PDF Compressor Pro ECOCOMBI ECM150MT35D Operator’s Manual PDF Compressor Pro IMPORTANT NOTICE TENSION OF MAIN DRIVE MUST BE CHECKED AND RESET AFTER THE FIRST 2-3 HOURS OF OPERATION. FAILURE TO DO SO MAY INVALIDATE WARRANTY. INSTRUCTIONS TO CHECK AND RESET TENSION ARE DETAILED IN SECTION 6.9. PDF Compressor Pro EcoCombi SECTION: CONTENTS 1 1. Introduction and Purpose 2. Technical Specifications, Dimensions, Noise Level, Lifting points 3. Safety and Symbols 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Ensure! Never! Always! Safety controls and switches Control cut-outs 'No Stress' system Symbols 4. Machine Preparation 4.1 4.2 4.3 4.4 Fuelling and parking Chipper infeed chute Shredder infeed chute Discharge chute 5. Operation 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Pre-work checks Starting machine Stopping machine Adjustable Feed roller control Operating hints Shredder feed control Preparing for Transport 6. Maintenance 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 Routine Maintenance schedule Engine Oil Coolant Hydraulic Oil Fuel level Drive Belts check Disc Blades Radiator screen Drive belt replacement Steam clean Air cleaner Electrical connections ©GreenMechLtd -1- 07/06 PDF Compressor Pro EcoCombi 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 CONTENTS 2 Battery Tyres and Wheels Brakes Bearings and Pivots Hydraulic connections Mountings Hydraulic Return Filter Wheel bearings Hydraulic Oil change Fuses and No Stress system Fault finding chart Blade sharpening 7. Storage 7.1 7.2 Storage Removal from storage 8. Disposal 9. Appendix 9.1 9.2 9.3 9.4 9.5 9.6 9.7 Hydraulic Circuit Electrical Circuits Certificate of Conformity Risk Assessment Noise Assessment Parts List Transcript of HSE leaflet 604 ©GreenMechLtd -2- 07/06 PDF Compressor Pro EcoCombi 1. INTRODUCTION AND PURPOSE 1-1 INTRODUCTION This manual explains the correct operation of your machine. Read these instructions thoroughly before operating and maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your GreenMech supplier if you do not understand the instructions in this manual. CAUTION! This symbol indicates important safety messages in this manual. When you see this symbol, be alert to the possibility of injury to yourself or others, and carefully read the message that follows. We recommend that you keep this manual with the machine in the box provided. Note in the box given the serial number and quote it in any communications. This is important when ordering spares. Remember to include all numbers and letters. Serial Number VIN number………………………………….. Serial Number............................................ Write in the number! Serial Number plate This manual covers the following models. Engine driven: ECM150MT35D This Manual is written for engine driven models. The information in this manual is correct at the time of publication. However, in the course of development, changes to the machine specification are inevitable. Should you find any information to vary from the machine in your possession please contact your GreenMech dealer for up to date information. The manual may contain standard and optional features and is not to be used as a machine specification. PURPOSE CAUTION! This machine is designed solely to chip and shred wood and must not be used for any other purpose. The machine should only be used by trained operators who are familiar with the content of this instruction manual. It is potentially hazardous to fit or use any parts other than genuine GreenMech parts. GreenMech Ltd disclaims all liability for the consequences of such use, which in addition voids the machine warranty. ©GreenMechLtd 1-1 06/06 PDF Compressor Pro EcoCombi 2. SPECIFICATIONS Fig 2.1 CM Models 2-1 Main Features Discharge chute Engine cover Chipper disc cover Chipper Control bar Shredder control bar Reset bar Shredder infeed chute Chipper Infeed chute Handbrake Drawbar Support leg other side Feed roller pivot TECHNICAL SPECIFICATION ECM150 Max Capacity chipper Max Capacity shredder Chipping Disc Speed Chipping blades Shredding blades Feed Rollers (chipper) Power Control Power Unit Length (work position) Length (transport) Width Height Weight ©GreenMechLtd 2-1 MT30D 150mm (6-inch diameter) 50mm (2-inch diameter) 500mm x 25mm 2400 rpm 4 discs 22 Discs – 3300 cuts/min 2 x Hydraulic & Spring Tensioned No-Stress Electronic Feed Roller Controller Isuzu 3 cyl 35hp 3700mm 4010mm 1550mm 2160mm 1200kg 06/06 PDF Compressor Pro EcoCombi 2. SPECIFICATIONS 2-2 Noise Noise