 250 567-2447
Tualatin, OR 97062 43-7675-3220 phone
Fax: (1) 250 567-2468 43-7675-3584 fax
USA E-mail:mlb@[Link]
Tel.: (1) 503 403-2000 E-mail to: kke@[Link]
Fax: (1) 503 691-2240
E-mail: sab@[Link]
Key Knife Eastern Canada
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St. Jerome, Quebec J7Y 4B6
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Tel.: (1) 450 438-3739
19100 SW 125th Court Fax: (1) 450 438-5757
Tualatin, OR 97062 E-mail: mjf@[Link]
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Tel.: (1) 503 403-2000 PO Box 424
Fax: (1) 503 691-2240 fax Unit 4 / 26 Isles Drive
E-mail: mlb@[Link] Coffs Harbour, NSW 2450
AUSTRALIA
Tel: (61) 2-665-18123
Key Knife - Southern US
Fax: (61) 2-665-18133
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Orion
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Rua Milano, 230 - Sao Braz
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Tel.: (55) 41 327201154
Email: [Link]@[Link]

Key Knife® Inc., reserves the right to make changes at any time without notice and without incurring any obligation. This publication may not
be reproduced, in whole or in part, without written permission. KEY KNIFE® INC., 2002, ALL RIGHTS RESERVED.

PN: 1008-D1
 High Yield User Manual • Table of Contents

High Yield Introduction Ch. 1

Installation of Components Ch. 2

Knife Change Ch. 3

System Set-Up & Application Ch. 4

Maintenance Ch. 5

Troubleshooting Ch. 6

Index App. A

Key Knife Definitions App. B

Tool List App. C

Torque Values App. D

Maintenance Schedule Sheet App. E

Basic Operator Training App. F

Installation Instructions App. G

Customer system Print & Parts List App. H

 High Yield User Manual • History

Key Knife History

1986 - Bob Bayly and Tom Carpenter joined forces in Portland, OR to design and build a
disposal knife for OSB plants. After a year of work, they chose to proceed with the de-
velopment of a second concept upon the recommendation of Dudley Smith, who
along with Bob’s mother, Jane Bayly, were two of Key Knife’s first financial supporters.
The second concept marked the beginning of today’s version of the Key Knife.
1987 - Bob and Tom hired Cecil Ostrander to build the first prototype of a chipper sys-
tem utilizing steel knife stock “borrowed” from a friendly competitor. The first installation
occurred at Mountain Fir Lumber of Dallas, OR in a Mobark chipper and ran for all of 30
seconds. Once they resolved the matters of hardness and radiuses, they hired their first
employee, Norma Sherratt in June of 1988 and production got underway in Cecil’s
barn. The achievement of producing one box of knives/day was considered a great
day. Only two machines could be operated at a time due to the lack of power to the
shop and the grinder was in a lean-to heated by a wood stove where the coolant had
to be defrosted every morning before start up.
1989 - The production shop was moved to a 3500 sq. ft. facility in Wilsonville, OR. During
this time, the official name of the privately held organization was changed from Com-
mercial Knife to Key Knife. $30,000 in sales for a month was considered record setting at
the time. A former saw shop owner and supporter; Herb Frelich became the first pro-
duction manager and the Chip-n-Saw concept was introduced in 1990. Neil Doherty
was hired as the first field rep in January of 1991 and the first CNC machine purchased
in 1992.
1993 - The manufacturing and office relocated from Wilsonville to a 20,000 sq. ft. build-
ing in Tigard, OR and the first High Recovery system was developed. In 1994, the first
Blohm (a computerized grinding machine) was purchased, revolutionizing the knife pro-
duction process. Two additional CNC machines and another Blohm were purchased in
1995.
1998 - The company relocated again, moving from Tigard to a newly built 50,000 + sq.
ft. facility in Tualatin, OR with room for additional expansion. A fourth Blohm and a fourth
CNC have since been added along with the establishment of a machine shop center
for further expansion into in-house product development. Likewise, in-house production
of additional Key Knife system components is taking place on a calculated basis as part
of the organization’s overall strategic plan.
2004-Key Knife had a record sale year, with sales increasing 26% over 2003. To meet the
growing demand for Key Knife products 3 more CNC machines were added. A new R
& D test center nicknamed the Big Beaver, was added to help with the theory and de-
sign of the next generation Key Knife chipping systems. To continue the growth Key
Knife has developed innovative products for the Pulp mill, Particleboard, and OSB indus-
tries. The demand for Key Knife products and services has taken the company to new
parts of the world, such as South America and Asia.
 High Yield User Manual • Misc. Information

About this Manual

This manual has been designed to be a user-friendly reference guide for the use and
operation of your High Yield System. Included in the manual is information on the
installation and operation of the System, in addition information and management
tools. It is our hope that this manual becomes a useable tool for you and your mill.
As always, your local Key Knife representative is always available to answer any
questions that you may have.

Key Knife Patents

The Key Knife High Yield Systems are protected under the following patents: 7,069,969
B2

Safety
The Key Knife conversion is designed to provide safe and dependable service, if
operated according to the instructions and intended use, in the chipping of wood
material. Any other use could be dangerous and is not recommended.
Be sure to read the entire System Manual before installing the Key Knife system. Failure
to do so could result in personal injury or equipment damage.
Key Knives are extremely sharp! When handling the knives, use extreme caution and
wear safety gloves.
Observe all equipment shutdown, lockout, and safety procedures as recommended by
the equipment manufacturers, as well as your company policies and guidelines.

Key Knife Warranty Policy

Key Knife warrants that on the date of shipment to Buyer and for one year thereafter
the Products will be free of defects in workmanship and material. If within one year
from date of shipment of the Products, Buyer discovers that the Products are not as
warranted above and promptly notifies Key Knife in writing thereof, Key Knife will, at
Key Knife’s option, repair or replace the item and any affected part of the Products, or
refund the purchase price therefore. Buyer shall assume all responsibility and expense
for removal and reinstallation in connection with the foregoing remedy. The same
obligations and conditions shall extend to replacement items furnished by Key Knife
hereunder. Buyer agrees to grant Key Knife access to the Products at all reasonable
times in order for Key Knife to determine the existence of a claimed defect in the
Products. Key Knife Product systems and accessories require installation by an
Authorized Key Knife Representative. Installation by anyone other than an Authorized
Key Knife Representative will void the terms of this warranty. This warranty does not
cover defects due to misuse, abuse, or improper or inadequate installation, storage,
service, modification or repair of the Products.
Chapter One

Introduction
 High Yield User Manual • Chapter One

Introduction Pg. 1

HY Segment Pg. 3

HY2 Counterknife Pg. 3

HY2 Clamp Pg. 5

Dimensioners Pg. 5

Spacers Pg. 5

Fasteners Pg. 6

Ridge XL Knife Pg. 6

Table of Contents
 High Yield User Manual • Chapter One

Introduction

Congratulations on purchasing a
Key Knife High Yield System! You
have chosen the finest wood
chipping technology and
equipment in the industry.

Key Knife developed the High Yield

2 (HY2) drum chipping heads for
progressive mills that want to
maximize the value of their wood
products and improve the
operating efficiencies tied directly to the process. The innovative HY2 product line
delivers unmatched gains in recovery, surface finish, chip quality, and operating
efficiencies.

The knife is indexible and disposable, eliminating the need

for grinding and babbitting. The innovative ridge design
eliminates problematic packing, protects the counterknife
from wear, and improves chip quality by providing chips a
smooth transition from knife tip to counterknife.

The unique design of the Ridge Knife XL makes changing knives a quick and safe
process.

High Yield Introduction Pg 1

 High Yield User Manual • Chapter One

HY2 Segment

HY2
Counterknife

Ridge XL
Knives

HY2
Clamps

HY2 Segment

HY2
Expanded
Gullet

High Yield Introduction Pg 2

 High Yield User Manual • Chapter One

HY2 Segment

The segment is the central Feature Advantage

component of the HY2 system. It
is designed with smoother and A514 (T1) plate Mill proven strength and durability.
larger expanded gullets improve
chip flow. Knife stops are
machined into each segment to lock in both ends of the Ridge Knife XL to eliminate
knife twist for precise edge placement.
Each segment is dynamically balanced to minimize system vibration.