levels vary depending on type of material being processed. Also duration of operation is variable. Noise emission tests have been carried out and the guaranteed sound power level is displayed on the CE plate as follows: Lwa 120dB Minimise noise by switching to idle or stopping the engine whenever chipping and/or shredding is not in progress. Full details are included in the Risk Assessment in the Appendix. CAUTION! Operators must wear appropriate ear protection. Bystanders must be kept away from proximity of machine. Lifting Points There is a central lifting point by the chipper disc cover. ©GreenMechLtd 2-2 06/06 PDF Compressor Pro EcoCombi 3. SAFETY 3.1 ENSURE: 3.1.1 All Operators must be fully trained in the use of their machine. (Certificated Operator training courses are available on request.) 3.1.2 The Operators Manual is read and understood. 3.1.3 The enclosed HSE guidance notes are read and understood. 3.1.4 The machine is positioned on level ground and the machine must be level with the infeed chute at no more than 600mm (23.62 inches) above ground level (fig 3.4.3). 3.1.5 When the unit is detached from towing vehicle (MT models) the handbrake is applied and if necessary the wheels are chocked. 3.1.6 The rear support leg is lowered when using the machine. 3.1.7 All guards are fitted and in good condition. 3.1.8 Blades are in good condition and secure. 3.1.9 All blades are sharpened or replaced in “Sets”. 3.1.10 All fasteners are checked regularly for tightness. 3.1.11 Only “WOODEN” materials free of nails etc., are fed into the machine. 3.1.12 Correct First Aid Kit including large wound dressing is available on site. 3.1.13 Fire extinguisher is available on site. 3-1 3.2.3 Operate with loose articles of clothing, including loose cuffs on gloves. 3.2.4 Work under a raised component without adequate safety support. 3.2.5 Operate the machine with untrained personnel or with individuals present who are not involved in the chipping operation. 3.2.6 Leave the machine unattended with engine running at full operating speed. (See section 4) 3.2.7 Put any part of your body into the infeed chute while the machine is running. 3.2.8 Operate the machine whilst under the influence of alcohol or drugs. 3.2.9 Operate inside a building or confined space. 3.2.10 Climb on the infeed chutes. 3.3 ALWAYS: 3.3.1 Check machine before starting (see Section 4 Preparation and Section 5.1 Operation: Pre-work checks). 3.3.2 Be aware of potential hazards in the work area, i.e. uneven ground, tree roots, obstructions and type of materials being fed into the machine. 3.3.3 Feed from the side. 3.3.4 Have a second trained operator within easy reach of the machine. 3.3.5 Maintain strict discipline at all times. 3.3.6 Service machine at specified periods. (see Section 6: Routine Maintenance). 3.3.7 Note direction of discharge chute and if necessary note the wind direction to prevent debris from being blown into highway or where it could affect members of the public. 3.3.8 Remove key before doing any maintenance. 3.2 NEVER: 3.2.1 Work on the machine until the chipper disc is stationary and engine or PTO has stopped. 3.2.2 Operate the machine without protective clothing (Eye protection, Earmuffs, and Gloves), or high visibility clothing when working on roadside. ©GreenMechLtd 3-1 06/06 PDF Compressor Pro EcoCombi 3. SAFETY 3.4 Safety Controls and Switches 3.4.1 Emergency Stop/Control Bar (fig 3.4.1) In the event of an emergency, push the emergency stop bar to STOP the feed rollers. This will lock in position 22.214.171.124 Once the emergency has been rectified the following sequence should be carried out: 126.96.36.199 To restart rollers pull the reset lever whilst pulling the control bar towards the Feed In position. 188.8.131.52 Should the stop bar be tripped accidentally in normal working conditions i.e. NOT an emergency, then the rollers can be recovered by performing the above sequence. 184.108.40.206 To reverse the rollers (Feed Out) push the control bar into the middle detent. Fig 3.4.1 Control Bar and Reset Lever Control bar Reset bar Control Bar positions Nearside STOP FEED OUT FEED IN Offside FEED OUT 3-2 FEED IN STOP CAUTION! When using chipper and shredder together, note that either control stops and reverses both sets of rollers. 