HY2 Counterknife

The HY2 Counterknife supports

Feature Advantage
the Ridge XL Knife in the head.
The counterknife fits between the Mill proven to provide twice the
segment and the knife. The high DC 60F Coating component life than traditional
capacity radius improves chip spray-on coatings.
flow and relieves pressure off the
Excellent wear resistance and
chip, greatly improving chip A8 Tool Steel (Chipper)
durability.
quality.
The HY2 Counterknife can be Resistant to corrosion and
Nickel plated
equipped with retaining ears cracking
that ensure the precise knife
placement and retention during a knife change.

High Yield Introduction Pg 3

 High Yield User Manual • Chapter One

HY2 Clamp

The clamp provides full contact

clamping over the entire length of Feature Advantage
the knife, eliminating packing and
knife flutter. A high, medium, and Resistant to corrosion
low profile clamp is available for Nickel plated
and cracking
various reliefs and log control needs.
Five Point Clamping: Significantly improves knife stability, for a precise and
repeatable cutting path.

Dimensioners
Feature Advantage

S7 shock resistant Superior strength and

steel durability.
Dimensioners are vertical blades
situated in the counterknife used to
For maximum
split large chips. They are retained in
56-58 Rc toughness and
the counterknife with a set screw
durability.
making them easy to replace when
worn or broken.

Spacers

Some Key Knife conversions require the use of spacers. Spacers are used when the
original arbor design is used yet fewer segments are required. They are simply used
to take up the extra space left from the original stack width.

High Yield Introduction Pg 5

 High Yield User Manual • Chapter One

Fasteners

Key Knife uses Feature Advantage

only Grade 8 bolts
in your Key Knife Grade 8 Fasteners Superior strength and durability.
High Yield Head.

Ridge XL Knife

The knife is Feature Advantage

indexible and Mill proven to provide superior strength
disposable, Chipper Steel (A8)
and durability.
eliminating
the need for 56-60 Rc For maximum toughness and durability.
grinding and
babbitting. The innovative ridge design eliminates problematic packing, protects
the counterknife from wear, and improves chip quality by providing chips a smooth
transition from knife tip to counterknife.
The knife is clamped at five points by the clamp and counterknife, significantly
improving knife stability, for a precise and repeatable cut. This full surface contact
minimizes knife twist and flutter. Through exceptional knife stability the High Yield
System with the Ridge XL Knife delivers improved finish, chip quality, and knife life.

High Yield Introduction Pg 6

Chapter Two

Installation
 High Yield User Manual • Chapter Two

Introduction Pg. 1

Installing High Yield System Pg. 2

Table of Contents
 High Yield User Manual • Chapter Two

Introduction

This chapter will introduce you to the proper installation of your new Key Knife High
Yield Head(s). Detailed instructions for installation can be found in Appendix G.

For a complete list of tools required for installation, see Appendix C.

For appropriate torque values, reference the table in Appendix D.

Some systems might have slightly different designs that require slight adjustments to
the steps highlighted below and in Appendix G. Your Key Knife Representative is
always available to provide you whatever assistance you desire.

Lubricants and Shim Stock:

Key Knife recommends the use of Nickel-Based Anti-Seize compounds, such as

Locktite 771, to help prevent corrosion of components.

Key Knife recommends the use of thread locking compounds, such as Locktite 242,
in certain applications.

Key Knife recommends the use of either Brass or Stainless Steel Shim Stock, where
shim is required.

High Yield Installation Pg 1

 High Yield User Manual • Chapter Two

Installing Key Knife High Yield

Systems

1. Remove existing system Follow manufacturer’s procedures for

safe removal.

Follow Lockout / Tagout procedures.

2. Install clamps, counterknives and

holders (SLICE) onto the segments.

3. Install the segments onto the arbor(s). Review the Engineering Prints when
installing multiple heads to ensure the
correct segments are installed on
each given head(s).

4. Install bearings and bearing housing Follow the machine OEM and
onto the arbors. bearing manufacturer instructions.

5. Install the Key Knife heads into the Follow machine manufacturers’
machine procedures.

6. Center the heads in the machine.

7. Install knives.

8. Measure and adjust anvil clearance.

9. Align the spline maker with the rail(s) As Required.

on the guide.

10. Start the machine and run for 4 – 12

hours to work in the bearings.

11. Run logs through the machine.

12. Check and retighten locknuts after

1-5 days of operation.

High Yield Installation Pg 2

Chapter Three

Knife Change
 High Yield User Manual • Chapter Three

Introduction Pg. 1

Knife Change SOE HY2 Pg. 2-3

Table of Contents
 High Yield User Manual • Chapter Three

Introduction

The Ridge XL Knives are double-sided knives providing two cutting edges per knife.
The procedure to remove and replace the knives is the same for rotating a knife as it
is for replacing the knife.

It is highly recommended that a schedule of knife changes be establish and

followed. Dull and damaged knives may cause excessive stress on the system and
reduce the quality of the cants. By implementing a regular schedule for knife
changes, you ensure your knives always maintain optimal performance.
Additionally, you will not lose production time for an unscheduled knife change in
mid-shift.

During the knife change, remember to look for maintenance issues, such as worn or
damaged components. See Chapter 5 for more details.

It is also important to emphasize the need to properly clean the pocket during a
knife change. To provide superior results, your High Yield System is designed with
precise and exact tolerances. When debris is left in the pocket, the potential for the
knife not locating on the keyway exists. With proper cleaning of the pocket, your
High Yield System will run safely and efficiently.

Warning: Key Knives are extremely sharp. When handling the knives, use extreme
caution and always wear safety gloves. Eye and ear protection should be worn when
operating tools and using compressed air during the knife change.

High Yield Knife Change Pg 1

 High Yield User Manual • Chapter Three

SEQ # 020 SEQ # 030

SEQ # 040 (a) SEQ # 040 (b)

SEQ # Task Description Additional Information

Blow down heads with compressed air to

010
loosen and remove any wood fibers.

Loosen Clamp Bolts in the first row of knives

020
with an impact wrench and the 13/16" socket.

030 Remove the knives.

(b) Clean both the knife clamping surfaces and

(a) Clean all counterknife and clamp surfaces
040 the shoulder at the back of the clamp/
thoroughly, blow away-loosened material.
counterknife.

High Yield Knife Change Pg 2

 High Yield User Manual • Chapter Three

SEQ # 060
SEQ # 050

SEQ # 080

SEQ # Task Description Additional Information

050 Clean all the knives that are to be rotated. Use a wire brush and compressed air.

Ensure the knives are properly located on the

Position the knives into place and torque the keyway and held firmly against the retaining ear
060 clamp bolt with the impact wrench and torque (where appropriate)
stick.
DO NOT over torque the Bolts

070 Repeat SEQ #020 - 060 for remaining knives.

Spot check the torque on the Clamp Bolts with

080 Reference Torque Specifications (Appendix D)
the torque wrench and 13/16" socket.

High Yield Knife Change Pg 3

Chapter Four

System Set-up
and Theory
 High Yield User Manual • Chapter Four

Theory Pg. 1

Options Pg. 1-2

Settings and Theory Pg. 2-3

Operating Parameters Pg. 4

Table of Contents
 High Yield User Manual • Chapter Four

Theory
Key Knife’s cutting edge Research and Development and expert knowledge of the
sawmill industry has led to the development of the most advanced indexible knife
equipment available for customization to meet your exact needs.
Using the latest testing equipment and research and development facilities, Key Knife has
developed the new cutting edge HY2 System designed to add value to both your existing
and future operations.
Because of our valuable research and testing, Key Knife has identified the most crucial
elements to maximizing board finish, chip quality, and recovery while increasing sawmill
efficiencies and uptime. This chapter will share with you some of our findings.

Options
Dimensioners
Drum style chipping heads often create larger chips that are of the appropriate thickness.
Because these chips are overly large, they tend to clog chip screens. Key Knife offers
dimensioners for mills where this is an issue. They are easy to install in your Key Knife heads,
and help to break up those larger chips. This option is available only on HY2 Systems.

Clamp Options
Based on the specified operating parameters of the machine center and the individual
head, the clamps can be custom designed for each head to provide stable surface
contact with the log/cant if it begins to surge.
Where it is desirable, Key Knife will design your clamps so that one part number will work in
all heads in the machine. This will greatly simplify inventory and maintenance. However,
doing this will also minimize the amount of control provided by the chipping heads. If your
machine has adequate control without the aid of the chipping heads, then this might be
a desirable option.

Knife Options
The Key Knife High Yield System
provides additional flexibility by
simply changing the Ridge XL
Knife. By changing the bottom
grind on the knife, a 31-degree
knife may have different attack
angles. These customization
features allow a mill to adapt to
changes in the operating environment quickly and easily.