220.127.116.11 To regain forward (Feed In) pull the control bar away from the chipper. It is not necessary to use the reset bar. 18.104.22.168 The Shredder control bar operates in the same way, linked to the chipper control bar. To restart, follow procedure 22.214.171.124 at the chipper infeed. Fig 3.4.2 Engine Stop Switch - (start key) Key to stop 3.4.2 Engine stop switch 126.96.36.199 To stop the engine, turn the start key anticlockwise to the ‘0’ position. (fig 3.4.2). CAUTION! Do not restart engine until hazard has been removed. Fig 3.4.3 Chipper Infeed chute height 3.5 Control cut-outs Cut-outs are installed to stop and prevent restarting due to specific events. 3.5.1 Engine overheating is protected by thermal cut-out switch in coolant circuit. 3.5.2 Low engine oil pressure is protected by pressure switch in the engine oil pump. There is a manual override to enable starting. 3.5.4 Engine cover opening is protected by a microswitch to shut off the fuel solenoid. 3.5.5 The infeed chute being raised to the transport position. Infeed chute height 600mm min. (24") ©GreenMechLtd 3-2 06/06 PDF Compressor Pro EcoCombi 3. SAFETY 3-3 3.6 No Stress system 3.6.1 Speed sensor disables feed rollers FEED IN or FEED OUT mode when engine speed is below factory pre-set value. 3.7 SYMBOLS on the MACHINE These relate to operator safety, correct use and maintenance of machine. Check that all personnel understand and are familiar with meanings before using the machine. Important Safety symbols Take the correct action shown on the display below the stated hazard (see table) General Safety Caution! Do not start engine Remove key Caution! Beware flying object hazard Beware noise hazard Beware trapping hazard Brakes off -incorrect Read instruction manual Wear helmet & visor Wear ear protectors Wear proper clothes Brakes on -correct Machine not level -incorrect Beware flying object hazard Beware exposed drives hazard Caution! Machine level -correct Keep bystanders away Fit all guards Keep nuts tight Beware flying object hazard Position and lock discharge chute Important Operating Checks Notice Before use carry out daily the stated checks in the order shown (see table) Daily Checks Every 8 Hours – Daily checks ©GreenMechLtd Remove key stop engine 1. Check coolant level 2. Check engine oil level 3. Check hydraulic oil level 4. Check machine is level 5. Check brakes are on 6. Check chipper disc is clear of debris 7. Check all guards are in place 8. Check infeed chute is clear of debris 9. Lock discharge chute 10. Pull control bar to work position 11. Start engine 12. Increase from Idle to Run 3-3 06/06 PDF Compressor Pro EcoCombi 3. SAFETY 3-4 Important Safety Information Caution! Beware of thrown object hazard Caution! Do NOT operate with infeed chute at less than 600mm from ground (bottom bar machine). Action: Keep away from fast discharge chute Caution! Beware of thrown object hazard Sound level Lift point Ear defenders must be worn. Action: Stand to side of infeed chute, NOT in centre. Caution! Transport Lock Lock this component before moving machine. Do NOT fold infeed chute unless control bar is in STOP position 1) Control bar in STOP position 2) Fold up infeed chute. 3) Lock infeed chute before transport. Do NOT transport with chute down ©GreenMechLtd 3-4 06/06 PDF Compressor Pro EcoCombi 3. SAFETY 3-5 Maintenance Information Diesel Filler Hydraulic Filler Radiator cleaning Grease point High temperature Grease 40 hours 40 hours / weekly 8 Hours Check radiator screen 40 Hours Blow out radiator core Reset lever: Left hand shown Operating Information Discharge chute control Pull to reset Control Bars: Chipper and Shredder Left hand shown Push to stop: Centre-feed out: Pull–feed in Green is UP: Blue is DOWN No-Stress indicator Engine throttle Fast ------------ ©GreenMechLtd Green is ON: Red is OFF Slow 3-5 06/06 PDF Compressor Pro EcoCombi 4. MACHINE PREPARATION Fig 4.1 Drawbar and Handbrake 4-1 4.1 Initial Fuelling and Parking 4.1.1 Fill the fuel tank with diesel. 4.1.2 Top up the hydraulic tank if necessary, with the correct oil. See Section 6. 4.1.3 Position the machine on level ground. 4.1.4 Apply the vehicle handbrake. 4.1.5 If the machine is detached from the vehicle, apply the trailer handbrake (fig 4.1) and chock the wheels. Handbrake Fig 4.2 Chipper Infeed chute catch CAUTION! A loaded vehicle increases the height of the infeed chute. Catch (transport) 4.2 Chipper Infeed Chute 4.2.1 Remove the transport pin for the infeed chute catch, release the catch (fig 4.2), using the control bar, lower the infeed chute to the work position and reset the catch (fig 4.2). 4.2.2 Measure the height of the infeed chute. If more than 600mm detach the machine from the vehicle and set with drawbar wheel. 4.2.3 Pull the reset lever to release the control bar for use. Catch (work) CAUTION! The chipper infeed chute must not be used at less than 600mm from the ground. (fig 3.4.3) CAUTION! Before travelling, always fold up and secure both infeed chutes. ©GreenMechLtd 4-1 06/06 PDF Compressor Pro EcoCombi 4. MACHINE PREPARATION 4-2 4.3 Shredder infeed chute 4.3.1 Remove the transport pin (fig 4.3) 4.3.2 Set the two antiluce catches in line to receive the infeed chute in its work position. 4.3.3 Using the control bar as a grip, fold out the infeed chute and lower over the two catches. 4.3.4 Turn up the two catches to retain the chute in work position. Fig 4.3 Shredder Infeed chute (transport) Pin (transport) CAUTION! Before travelling, always fold up and secure both infeed chutes. Shredder Infeed chute (work) Catches each side (work) Fig 4.4 Discharge Chute 4.4 Discharge Chute (Fig 4.4) 4.4.1 Release the swivel clamps and point the chute in the desired direction. 4.4.2 Set the flap at the desired height and tighten the clamp. Flap lever CAUTION! Lock the discharge chute in the forward position when travelling. Swivel clamps ©GreenMechLtd 4-2 06/06 PDF Compressor Pro EcoCombi 5. OPERATION 5-1 5.1 Pre-Work Checks: 5.1.1 Check machine is stationary, start key removed, and hand brake applied with support leg lowered (fig 5.1.1) if separated from vehicle. 5.1.2 Check that machine is level and infeed chute is greater than 600mm from ground (fig 3.4.3). 5.1.3 Check engine oil level (See Engine instruction manual). 5.1.4 Check hydraulic oil level (See Section 6). 5.1.5 Check fasteners for tightness and hydraulic connections for leaks. 5.1.6 Check condition of disc blades. 188.8.131.52 With shredder chute in work position, raise engine cover. Check nothing is rotating. 184.108.40.206 Remove the two bolts retaining chipper disc cover. 220.127.116.11 Fold shredder chute back to transport position and fit locking pin. 18.104.22.168 Using discharge chute as a lever, lift and swing back disc cover with shredder chute on to stop to expose chipper disc and shredder blades (fig 5.1.2) Fig 5.1.1 Support Leg Support Leg Fig 5.1.2 Disc and shredder cover Disc Cover locating bolts CAUTION! This operation is heavy to start and may require two people. 22.214.171.124 Carefully rotate chipper disc to check tightness of disc blade bolts and condition of blades. 126.96.36.199 Remove any loose wood material. 188.8.131.52 If any bolts are loose, refer to maintenance section for further action. 184.108.40.206 Replace disc cover with care and tighten bolts securely. 5.1.7 Remove any loose material and dust from radiator and engine bay 5.1.8 Fold shredder chute back to work position. 5.1.9 Replace engine cover. 5.1.10 Check discharge chute is in desired position and all clamps are tight. (see Section 4.4) 5.1.11 Check infeed chute (fig 4.3.2) is locked in position with catch. 5.1.12 Check work area and erect signs and cone off discharge area if necessary. 5.1.13 Check ALL safety procedures have been followed. ©GreenMechLtd 5-1 06/06 PDF Compressor Pro EcoCombi 5. OPERATION Fig 5.2.1 Engine control box 5-2 5.2 Starting Machine: 5.2.1 Put throttle lever into idle position (fig 5.2.1) 5.2.2 Check all other personnel are clear of machine. 5.2.3 Check that feed roller control bars are pushed to the FEED OUT or STOP position, to make the machine safe. 5.2.4 Turn start key to pre-heat position and depress low oil pressure override button for 5 seconds. 5.2.5 Keeping the override button depressed, turn the start key to START position. 5.2.6 When the engine starts, keep the override button depressed until the red warning light goes out. 5.2.7 Put the throttle lever to increase the speed to operating speed. The green No Stress light will come on (fig 5.2.2). 5.2.8 Pull the reset lever to release the control bars for work. Throttle lever Run ä å Idle Oil override Key Fig 5.2.2 No stress light No Stress 5.3 Stopping Machine 5.3.1 Push the control bar to STOP position. 5.3.2 Move throttle lever (fig 5.2.1) to Idle position and allow chipper disc to slow down. 5.3.3 Switch start key to position 0 to stop the engine (fig 5.2.1). 5.3.4 Wait for chipper disc to stop. CAUTION! The chipper disc will take several minutes to stop due to its inertia. ©GreenMechLtd 5-2 06/06 PDF Compressor Pro EcoCombi 5. OPERATION 5-3 5.4 Adjustable Speed Feed Roller Control (chipper and shredder infeed) When chipping wood sizes larger than 150mm diameter it is necessary to reduce the feed roller speed to suit the material being chipped. 