High Yield System Set-up and Theory Pg 1

 High Yield User Manual • Chapter Four

Extended Counterknives

Some chipping operations see a higher rate of wear than

others. For these situations, the extended counterknife is
offered.
It sits in the high wear zone of the segment and is specially
designed to ensure consistent chip flow without jeopardizing
the integrity of the expanded gullets.
Where used, the segments must be built, or modified, to
accommodate the extended counterknives.

Settings and Theory

CAM
Description: Camed surfaces are the top
surface profile designed into the segments to
match the operating parameters of the
machine center.
Function: Prevents overfeeding (surging) of the
cant / log. If the cant / log attempts to surge,
the profile of the segment acts as a “brake,”
limiting the forward movement of the cant.
Measurement: The camed surface is
measured as the drop in the segment profile
as measured from the knife tip.

Guide Clearance
Description: The distance from the spline(s) created
by the bottom head and the sides and bottom of the
guide bar.
Function: The clearance must be large enough to
prevent the cant from sticking in the machine. The
clearance must also be small enough to prevent
excessive cant movement while in the cut zone of
the chipping heads and saws.
Measurement: The clearance is measured as the
distance between the spline and the two sides of the guide bar as well as the
distance between the bottom of the guide bar and the bottom of the spline.

High Yield System Set-up and Theory Pg 2

 High Yield User Manual • Chapter Four
Anvil Clearance
Description: The distance from the cut
circle of the drum head to the anvil.
Function: The anvil clearance stabilizes the
cant as it exits the cut zone of the chipping
head, while providing enough clearance
to prevent sticking in the machine.
Measurement: The distance from the anvil
to the cut circle of the drum head measured tangent to the cut circle.
Effects of Anvil Clearance: An anvil clearance set to tight will cause excessive cant
sticking in the machine causing unnecessary downtime and slowing production.
However, an anvil clearance set too loose will allow excessive cant movement while
in the cut zone of the chipping heads and the saws leading to inaccurate target
sizes and degraded surface finish.

Knife Relief
Description: The angle between the top of the knife and
the cut line or cut path of the head.
Function: The knife relief provides a clearance for the top
of the knife. This clearance prevents heat generation
and premature dulling of the knife.
Measurement: The drop from the tip of the knife to the
heel of the knife, measured in inches.

Knife Attack Angle

Description: The angle drawn between the center
of the head to the tip of the knife.
Function: Attack angle controls the
aggressiveness of the chipping action. The
aggressiveness is directly related to the surface
finish of the cant as well as knife life.
Measurement: Knife attack angle is not easily
measured. It will usually be calculated once the
knife relief is known.
Key Knife Customization Ability: Key Knife designs the optimum attack angle for
each individual system to match the operating parameters of the mill.

High Yield System Set-up and Theory Pg 3

 High Yield User Manual • Chapter Four

Operating Parameters
Target Spline Clearance: 0.032” (1/32”) on both sides and the bottom of the spline.
Splines that are to be cut into dimensional lumber will meet the mill’s desired spline
dimensions.
Target Anvil Clearance: 0.020” – 0.040” Anvil clearance is dependent upon the
wood species and design of the machine.
Knife Relief: Knife relief is designed for each individual system. The designed knife
relief for this system can be found on the system design prints in Appendix H.
Target Knife Overlap: 0.031”

High Yield System Set-up and Theory Pg 3

Chapter Five

Maintenance
 High Yield User Manual • Chapter Five

Section A. Daily Operations Pg. 1

Section B. Routine Preventive Maintenance Pg. 1

Section C. Component Wear Pg. 2-4

Section D. Operating in Frozen Wood Pg. 5

Section E. Parts Rotation Pg. 5

Section F. System Crash Recovery Pg. 5

Section G. Spare Parts Inventory Pg. 6

Section H. Key Knife Services Overview Pg. 6-7

Table of Contents
 High Yield User Manual • Chapter Five

Maintenance
Over time and heavy use, your High Yield 2 System will wear. Worn parts must be
replaced as soon as possible to minimize the possibility of component failures. Proper
daily knife changes and routine maintenance on the system will help ensure it runs
optimally.

Section A. Daily Operations

The routine knife change is an opportune time for operators to note and report
potential issues with the machine. Evidence of impact damage should always be
noted and the appropriate actions taken to prevent further damage to the system.

Section B. Routine Preventive Maintenance

This section highlights the maintenance requirements for your High Yield System to run
efficiently and effectively. Because each mill has different operating conditions, this
schedule is considered the minimum requirement. Your Key Knife Representative can
work with you to develop a maintenance schedule that fits your mill’s needs.
Appendix E includes examples of maintenance schedules that can be used to
effectively manage your mill’s maintenance program.

Weekly Maintenance
• Lubricate the Clamp Bolts with anti-seize.
• Thoroughly clean debris from the keyways between the clamps and
counterknives as well as the back shoulder of the clamp and counterknives.
• Visually inspect the counterknives and clamps for impact damage or wear.
ƒ Change, or rotate, damaged components as needed.
Monthly Maintenance or 35 MMBDT, whichever comes first.
In addition to the weekly maintenance checklist, do the following:
• Remove all knives, and clamps from the head(s).
• Thoroughly clean all components.
• Check proper torque on counterknife cap screws.
• Visually inspect segments for wear or impact damage.

Quarterly Maintenance or 100 MMBDT, whichever comes first.

In addition to the monthly maintenance checklist, do the following:
• Measure and set anvil clearance
• Measure and set the guide bar clearances.
• Check the head(s) for excessive bearing movement / play.
Replace the system components, following the installation instructions found in
Chapter 2 and Appendix G.

High Yield Maintenance Pg 1

 High Yield User Manual • Chapter Five

Section C. Component Wear

As stated in Chapter 1, your new Key Knife High Yield 2 Chipping System is designed
for maximum wear ability. It also has a modular design, allowing for component
rotation into and out of the work zone. This allows for longer part life.
There is a critical balance that must be maintained when deciding when / if a
component is ready to be changed out. Parts must be run up to, or near their
designed life. Changing too early results in waste, changing too late can result in
system failure, which can outweigh savings from running a little longer.
The main components that must be watched are:
9 High Yield Counterknife
9 High Yield Clamps
9 High Yield Segments

With all components, impact damage from foreign material is cause for concern,
especially when that damage effects the knife clamping. Impact damage is further
discussed in the Section F: Crash Recovery.

High Yield Counterknife

The counterknife is probably the most important part in the system to monitor. It
experiences some of the highest wear and stress in the entire system. Counterknives
will wear differently from part to part, and system to system. It is important to learn to
visually recognize when a counterknife needs to be replaced, since a precise
measurement, is not practical or accurate.

Chip Flow Wear: Chip Flow will eventually break through the hard surface on the face
of the counterknife, and begin to remove, and dish out the base metal. This wear
does not jeopardize the integrity of the system until it starts to wear into the knife
clamping area of the counterknife. When this wear creates a sharp point at the
keyway, the part needs to be replaced.

Here are two examples of Counterknife Chip Flow Wear that has not yet
jeopardized the integrity of the knife clamping.

High Yield Maintenance Pg 2

 High Yield User Manual • Chapter Five

When the tip of the

Counterknife is worn to a
sharp edge, as illustrated
to the right, it needs to
be replaced.

CAUTION: Rebuilding of Key Knife counterknives is not recommended. The

counterknife has a very precise heat treatment and several other processes.
Simple rebuilding, or “re hard surfacing” erases the effects of these processes, and
will result in a drastically weakened part.

High Yield Clamps

Clamps typically do not experience excessive wear from normal operation. Most
damage will result from crashes in the machine center, and this is addressed in
Crash Recovery Section. Typical clamp wear to be aware of include:
o Normal Polishing Wear
o Keyway Wear
Normal Polishing Wear: clamps function to hold the knife in place, and in some
cases to prevent cant surging, by limiting the advance of the cant. The clamps
will often show polishing wear on the top surface as a result of this limiting action.
This is normal and not a cause for concern. Unless evidence of cant surging is
found, or the wear appears to be unevenly distributed, this polishing of the clamp
does not warrant a worn part.

Left Clamp – example

clamp that rarely contacts
the cant. Note the “gun
metal” appearance.

Right Clamp – example

clamp that displays normal
polishing wear from
CAMMING.