5.4.1 Turn the valve control knob (fig 5.4) clockwise until valve is closed. 5.4.2 Turn the knob anticlockwise to the recommended setting in the table. Fig 5.4 Adjustable feed roller control Control Knob 5.5 Operating Hints 5.5.1 Check that chipper disc is at full speed with green light showing on NoStress control (fig 5.2.2). NOTE: The “No Stress” system will only allow FEED IN (Forwards) operation of the feed rollers when the machine is running at FULL operating speed. 5.5.2 Reduce speed to idle whilst further material is collected for chipping. 5.5.3 Take care when feeding wood into the machine to allow for awkward shapes to “KICK” when contacting the feed rollers. 5.5.4 Position the end of larger sections of wood inside the infeed chute and then support the other end whilst pushing the wood into the feed rollers. Control knob settings Material Setting up to 150mm Fully open (3 turns) 150 -250mm 1/2 - 3/4 turn Fig 5.6 Shredder control CAUTION! Do not release discharge chute clamps when chipping is in progress. Elevation of the discharge is altered by means of the adjustable flap (fig. 4.4). Shredder control CAUTION! Keep working area around the machine clear at all times and check only authorised personnel are present. 5.6 Shredder feed control 5.6.1 To reduce shredder roller speed, turn control knob clockwise (fig 5.6). ©GreenMechLtd 5-3 06/06 PDF Compressor Pro EcoCombi 5. OPERATION 5-4 5.7 Preparing For Transport On Completion Of Work 5.7.1 Check that engine has stopped and chipper disc is stationary. 5.7.2 Remove surplus material from infeed chute and machine surfaces. 5.7.3 Lift up both infeed chutes to transport position (fig 5.7.1), secure with catch and locking pins. 5.7.4 Set discharge flap into lowest position and tighten clamp. 5.7.5 Release clamps, turn discharge chute to forward position in line with trailer, tighten clamps. 5.7.7 Raise support leg and secure with clamp (fig 5.7.2). 5.7.8 If detached, re-attach trailer to vehicle. Fig 5.7.1 Transport position Fig 5.7.2 Support Leg raised CAUTION! Remember to raise support leg before driving off. Support leg raised ©GreenMechLtd 5-4 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-1 ROUTINE MAINTENANCE SCHEDULE CAUTION! Always remove key and check for rotation before carrying out any maintenance. Action DAILY Check engine oil level and coolant (ref: engine manual) Check hydraulic oil level Check fuel level Check all drive belts Check condition of disc blades and retaining bolts Clean radiator screen and around radiator Check feed roller control bar function Section Page 6.2 – 6.3 6.4 6.5 6.6 6.7 6.8 3.4 6-4 6-4 6-4 6-4 6-5 6-6 3-2 First 50 hours Check drive belt tension Check battery levels Check wheel and tyre condition and pressures Check brake condition and operation Check hydraulic connections Check all mountings Check feed roller control bar function Service engine 6.9 6-6 6.13 6-8 6.14 6-8 6.15 6-9 6.17 6-9 6.18 6-10 3.4 3-2 Refer to engine manual Weekly in addition to Daily actions Blow out radiator core with air line Check drive belt tension Steam clean machine Clean air cleaner Check electrical connections Check battery levels Check feed roller control bar function Check wheel and tyre condition and pressures Check and adjust brakes Grease all bearings and pivots Check hydraulic connections Check all mountings 6.8 6.9 6.10 6.11 6.12 6.13 3.4 6.14 6.15 6.16, 6.1 6.17 6.18 250 hours in addition to Daily and Weekly actions Check all fluid levels Check brake condition and operation Check condition of bearings and pivots Service engine Check axle mounting bolts for tightness Replace return filter element Check and grease wheel bearings 6.2, 6.3, 6.4 6-4 6.15 6-9 6.16 6-9 Refer to engine manual 6.18 6-10 6.19 6-10 6.20 6-10 ©GreenMechLtd 6-1 6-6 6-6 6-7 6-7 6-7 6-8 3-2 6-8 6-9 6-9 6-9 6-10 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 1000 hours in addition to 250 hour actions Change hydraulic oil when replacing filter element DIESEL ENGINE MAINTENANCE Tyre Pressure 6.21 6-10 REFER TO ENGINE MANUAL 2.7 bar (40 lb/in2) Recommended lubricants Hydraulic Oil Grease Engine ©GreenMechLtd 6-2 Specification ISO 32 Complex grease EP2 SAE 15W-40 APICD 6-2 (high temperature) 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-3 6.1 Lubrication Points (see 6.14) Fig 6.1c Lubrication Points EcoCombi ECM150MT30D 6.1.3 6.1.4 6.1.5 6.1.2 6.1.6 6.1.9 6.1.7 6.1.10 6.1.1 6.1.8 Grease except where stated 6.1.1 Drawbar 2 nipples 6.1.2 Top Feed roller pivot 1 nipple 6.1.3 Top Feed roller bearing 1 nipple 6.1.4 Chipper Disc front bearing 1 nipple inside chipper chamber 6.1.5 Chipper Disc rear bearing 1 nipple inside chipper chamber 6.1.6 Infeed chute hinges Oil 6.1.7 Mechanical reset mechanism Clean and grease 6.1.8 Bottom Feed roller bearing 1 nipple 6.1.9 Engine output shaft 1 nipple 6.1.10 Shredder feed roller bearing 1 nipple Note. Do not overgrease bearings as damage to seals may occur. Note: Use high temperature grease on chipper disc bearings. ©GreenMechLtd 6-3 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-4 Fig. 6.2 Dipstick 6.2 Engine Oil 6.2.1 Check daily (fig 6.2). Refer to engine manual to refill. Dipstick 6.3 Coolant 6.3.1 Check daily (fig 6.3). Refill as required. Check antifreeze. CAUTION! Do not remove cap when engine is hot. Fig.6.3 Coolant Filler 6.4 Hydraulic Oil 6.4.1 Check daily (fig 6.4). If below mark check for leaks and refill to correct level. Fig. 6.4 Hydraulic Oil Hydraulic Oil Filler 6.5 Fuel Level 6.5.1 Check daily before work and fill as required (fig 6.5). CAUTION! Use clean fuel only of the correct type. If in doubt, use a funnel with a filter. Fig 6.5 Fuel Tank 6.6 Drive Belts CHECK TENSION AFTER FIRST 2-3 HOURS Check daily, before work, the condition of all drive belts and replace if worn. See section 6.9 Diesel Filler ©GreenMechLtd 6-4 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-5 6.7 Disc Blade Rotation and Replacement The design of the blades permits relocation in at least three rotated positions before regrinding or replacement is required. 6.7.1 Check engine is switched off and start key removed. 6.7.2 With shredder chute in work position, raise engine cover and check any rotation has stopped. 6.7.3 Remove the two bolts retaining chipper/shredder disc cover (fig 6.6.1). Fig 6.7.1 Disc and shredder cover Disc Cover locating bolts CAUTION! Take care. Blades are extremely sharp. 6.7.4 Fold shredder chute back to transport position and fit locking pin. 6.7.5 Using discharge chute as a lever, lift and swing back disc cover with shredder chute on to stop to expose chipper disc and shredder blades (fig 5.1.2) Fig 6.7.2 Discs and disc blades Torque to 150Nm CAUTION! This operation is heavy to start and may require two people. 6.7.6 Slacken disc blade retaining bolt, remove disc, clean mounting face and location (fig 6.6.2). 6.7.7 Replace disc in a rotated position to present a sharp section to the shear bars. 6.7.8 Torque up bolt to 150NM (110lb.ft.) 6.7.9 Check condition and security of shear bars. Rotate or replace if required. Do not regrind. Disc blades CAUTION! Disc blades must only be sharpened by grinding the angled back face on a bench grinder. Grinding of the front face will upset the gap, which is factory set. Do not sharpen with hand held equipment. Note. If any of the Disc-Blades are worn below the flat annular section a complete set should be replaced. Inspect condition of nuts and bolts and replace if any signs of wear. All blades must be sharpened in “sets” with equal amounts removed to maintain balance. (See section 6.24 for disc regrinding.) ©GreenMechLtd 6-5 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-6 6.8 Radiator Screen Daily 6.8.1 Lift out radiator screen, clean and replace (fig 6.7). Note: There is no screen on the petrol model. 50 hours 6.8.2 In addition to above, blow out radiator core from rear with suitable airline and clear from front. Fig 6.8 Radiator Screen CAUTION! A build up of debris risks overheating of the engine and a risk of fire. 6.9 Drive belts (Figs 9) AFTER FIRST 2-3 HOURS and then 50 hours The chipper drive belts are tensioned by an adjustable idler pulley supported by a central M12 mounting bolt and an M10 adjuster bolt. Belts need re-tensioning after first use and every 50 hours after. 6.9.1 Undo central clamp bolt until finger tight only. 6.9.2 Screw lower lock nut along adjuster bolt to move idler pulley until correct tension is achieved. This is when a setting force of 45 Newtons (4.6 kgf/10lbf) applied to the centre of the belt span opposite to the idler pulley, produces a deflection of 4mm. 6.9.3 Press firmly on the centre of the span of an individual belt. It should just be possible to depress a belt until its top edge is in line with the bottom of adjacent belt. 6.9.4 When tension is correct, tighten central M12 clamp bolt and second M10 locknut against the first nut. To replace belts 6.9.5 Slacken off M12 clamping bolt. Slacken off two M10 locknuts on adjuster bolt, move idler pulley to end of slot in mounting bracket and remove belts. 