High Yield Maintenance Pg 3

 High Yield User Manual • Chapter Five
Keyway Wear: Although not common, this is a more serious type of wear that
deserves immediate attention. After several years of use, the two knife contact
points on the top key may start to show wear lines and should be replaced
immediately. If not replaced, the knives might not clamp properly and jeopardize
the integrity of the system.

Right image – example

clamp with keyway wear
that needs to be replaced
immediately.

Left image – look here for

wear lines.

Segments
Segments typically do not experience excessive wear from normal operation.
However, the expanded gullets on the segments are designed to enhance chip
flow and maximize chip quality by protecting the chips in the smooth, open design.
By the very nature of the design, the gullet may show Chip Flow Wear as a result of
maximizing chip quality.
Chip Flow Wear: Chip Flow could eventually start to remove, and dish out the base
metal on the segments after extended use. Normally, this is not critical wear.
However, if it is a concern, retrofitting the current segment assemblies with
extended counterknives will resolve the issue.

These are two examples of segment chip flow wear. In both of these examples,
retrofitting the existing segments with Extended Counterknives will alleviate the
problem considerably.

High Yield Maintenance Pg 4

 High Yield User Manual • Chapter Five

Section D. Operating in Frozen Wood

Operating in extreme cold weather presents many challenges in wood chipping
applications. The durability of the Key Knife system has been proven to withstand
the rigors of this extreme environment.
As the wood fibers freeze, the wood reacts differently. Often, a mill operating with
frozen wood will see their pins and fines increase, in addition to a shift in their
distribution towards thinner chips.
Contact your Key Knife representative if you have any questions regarding these
conditions.

Section E. Parts Rotation

Unlike other drum style chipper systems, Key Knife High Yield parts can be rotated in
and out of the high work zone for a longer part life.
When a counterknife in the high work zone is showing chip flow wear, simply rotate
the part out of the work zone*. This will prolong the life of the counterknife. Clamps
can also be rotated in this manner.
As each individual mill is different, your Key Knife Representative will be happy to
assist you in developing a parts schedule that meets your needs and provides you
with the most value.
* Note – counterknives may have different retaining ear configurations. Ensure that
when replacing or rotating these components, the same configuration gets put
back into the head.

Section F. System Crash Recovery

Although Key Knife High Yield Systems are extremely
durable, they are not completely” bulletproof”.
Inadvertent crashes from foreign debris in the mill, is
unfortunately a fact of life.
Fortunately, the advanced modular design of your
Key Knife System is of significant value when
contaminants enter the system. Instead of having to replace the entire assembly,
simply replacing the damaged parts saves time and money.

High Yield Maintenance Pg 5

 High Yield User Manual • Chapter Five
After a system crash simply follow the following guidelines to get your operation up
and running in a safe and timely manner.
1. Inspect all system components in the segments where damaged has incurred. Pay
close attention to the components responsible for clamping the knife into place, as
highlighted.
2. Replace all damaged components. (Reference Appendix G for instructions)
• Always replace clamp bolts when changing clamps
• Always replace counterknife Fasteners when changing counterknives.
• Always replace holder fasteners when replacing the holder(s) (SLICE only).
3. Replace knives and continue operations.
Warning -Bolts and studs often sustain damage that is not readily visible. Hairline cracks
are often common after a crash. If these fasteners are then put back into service, you
risk another crash when they fail. Always replace bolts and studs when the component
they are holding is damaged.
Key Knife is committed to the welfare of your business. If you are unable to determine
the exact cause of a crash, set the damaged parts aside and contact your Key Knife
Representative who can assist you investigate the cause of the crash.

Section G. Spare Parts Inventory

Maintaining an adequate supply of spare parts is a responsible method of hedging
against unneeded down time resulting from a crash.
Your Key Knife Representative will work with you to provide an Operations Model that
will show your projected parts usage for the year as well has the recommended
quantity of spare parts. From this analysis, you can establish a scheduled deliveries
program with Key Knife to ensure you have the right parts in the right place at the
right time.
Although each mill is different, and there is no standard spare parts list, Key Knife
recommends that at least one full set of spare parts be maintained on site. Use this
general rule of thumb, and the expert knowledge of your Key Knife Representative for
establishing proper inventories for success.

Section H. Key Knife Services Overview

Key Knife services are not structured around typical maintenance programs. Instead
our services focus on your operation as a whole and on the areas of your operation
where we can add the most value.

High Yield Maintenance Pg 6

 High Yield User Manual • Chapter Five
Your Key Knife Representatives are knowledgeable and skilled in chipping application
and chip theory. Most of our Account Managers have extensive backgrounds in the
forest products industry and have seen and worked on just about every type of
machine running in a mill today. This knowledge is utilized to provide you with the
resources necessary to increase your mill’s overall operating efficiency.

At no added cost, we provide scheduled deliveries, Operations Model Analysis,

benchmark reporting, and frequent checkups of your operation. By taking advantage
of these value adding service programs you will lower your purchasing costs, optimize
inventory levels, and always receive the right products, in the right place, at the right
time.
We also offer regularly scheduled maintenance programs to ensure your Key Knife
system always performs at an optimum level. This extra level of service can be
customized to meet the needs of your operation, including maintenance and
optimization of individual machine centers, machine center performance analysis, mill
staff training, inventory analysis, troubleshooting and providing solutions.

Contact your Key Knife Representative for more information on our Service Programs.

High Yield Maintenance Pg 7

Chapter Six

Troubleshoot
 High Yield User Manual • Chapter Six

Introduction
This chapter provides some commonly seen problems that occur in all chipping
operations. Most issues arrive as a result of worn or damaged components or as a
result of incorrect torque on critical knife clamping fasteners.
These troubleshooting tools are not meant to be all-inclusive. They are tools to assist
you in your chipping-head operation. If you have tried unsuccessfully to fix a
problem, or have any questions, call your local Key Knife Representative who will
assist you to maximize the operation of your Key Knife System.

Troubleshooting Matrix

Condition Possible Cause Corrective Action

Replace old knives
Dull or damaged knives
Reduce the number of Rehones
Ensure hold down rolls have adequate pressure on
Torn Grain
Log is vibrating in cut zone cant
Ensure anvils do not have excessive clearance
Excessive knife relief Confirm operating parameters for system design.
Excessive / Inconsistent anvil clearance Ensure anvil clearance is set appropriately

Sniping Infeed system not aligned to the machine

Ensure infeed system is properly aligned to the
causing long/cant to “dive” into the
machine.
chipping heads
Ensure there is no packing between the
High Knife causing deep scallop
counterknife and knife
Inconsistent Scallops Excessive knife relief Confirm operating parameters for system design.
Ensure anvil clearance is properly set to
Excessive anvil clearance
recommended clearances
Replace knives
Dull knives
Reduce number of Rehones
Check to ensure head RPM has not changed
(slowed down) from system design
Excessive knot tear Excessive Chip Length
Check to ensure the feed speed has not increased
from system design.
Insufficient knife speed Check to ensure head RPM has not changed
Cant is surging in the machine Confirm operating parameters for system design

High Yield Troubleshoot Pg 1

 High Yield User Manual • Chapter Six

Knives should sit squarely on both keyways

Knives not properly installed
Ensure clamp bolts are properly torque’d
Counterknives damaged or excessively
Replace counterknives
Packing between knife worn along keyway
and counterknife Clamps worn and bottoming out Replace clamp immediately
Ensure proper knife change includes cleaning
Dirt buildup on the bottom of clamp(s) keyway
Ensure proper torque is applied to Clamp Bolts
Need Dimensioners Install Dimensioners in the head(s)
Over-Wide Chips Worn or damaged Dimensioner Replace Dimensioners
Low knife speed Check to ensure head RPM has not changed
Ensure chip length settings are to designed
Change in operating parameters
parameters
Feed Rolls are worn Replace worn feed rolls
Cants / boards have
Feed Rolls are not timed properly Check timing of feed rolls
started Surging in the
machine Replace old, worn clamps
Clamps are too low
Change parts to a higher clamp
Segment is excessively worn Check segment CAM relief
Anvil Clearance set too tight Check anvil clearance and adjust accordingly
Check spline width to ensure it is within
Spline is not aligned properly with rail tolerance
Cant sticking in (HIGH YIELD) Check spline clearances to ensure they are
machine within the target parameters
Excessive knife grinding reducing the Follow Key Knife’s recommended rehoning
anvil clearance schedule
Check the feed rolls to ensure they have
Inadequate pressure on feed rolls
adequate pressure
Replace worn / damaged counterknives
Knife flutter from reduced clamping force
Ensure Clamp Bolts are properly torque’d
Reduced knife life
Foreign debris, excessive bark, sand, dirt, Excessive amounts of the listed materials will
(unexplained)
etc on the logs degrade knife life
Follow Key Knife’s recommended rehoning
Excessive knife rehoning
schedule
Foreign debris, excessive bark, sand, dirt, Excessive amounts of the listed materials will
Chipped knives
etc on the logs degrade knife life
Ensure Holder Bolts have proper torque
Holder not properly installed Ensure holder sits square on the segment and
Holders (SLICE)
that dowel pins seated properly
moves or raises up
Remove burrs, debris from beneath holder
during operation
Replace worn segments where the holder can
Segment has excessive wear
not sit squarely on the mounting surface.

High Yield Troubleshoot Pg 2

 High Yield User Manual • Appendix A
Anvil Clearance
Description Ch 4, pg. 3

CAMS
Description Ch 4, pg. 2

Dimensioners
Description Ch 1, pg. 5
Installation App G, pg. 10

Fasteners
Description Ch 1, pg. 6

HY2 Clamp
Description Ch 1, pg. 5
Installation App G, pg. 4-5
Wear Ch 5, pg. 3

HY2 Counterknife
Description Ch 1, pg. 3
Installation App G, pg. 4-5
Wear Ch 5, pg. 2

HY2 Segment
Description Ch 1, pg. 3
Installation App G, pg. 1-3
Wear Ch 5, pg. 4

High Yield System

Installing Ch 2, pg. 2
Section A. Daily Operations Ch 5, pg. 1
Section B. Routine Preventive Maintenance Ch 5, pg. 1
Section C. Component Wear Ch 5, pg. 2-4
Section D. Operating in Frozen Wood Ch 5, pg. 5
Section E. Parts Rotation Ch 5, pg. 5
Section F. System Crash Recovery Ch 5, pg. 5
Section G. Spare Parts Inventory Ch 5, pg. 6

High Yield Index Pg 1

 High Yield User Manual • Appendix A

Key Knife Services Overview

Description Ch 5, pg. 6-7

Knife Attack Angle Ch 4, pg. 3

Knife Change Ch 3, pg. 2-3

Knife Relief Ch 4, pg. 3

Maintenance
Routine preventative Maintenance Ch 5, pg. 2
Monthly Maintenance Schedule App E
Quarterly maintenance Schedule App E

Options Ch 4, pg. 1-2

Operating Parameters
Description Ch 4, pg. 3

Ridge XL Knife
Description Ch 1, pg. 6
Option Ch 4, pg. 1

Setting and Theory

Description Ch 4, pg. 2-3

Spacers
Description Ch 1, pg. 5

Theory
Description Ch 4, pg. 1

Training
Lesson Plan App F, pg. 2
Test App F, pg. 3-5

Terminology App B

Tool List App C

Training Lesson Plan App F

Troubleshooting Ch 6

Torque Values App D

High Yield Index Pg 2

 High Yield User Manual • Appendix B

Anvil: A stationary (either vertical or horizontal) knife opposing the main knife assembly.
The knife passes the anvil like scissors blades to cut the wood. Anvil is a sawmill term;
also known as the cutter bar or bed knife to the Tree Industry.
Application: The task needing to be done with the wood, such as edging, canting, etc.
Assembly: All parts needed for a system setup (segment, clamp, holder, counterknife
etc.) and the necessary hardware (bolts, screws, etc.) as a unit.
Babbitting: 1) The molten metal added to the bottom of a non-indexable knife after
grinding to correct the height. 2) The process of adding babbitting to the knife.
Band Saw: A saw used as a canter or in primary recovery consisting of a continuous
piece of flexible steel with teeth on one or both sides.
Bent Knife: 1 )An old bent blade knife design used on conical saw heads 2) Key Knife
updated the design by replacing the one knife with two smaller knives set at an
angle. This term is now outdated, and the knife/knife systems should be referred to as
High Recovery.
Board: A piece of lumber nominally less than 2" thick and 1 " or more wide.
Board Foot: The basic unit of measurement for lumber; equal to a 1 by 12 by 12-inch
board. An 18 foot long 2 X4 would be 10 board feet, as would a 9 foot long 2X8.
Bottom Head: A cutting head/saw responsible for processing the bottom of a log.
Bow: A Flatwise deviation along the length of a piece of lumber measured at the point
furthest from the optimal shape line. Bowing is the curving of the wood.
Butt: The bottom of the tree after being cut down; this end is wider and directly above
the bottom-most cut on the tree (right above the stump).
Butt Log: The first log from the butt of the tree.
Camber: The curve or bend found in lumber not under stress.
Cant: 1) A log with two or more sides squared 2) A log that has gone through primary
recovery and is destined for processing by other saws.
Canter: 1) Sawmill application, a) top and bottom already flat; sides are squared. b) all
sides are squared 2) A cutting device to square two or more sides of a log.
Cards: Blocks of chips un-separated from each other.
Carriage: A track-mounted vehicle that carries the log through the head saw in a
sawmill.
Chip: A small, thin wafer of wood cut at a precise angle to the grain with both side
corrugated or striated as a result of being split from the parent wood (a log, slab, etc.)
Chips are thicker and coarser than sawdust, and usually headed for a pulp mill.

Key Knife Terminology Pg 1

 High Yield User Manual • Appendix B

Chip Accept: Any chip suitable for making pulp; not too wide or small like overs, fines,
etc.
Chip 'N' Saw: A type of sawmill knife system; disk shaped segments are stacked to
make a drum/barrel shaped head. Each segment has several knife pockets, and
the knives are staggered along the head surface. (Note: Originally a brand name of
one type of chipping head-rig, it has come to mean all such machines).
Chipper: A machine used solely for converting wood into chips.
Chipper-Canter: A machine that makes cants from logs using only chipping heads (no
saws).
Chipping Head-rig: A machine that mills small logs simultaneously into lumber and
chips; the outside is chipped away and the inside is sawn, usually into 2X4's.
Chute: A dry trough for moving logs from the logging area to a landing, body of water
for rafting/ storage, or a mill. The trough may be wooden or gouged into the earth.
Circular Saw: A round saw with cutting teeth around the perimeter; it has been largely
replaced in sawmills by band saws.
Clam Shell: Tilts the upper infeed portion of the gang upward to allow easy access to
the saw guides.
Clamp: The clamp is placed on top of the knife, holding it in the knife pocket. It also
provides a full length clamping force on the knife.
Clearance Angle: The angle between the ground bevel of the knife and a line
tangent to the cutting circle at the knife cutting edge.
Coarse Grain: Wood grain with wide, conspicuous annual rings of less than four rings
per inch.
Counterknife: An angled plate used in some knife assemblies to protect the knife
assembly and aid in separating the wood. The counterknife is placed under the
knife and braces it the knife pocket. Also known in the Tree Care industry as a gib.
Crook: Deviation along the edge of a piece of lumber from end to end, and
measured at the point on the deviation furthest from the ideal line of cut.
Cup: Deviation along the face of a piece of lumber, measured at the point(s) not
conforming to the ideal line of cut from end to end and edge to edge.
Curve Sawing: Applications performed on a curved log; generally the log remains
stationary as the saws move around.
Cutter Head: Rotating planer piece that contains the knives/planers. See HUB.
Cutting Angle: The angle between the ground bevel of a knife and a line tangent to
the cutting circle at the knife cutting edge.

Key Knife Terminology Pg 2

 High Yield User Manual • Appendix B

Cutting Circle: The range of the knives on a cutting head in motion; diameter
measured as the distance from the tip of one knife to the tip of the opposite knife
Cylinder: See CUTTER HEAD.
Depth of Cut: The thickness of material removed by a knife from the surface of a piece
of lumber.
Dog: 1 )A sawmill machine for gripping a log; for example, a dog holds a log in place
prior to sawing. 2) Any device designed to bite into and hold something securely. 3)
A spike designed to hold the chains on a log raft to the log.
Disk: A style of cutting heads shaped like a flat, narrow disk.
Drum: A style of cutting heads shaped like a cylinder. The head may be one piece, or
made up of many segments stacked together .
Edger: 1) A sawmill application; cutting the sides off of tapered or misshapen boards.
2) A cutting device that performs this application.
Edging: Waste wood cut from misshapen lumber by an edger.
Extended Counterknife: A continuation of the counterknife designed to protect High
Yield segments from chip flow wear.
Extension: See KNIFE EXTENSION.
Face: 1) A flat, rather than rounded, side of a cutting head, where the axle runs
through. 2) The best looking side of a piece of lumber; the side from which the grade
is determined.
Feed Speed: The rate lumber passes through a cutting assembly or assemblies. Usually
measured in Feet Per Minute (FPM).
Feed Rolls: Any rolling piece of machinery, usually power driven, for moving wood up
to and/or through a cutting machine at a specified speed.
Fines: Any chips very short in length, and/or less than 5.3 mm in cross-sectional
measurement. Coarser than sawdust, but not big enough for accepts.
Fine Sawn: A term to describe surfaced lumber that has been passed through a saw
to gain a textured face. Rougher than actual surfaced lumber, but smoother than
unsurfaced lumber.
Gang: A machine designed to cut a cant into multiple boards. Usually a guided
machine with multiple saw heads; to begin cutting, the cant is rotated, or the saws
rotate around the cant.
Gang-saw: 1) A saw used in a gang to cut the cant into boards. 2) A number of saws
on a common arbor.