6.9.6 Fit new belts, ensuring they sit snugly in the grooves of engine and flywheel pulleys. 6.9.7 Slide idler pulley along the slot until the slack in belts is taken up. 6.9.8 Tension belts as from 6.9.1 above and check after first 2 hours use. Fig 6.9a Belt adjuster Belt adjuster Clamp bolt Fig 6.9b Drive belt tension ©GreenMechLtd 6-6 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-7 6.10 Steam Cleaning 50 hours 6.10.1 Check all covers are fitted and closed 6.10.2 Steam clean machine surfaces. 6.10.3 Clean electrical components with a damp rag, spray with WD40 and then wipe with dry rag. Fig 6.11 Air Cleaner CAUTION! Do not steam clean directly on to electrical components, e.g. control boxes. 6.11 Air Cleaner 50 hours 6.11.1 Release strap and move cleaner clear of control bracket. 6.11.2 Remove cover (fig 6.11) and release clips. 6.11.3 Slide out element and either blow out with air-line or gently tap on smooth ground to release debris. 6.11.4 Replace cover and replace clips. Strap Clips 6.12 Electrical connections 50 Hours 6.12.1 Check all wiring loom connections are secure. CAUTION! Poor connections will affect engine security cut-outs and may prevent starting. ©GreenMechLtd 6-7 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-8 Fig 6.13 Battery 6.13 Battery 50 hours 6.13.1 Remove M6 bolts to remove battery cover. 6.13.2 Check electrolyte level and top up if required (fig 6.13). 6.13.3 Replace cover. CAUTION! Gases are explosive. Electrolyte is corrosive. Avoid sparks and spillage. Removal of battery 6.13.4 Remove cover. 6.13.5 First disconnect negative (-) cable. 6.13.6 Disconnect positive (+) cable. 6.13.7 Remove clamp, carefully slide battery forward if necessary and lift. 6.13.8 Replace by connecting positive cable before negative. 6.13.9 Replace cover. Cover removed Positive Negative 6.14 Tyres and Wheels 50 hours 6.14.1 Check condition of tyres. 6.14.2 Check pressures and inflate to 2.7bar (40lb/in2) pressure as required. 6.14.3 Check wheel nuts are tight to 110Nm (80lbft) torque. ©GreenMechLtd 6-8 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-9 6.15 Brakes 50 hours or weekly 6.15.1 Check operation and effectiveness of overrun and handbrake. 100 hours 6.15.2 Adjust brakes as follows. 220.127.116.11 Chock machine, release handbrake and check drawbar is fully extended. 18.104.22.168 Jack up both wheels and support on axle stands. 22.214.171.124 Turn brake adjuster clockwise whilst rotating each wheel forwards until tight (fig 6.13). 126.96.36.199 Check brake linkage is free from slack. 188.8.131.52 Back off one notch and check wheel is free and repeat for opposite wheel. Note: Servicing of brakes may be required more often if above average mileage is covered. Fig 6.15 Brake adjustment Adjuster CAUTION! Reverse rotation of wheel may prevent correct adjustment. 6.16 Bearings and Pivots 50 hours See paragraph 6.1 for routine lubrication. 250 hours 6.16.1 Check rotating components for excessive movement and noise in operation. 6.16.2 Replace as required. 6.17 Hydraulic connections 100 hours 6.17.1 With the aid of the circuit diagram to follow the hose routings, check all hoses and connections for leaks and damage. 6.17.2 Replace any worn or damaged hoses with the correct type and length. 6.17.3 Before removal, check routing and ensure replacement hose is fitted free of strains, twists or kinks. CAUTION! Ensure any residual pressure is released before dismantling. CAUTION! Ensure hoses are refitted free of twists and kinks. ©GreenMechLtd 6-9 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6-10 6.18 Mountings 100 hours 6.18.1 Check that all mounting bolts are tight. Fig 6.19 Hydraulic Return Filter 6.19 Hydraulic Return Filter 250 hours 6.19.1 Check oil is cool. 6.19.2 Unscrew filter cover (there is a spring under the cover) and carefully lift out element, it may require gentle prising out, discard safely (fig 6.18). 6.19.3 Fit a new filter element of correct specification and replace cover and spring. Hydraulic filter CAUTION! Do not overtighten. 6.20 Wheel bearing adjustment 250 hours 6.20.1 Remove cap to reveal nut and split pin. 6.20.2 Remove split pin and slacken nut. 6.20.3 Clean out old grease. 6.20.4 Tighten nut to relocate bearing until hub is stiff to turn. 6.20.5 Slacken nut to next slot and fit new split pin. Check that hub is free to turn. 6.20.6 Repack with new grease and replace cap. 6.21 Hydraulic Oil change 1000 hours 6.21.1 Remove hydraulic oil with suction pump at filter/filler and replace with new oil and filter of correct specification. 