Key Knife Terminology Pg 3

 High Yield User Manual • Appendix B
Grain: A general term referring to the appearance, direction, and arrangement of
wood fibers; examples include fine, coarse, spiral, vertical, and curly.
Gullet: The place on a cutting head between the cutting edge of the knife and the saw
one head below; where any resulting chips/wood particles strike. This area of the
cutting head wears out quickly.
Head: The entire body of the cutting assembly, hub/segments etc. and the knife
assembly.
Head Rig: A carriage on rails that can transport a variety of saws/cutter heads.
Hood: In planers; part of the blower pipe that fits over the cutting head.
Holder: Is the support for the base for the counterknife, knife and clamp. It also provides
a means to attach the assembly onto the hub.
Hub: The main body of a cutting assembly. The knife assemblies mount to special
pockets on the hub, and as the hub turns on an axle, the knives spin to cut or chip the
wood.(See HEAD). A hub can be called a cutting head, but the head can not be
called a hub. Also called Rotor in the tree care industry; Segment or Drum in Chippers
and Chip 'N' Saws.
Infeed: The end of the edger, gang, or planer where the wood enters the machine.
Kerf: The width of a saw cut; the amount of wood lost to sawdust after each pass of the
saw (For example; 3/32 of an inch is considered narrow kerf).
Knife Extension: The amount a knife projects beyond the cutter head body/hub.
Lead Bar: See MAIN GUIDE.
Live Rolls: Powered rollers used to move lumber or cants in a sawmill.
Main Guide: A straight metal bar extending from the first bottom infeed roll to the inside
saw head. The main guide directs lumber flow precisely in to the inside head.
Multi-spline: Sawmill application. A number of splines are cut into the bottom of a log to
control it during processing.
OEM: Original Equipment Manufacturer.
Outfeed: Refers to the discharge end of the edger, gang, or planer.
Overs: Oversize and/or overly thick chips; any completely separated material over
76mm long and/or 10mm thick.
Pins: Very narrow chips; any material within the normal length range but less than 9.5mm
and over 5.3mm wide. May also include very short chips.
Pocket: The location on a cutter machine hub where knife assemblies are mounted
('pockets' are cut into the hub).
Primary Breakdown: 1) Sawmill application; the whole log is round, cut off all sides. 2) The
first processing the log experiences after being in log form.

Key Knife Terminology Pg 4

 High Yield User Manual • Appendix B
Roll: A series of long large cylinders on individual axles mounted side by side
lengthwise. Logs, lumber, and wood scraps can roll or be rolled (as in an electricity
powered live roll) from one location to another.
Screening: Passing chips through a wire mesh or similar type screen in order to
separate accepts from unacceptable chips.
Segment: A round, disk shaped foundation of metal that can be stacked with other
segments to form the main body of a cutter head.
Setup: The preparation of a series of cutting assemblies designed to cut a specific size
and pattern of lumber (planer, gang) prior to cutting a batch, including aligning
and adjusting the equipment.
Shim: A thin piece of metal for filling spaces between machine parts, adjusting part
extension, or bracing two pieces (i.e., filling the gap between a converted cutting
head pocket and the new holder).
Side Head: A cutting assembly in a mill placed to process one side of a log.
Side Head Hold down Shoe: An adjustable metal bar positioned directly above the
matcher plates at the side heads. The hold down shoe prevents lumber from moving
vertically as it passes the side head knives.
Slab: A side of a log that has been cut off. See SLABBER
Slabber: Sawmill application; whole log is round, one side is cut off.
Snipe: When a log moves laterally in the machine, creating a tapered end.
Snatching: When a log jumps or surges as it goes along the mill line and does not feed
through at an even rate.
Spline: A 'track' that can be sawn into the bottom of a log to make it easier to lead
the log down the log line. The splines can be chipped off later.
Sweep: The curvature in a log, pole, or piling, classified as a defect.
System: A type of knife assembly used for certain applications, such as basic High
Recovery, Chippers, or Chip 'N' Saw.
Tear-out: When wood splits or pulls out deeper than the knife depth of cut while being
processed; resulting in a ragged, uneven surface.
Top Head Reman: Sawmill application; board is round on top or too thick; cut off top.
Torn Grain: An irregularity in the surface of a piece of wood or log.
Warp: Any variation from a true or plane surface. See CROOK, BOW, or CUP.
Wastewood: 1) Unusable wood such as ends, edges, scraps, etc. 2) The wood industry
application for processing this type of waste and scrap wood into useable chips. The
chippers used can be very large; free standing monoliths in sawmills, or very small;
truck mounted portable chippers for arborists in the field.

Key Knife Terminology Pg 5

 High Yield User Manual • Appendix C

Tool List
This appendix lists the tools required to install and operate a High Yield System in your
mill. Table One lists the tools needed to install your system and Table Two lists the
tools needed during the daily operation of the system*.
To ensure fast and smooth knife changes, and change out of wear components, Key
Knife recommends that two air-lines be available at the chipper to operate
pneumatic tools.
Vendor names and part numbers are provided for your convenience only and do
not represent any endorsement by Key Knife, Inc.

* Note that some of the tools needed for installing your High Yield System can also
be used during the daily operations of the system.

Installation of High Yield System

Key Knife
Item Description Order Store Name Order Number
Number
Torque wrench, 1/2" drive, 50-250 ft/lbs 27802 GRAINGER 4LY37
5/32" Allen Wrench * GRAINGER 4R615
1/4" Allen Wrench * GRAINGER 4R615
1/4" Hex Bit Socket, 1/2" Drive * GRAINGER 4JX16
3/8" Hex Bit Socket, 1/2" Drive * GRAINGER 4JX16

Socket, 13/16", 1/2" drive 13407 GRAINGER 1AW41

Impact Wrench, 1/2" drive GRAINGER 3Y495
Torque Stick, 120 ft/lb 16568

Anti-seize, Nickel Based GRAINGER 4KM51

Rubber Mallet / Dead Blow Hammer n/a
Spanner Wrench (for arbor locknuts) n/a
Hammer n/a
Center Punch n/a
Rags n/a
Machinist Level n/a
Notch Gauge n/a

* The listed part numbers are for multiple-piece sets.

Operation of High Yield System

Key Knife
Order
Item Description Order Store Name
Number
Number
Impact Wrench, 1/2" drive GRAINGER 3Y495
Socket, 13/16", 1/2" drive 13407 GRAINGER 1AW41
Wire brush NAPA SER 2310
Torque wrench, 1/2" drive, 50-250 ft/lbs 27802 GRAINGER 4LY37

Key Knife Tool List Pg 1

 High Yield User Manual • Appendix D

Torque Values

KK
Part Description Torque ft/lbs Torque Nm
Part #

HY2 Clamp Bolt Hex Bolt 5/8-11 UNC KK* 21667 120 - 160* 163 - 216*

Counterknife Bolt Cap Screw Socket 5/16-18 UNC 10977 23-29 31-39

Slice Clamp Bolt Hex Bolt 5/8-11 UNC KK* 15124 120 - 160* 163 - 216*

Holder Bolt Cap Screw Socket 7/16-14 UNC 25403 61-76 83-103

* KK Special Torque Recommendation

Key Knife Torque Values Pg 1

 High Yield User Manual • Appendix E

Key Knife High Yield Monthly Maintenance Schedule

Month: Machine Center:

Task Week 1 Week 2 Week 3 Week 4

Clean debris from the keyways between the clamps and
counterknives as well as the back shoulder of the clamp and
counterknives
Lubricate the Clamp Bolts with anti-seize.

Inspect the counterknives and clamps for impact damage or

wear. Change, or rotate, damaged components as needed.

Remove all knives, and clamps from the head(s).

Check proper torque on counterknife cap screws.

Visually inspect segments and SLICE holders for wear or
impact damage.

Week 1 Notes: Week 2 Notes:

Conducted By: __________________________ Conducted By: __________________________

Week 3 Notes: Week 4 Notes:

Conducted By: __________________________ Conducted By: __________________________

Key Knife Maintenance Schedule Sheet Pg 1

 High Yield User Manual • Appendix E

Key Knife High Yield Quarterly Maintenance

Schedule
Date: Machine Center:

Conducted By:
Task Yes No N/A

Clean debris from the keyways between the clamps and counterknives as
well as the back shoulder of the clamp and counterknives

Lubricate the Clamp Bolts with anti-seize.

Inspect the counterknives and clamps for impact damage or wear.

Change, or rotate, damaged components as needed.

Remove all knives, and clamps from the head(s).

Check proper torque on counterknife cap screws.

Visually inspect segments and SLICE holders for wear or impact damage.

Measure and set anvil clearance

Measure and set the guide bar clearances

Check the alignment of the spline maker head

Check the head(s) for excessive bearing movement / play.

Anvil Clearance (Right Head): Anvil Clearance (Bottom Head):

Anvil Clearance (Left Head): Anvil Clearance (Top Head):

Spline Clearance (sides): Anvil Clearance (Spline Remover):

Spline Clearance (bottom):

Notes:

Key Knife Maintenance Schedule Sheet Pg 2

 High Yield User Manual • Appendix F

LESSON PLAN

Basic Operator Training for the Key Knife High Yield Systems

The following training checklist and testing materials are meant to serve as a tool for
supervisors and shift leads to use in conducting new employee training, or refresher
training on the Key Knife High Yield System.

The training checklist should be used in conjunction with the content of this System
Manual. Next to each topic is the chapter and section identification where the
instructor can find the information to be taught.

Each item on the checklist is deemed critical knowledge for operators to safely and
effectively operate your High Yield System.

The Test in section two is another tool Key Knife has provided for use by the
instructors to ensure that the presented material has been understood and retained
by the operator(s).

Revised: ____date___________

Key Knife Basic Operator Training Pg 1

 High Yield User Manual • Appendix F

High Yield Basic Operator Training Checklist

1. Review the System Components. Identify the name and purpose for the
following items (Chapter 1):
a. Segments
b. Counterknife
c. Clamps
d. Holders (SLICE only)
e. Clamp Bolts
f. Ridge XL Knife

2. Installing and Replacing Clamps and Counterknives (See Appendix G “Install

High Yield Clamps and Counterknives”)
a. Review procedures for removing and installing components
b. Emphasize the use of Anti-Seize on all fasteners
c. Emphasize the proper Torque Value for the Clamp Bolts.

3. Knife Change (See Knife Change Procedures, Chapter 3)

a. Review the required tools to conduct a knife change.
b. Review the procedures for removing and replacing Key Knives.
c. Emphasize the proper cleaning of the keyway during the knife change.
d. Emphasize proper knife location on the keyway(s).
e. Emphasize the proper Torque Value for the Clamp Bolts.

4. Component Wear (Chapter 5)

a. Review normal wear patterns for counterknives and clamps.
b. Review when a counterknife and clamp should be replaced.
c. Review the normal wear patterns for the SLICE Holder (SLICE only).

5. Proper torque values (Appendix D)

a. Clamp Bolts
b. Counterknife Bolts
c. Holder Bolts (SLICE)

6. Troubleshoot the system (Chapter 6)

a. Review the Troubleshooting Matrix in Chapter 6.
b. Review common board finish issues and corrections.
c. Review common maintenance issues and corrections.

7. Procedures to inspect and replace components after a crash (Chapter 5).

a. Review the critical areas to inspect on components
b. Review part replacement procedures (including fasteners)

Key Knife Basic Operator Training Pg 2

 High Yield User Manual • Appendix F

Test: Basic Operator Training for the Key Knife

High Yield System
Written Test
Q1 – Explain the importance of cleaning the counterknife thoroughly during a
knife change.
(a) A dirty counterknife will decrease knife life.
(b) The knife will not locate on the keyway properly with excessive debris in
the pocket.
(c) To increase component life.
(d) All of the above
(e) None of the above

Q2 – The purpose of the counterknife is:

(a) To support the knife in the head.
(b) To split larger chips.
(c) To provide log / cant control.
(d) All of the above
(e) None of the above

Q3 – The Counterknife should be replaced:

(a) When the chip flow finally breaks through the hard surface.
(b) When the tip of the counterknife is worn to a sharp edge.
(c) Every three months.
(d) All of the above
(e) None of the above

Q4 – After a crash, the clamp bolts should:

(a) Assumed to be fine and kept in the machine.
(b) Replaced only when the segment(s) needs to be replaced.
(c) Replaced when the corresponding clamp and / or counterknife is
replaced.
(d) All of the above
(e) None of the above

Q5 – When tightening Clamp Bolts with the impact wrench and torque stick
during a knife change, you should always:
(a) Spot Check the clamp bolts with the torque wrench to ensure proper
torque.
(b) Check the torque on each clamp bolt with the torque wrench.
(c) Assume the clamp bolts are properly torqued.
(d) All of the above
(e) None of the above

Key Knife Basic Operator Training Pg 3

 High Yield User Manual • Appendix F

Q6 – Give the proper torque value for the Clamp Bolts:

(a) 120 ft / lb
(b) 490 ft / lb
(c) 350 ft / lb
(d) All of the above
(e) None of the above

Q7 – The Clamps should be replaced:

(a) Whenever you feel like it.
(b) When a wear line appears on the bottom of the keyway.
(c) When normal polishing wear is uneven.
(d) Both (b) and (c)
(e) All of the above

Q8 – A recent reduction in knife life can be explained by:

(a) Foreign debris, excessive bark, sand, dirt, etc on the logs.
(b) Knife flutter from insufficient clamp bolt torque.
(c) Excessive rehoning of the knives.
(d) Both (b) and (c)
(e) All of the above

Q9 – The Keyway on the Ridge XL Knife is designed to:

(a) Index the knives into place consistently.
(b) Increase chip quality.
(c) Makes packaging easier.
(d) All of the above
(e) None of the above

Q10 – The proper torque value for the counterknife Bolt is:
(a) 25 ft /lb
(b) 70 ft / lb
(c) 120 ft / lb
(d) All of the above
(e) None of the above

Practical Application Test

PA #1 – Demonstrate a knife change

Key Knife Basic Operator Training Pg 4

 High Yield User Manual • Appendix F

Answer Key

Written Test
Q1 – Explain the importance of cleaning the counterknife thoroughly during a knife
change.
(b) The knife will not locate on the keyway properly with excessive debris in the
pocket

Q2 – The purpose of the counterknife is:

(a) To support the knife in the head.

Q3 – The Counterknife should be replaced:

(b) When the tip of the counterknife is worn to a sharp edge.

Q4 – After a crash, the clamp bolts should:

(c) Replaced when the corresponding clamp and / or counterknife is replaced

Q5 – When tightening Clamp Bolts with the impact wrench and torque stick during a
knife change, you should always:
(a) Spot Check the clamp bolts with the torque wrench to ensure proper torque

Q6 – Give the proper torque value for the Clamp Bolts:

(a) 120 ft / lb

Q7 – The Clamps should be replaced:

(d) Both (b) and (c).

Q8 – A recent reduction in knife life can be explained by:

(e) All of the above

Q9 – The Keyway on the Ridge XL Knife is designed to:

(a) Index the knives into place consistently

Q10 – The proper torque value for the counterknife Bolt is:
(a) 25 ft /lb

Practical Application Test

PA #1 – Provide the trainee with the necessary tools to change the knives in the Key
Knife HY2 or SLICE System. Ensure the trainee properly follows the knife changing
procedures as shown in Chapter 3. When the trainee has completed the procedures,
check to ensure the knife is properly located on the keyway and that the Clamp Bolts
are properly torqued.

Key Knife Basic Operator Training Pg 5

 Appendix G

Installation – Segments onto Arbor Pg. 1-3

Installation – Clamps & Counterknives Pg. 4-5

Center – Heads in Machine Pg. 6-7

Allign Spline Maker Pg. 8-9

Dimensioner Pg. 10

Tighten Locknuts on Arbor Pg. 11-12

Table of Contents
 High Yield User Manual • Appendix G

SEQ # 010

SEQ # Task Description Additional Information

First, determine where the nut should be located
to properly locate the segments on the arbor.
Install one lock nut onto the arbor opposite the Top & Bottom heads should be centered. Side
010
drive side. Heads should be installed approximately 1/4" high
on the arbor to facilitate easier adjustments in the
machine.
Stand the arbor on end, with the drive side of the
020
arbor facing up.
Install the keyway(s) onto the arbor, using a rub-
030 ber mallet or dead blow hammer to ensure it is
fully seated.
Wipe down the arbor to ensure it is clean and
devoid of burrs.
040 Apply a thin coat of anti-seize to the arbor to as-
sist installing the segments.

Installation—Segments Pg 1
 High Yield User Manual • Appendix G

SEQ # 050

SEQ # 060

SEQ # 070

SEQ # Task Description Additional Information

Install the first segment onto the arbor, ensuring Reference the engineering prints for proper seg-
the knife direction is correct for the rotation of the ment count and alignment. See Appendix H.
050 head.
Slowly lower the segment down to the lock nut: Lightly jiggle the segment if it doesn't easily slide
DO NOT let it slam onto the lock nut. onto the arbor.
Allow these subsequent segments to slam into
Install the remaining segments onto the arbor, place.
060 ensuring that each alternating segment is in-
stalled opposite the previous. Install spacers onto the arbor as referenced on
the engineering prints. See Appendix H.
Install the lock ring on the drive side of the arbor.
Bend down one locking tang so that it extends
070
into the tang hole on the segment and the ring
lays flat and centered on the segment.

Installation—Segments Pg 2
 High Yield User Manual • Appendix G

SEQ # 080

SEQ # 100

SEQ # Task Description Additional Information

Install the remaining lock nut onto the drive side of Ensure the lock ring remains centered on the
080
the arbor and tighten. arbor, and on the nut itself.

Lay the arbor down on it's side.

090
Remove the first locknut and install the lock ring
and lock nut per SEQ #070 - 080.

Tighten the locknut on the arbor with a spanner Do Not push down the locking tang until
100 wrench or center punch to snug the segments into heads are properly centered in the ma-
place. chine.

Installation—Segments Pg 3
 High Yield User Manual • Appendix G

SEQ # 030 (a)

SEQ # 030 (b)

SEQ # 040

SEQ # Task Description Additional Information

010 Inventory on-hand components. Reference the system prints located in Appendix H.

Thoroughly clean the segment mounting sur-

020 Remove all debris and burrs.
face (s).

Use a plastic hammer to seat the counterknives

030 Position the counterknives on the segment.
flush on the segment (as required).

Install the Counterknife cap screws and tighten

040 Use nickel-based anti-seize on bolts.
until snug.

Installation — Clamps & Counterknives Pg 4

 High Yield User Manual • Appendix G

SEQ # 050

SEQ # 060 (a) SEQ # 060 (b)

SEQ # Task Description Additional Information

Torque the counterknife cap screws with the torque

050 Reference Torque Values Appendix D.
wrench and 1/4" Hex Bit Socket.

Position the clamps on the counterknife surface and

060 hand tighten the clamp bolts. Ensure the clamp is Use nickel-based anti-seize on bolts.
seated properly on the back of the counterknife.

Installation — Clamps & Counterknives Pg 5

 High Yield User Manual • Appendix G

SEQ # 010

Loosen Locknut

Tighten
Locknut
SEQ # 030 (a) SEQ # 030 (b)

SEQ # 020

SEQ # Task Description Additional Information

Top / Bottom Heads - should be centered be-

tween the frame and end segments.
Determine the position of the head and which Spline makers should be centered on the rail
010
direction it needs to be moved. (see “Align Spline Maker” Appendix G pg. 8-9)
Side Heads - the bottom segment should be po-
sitioned approximately 1/4" - 1/2" below the rail.

Loosen the lock nut (with hammer and spanner

Ensure the lock ring stays centered on the arbor
020 wrench) on the side of the arbor that the seg-
and nut.
ments need to move.

Tighten the opposing locknut, moving the seg- Tighten with spanner wrench and hammer until
030
ments in the desired direction on the arbor. nut does not advance further.

Continue SEQ #020 - 030 until head is properly

040
centered / positioned in the machine.

Center Heads in machine Pg 6

 High Yield User Manual • Appendix G

SEQ #060

SEQ # Task Description Additional Information

050 Ensure both lock nuts are tight. Tighten with the spanner wrench and hammer.

Push down a tab on the lock ring in the lock nut Ensure the tab is positioned to prevent any
060
on both heads with a center punch and hammer. movement / slippage of the locknut.

Center Heads in Machine Pg 7

 High Yield User Manual • Appendix G

SEQ # 020 (a) SEQ # 020 (b)

SEQ # 020 (c)

SEQ # 020 (d)

SEQ # Task Description Additional Information

010 Visually center the spline maker with the rail.

Measure the side clearance between the edge of

the knives and the edge of the rail, on both sides
of the center rail with the Notch Gauge. Determine the clearance to the nearest 0.005"
020
measurement increment.
Ensure the Notch Gauge is held flush to the side
of the rail.

Determine the distance and direction the head

See Chapter 4 “Operating Parameters” for ap-
030 needs to be moved to create the required clear-
propriate spline clearance.
ance between spline maker and the rail.

Adjust the head, as required. It is best to make

See "Center Heads in the Machine" Appendix G
040 several small adjustments verses one big adjust-
for procedures to center the heads.
ment.

Align Spline Maker Pg 8

 High Yield User Manual • Appendix G

SEQ # 060 (a) SEQ # 060 (b)

SEQ # 060 (c) SEQ # 070

SEQ # Task Description Additional Information

Once the head is centered properly, push down
Repeat SEQ # 020 - 040 until the required side
050 a tang on the lock ring in the lock nut on both
clearance has been achieved.
locknuts.
Position the Notch Gauge on the bottom of the rail,
- The clearance is properly measured when the
and measure the spline clearance at the bottom of
knife tip just barely brushes the Notch Gauge so
the rail.
060 that it is not pushed up, but the knife can be felt.
Rotate the head backwards so that the knife
- Determine the clearance to the nearest 0.005"
passes the recessed portion of the notch gauge at
measurement increment.
the highest point of the cut circle.

Position the Notch Gauge on top of the rail, and Determine the clearance to the nearest 0.005"
070
measure the clearance. measurement increment.

Determine if the head needs to be moved up or See Chapter 4 “Operating Parameters” for ap-
080
down to create the required clearance. propriate spline clearance.

As Required.
Adjust the head up or down, as required.
090
Use the machine OEM Manual for making head
Use mill personnel and the OEM machine manual.
height adjustments.

Align Spline Maker Pg 9

 High Yield User Manual • Appendix G

SEQ #010
SEQ #020(a)

Correct Wrong

SEQ #020(b)

SEQ # Task Description Additional Information

Insert the dimensioner into the counterknife.

010
The dimensioner fits over the dowel pin.

Insert and tighten the set screw with a 5/32" Al-

len Wrench until it is snug against the dimen-
sioner. CAUTION - The counterknife will not sit on the
segment correctly if the dimensioner is installed
020
The dimensioner should sit just below the bottom where it sticks out past the bottom of the coun-
of the counterknife. The set screw does not terknife.
need to be installed tightly to keep the dimen-
sioner from coming out.

Installation—Dimensioners Pg 10
 High Yield User Manual • Appendix G

Correct - Key sits Correct - Lockwasher

below the segment set in segment / spacer

SEQ # 010 SEQ # 010

Correct - Lockwasher
sits flat to segment

Wrong - Lockwasher incorrectly

installed and NOT flat to segment

SEQ # 010

SEQ # 010

SEQ # Task Description Additional Information

Segments properly positioned on the arbor.

010 Inspect the head before tightening the locknuts. Key is NOT proud of the segments / spacers.
Lockwasher properly installed on arbor.

Tighten Locknuts on Arbor Pg 11

 High Yield User Manual • Appendix G

Tab bent down to prevent

Locknut rearward movement.

SEQ # 020 SEQ # 030

SEQ # Task Description Additional Information

Tighten Locknut(s) with Spanner Wrench and

020 Locknuts can NOT be over tightened
10lb hammer

Push down a locking tab on the Lockwasher with Ensure the tab is positioned to prevent any loos-
030
a punch. ening of the Locknut.

Tighten Locknuts on Arbor Pg 12