6.21.2 Replace suction filter. 6.21.3 Dispose of waste oil according to local authority environmental procedures. 6.22 Fuses and No Stress system There are two fuses within the wiring harness. 6.22.1 A 40 amp in-line fuse protects the engine pre-heat and start circuit. 6.22.2 A 20 amp fuse protects the Power Protection System. Note The engine operating speeds for the No Stress system are factory set for particular machine builds and must not be readjusted. ©GreenMechLtd 6-10 06/06 PDF Compressor Pro EcoCombi 6. MAINTENANCE 6.23 Fault finding Fault Engine will not start Engine not at correct speed Blade disc will not start Feed rollers do not turn Feed will not reverse Discharge does not flow Machine unsteady Unusual noise(s) Check Battery Fuel Oil pressure Thermal cut-out Fuses Throttle lever Drive belts Control bar Hydraulics Control bar Hydraulic valve Discharge chute Blade disc Support leg Blade disc and bearings 6-11 Action Recharge Fill tank Check Oil level Check operation Check Check operation Replace Reset and check Check solenoid valve Reset and check Check operation Check for blockage Check for blockage Set to correct position Check and replace Page 6-8 6-4 6-4 6-4 6-10 5-2 6-6 3-2 5-2 3-2 5-2 4-2 5-1 5-1 5-1 6.24 Chipper Disc Re-grinding 6.24.1 Examine set of chipper discs for damage. If front face ‘A’ is worn the disc must be scrapped. If chips have broken off the cutting edge they can be re-dressed provided that they do not go inside the 90mm diameter. 6.24.2 Always regrind the worst damaged disc first, as this will establish the target weight for the other discs. 6.24.3 If large chips exist over less than 30% of the circumference the disc may be re-ground provided the large damaged area is not used for chipping. 6.24.4 Chips may be repaired by grinding a cutting edge around the damaged area using a bench grinder. 6.24.5 With chipper disc mounted on a mandrel re-grind remainder of cutting edge at 43º as shown 6.24.6 Re-grind in increments of approximately 0.01mm (0.004") until sharp edge is restored. 6.24.7 If re-grinding breaks into the 90mm diameter the disc must be scrapped. 6.24.8 After re-grinding the weight of discs within a set must not vary by more than +/- 1gm (0.03oz). The weight of each disc must not be less than 560gm (20oz) ©GreenMechLtd 6-11 06/06 PDF Compressor Pro EcoCombi 7.1 7. STORAGE 7-1 Storage 7.1.1 Thoroughly clean machine and note any replacement parts required. 7.1.2 Carry out 250 hour service if not already done. Refer to Section 6 7.1.3 Fit replacement parts when available. 7.1.4 Remove battery Refer to 6.10 7.1.5 Drain fuel 7.1.6 If machine is to be stored for more than 3 months, place on axle stands to remove weight from wheels. 7.2 Removal from Storage 7.2.1 7.2.2 7.2.3 7.2.4 Charge battery and refit Check tyre pressures Check brake operation Carry out machine preparation as necessary ©GreenMechLtd 7-1 Refer to 6.10 Refer to 6.12 Refer to 6.13 Refer to Section 4 06/06 PDF Compressor Pro EcoCombi 8. DISPOSAL 8-1 When the machine is finally scrapped, the following items should be disposed of only at authorised waste disposal facilities. Engine oil. Hydraulic oil. Antifreeze. Battery. Tyres. If in doubt, consult the Local Authority environmental department. Major non-ferrous items such as engine cover and hydraulic hoses may also be disposed of separately. ©GreenMechLtd 8-1 06/06 PDF Compressor Pro Safety Guides and Checklist as Transcribed from and Advised by Arborculture & Forestry Advisory Group and Issued as Leaflet 604 by HSE, issued 04/03 INTRODUCTION This leaflet covers the safe working practices to be followed when operating a wood chipper. It does not cover a combination of machines working within each other’s risk zones (see AFAG leaflet 605 Mechanical roadside processing) You can use this leaflet, along with the manufacturer’s handbook, as part of the risk assessment process to help identify the controls to put in place when using a wood chipper. You must also assess the effect of the site and the weather as well as following this guidance All operators must have had appropriate training in how to operate the machine and how to carry out the tasks require (see AFAG leaflet 805 Training and certification) PERSONAL PROTECTIVE EQUIPMENT (PPE) • • Safety Boots with good grip and ankle support (complying with EN345-1) Non-Snag Outer Clothing appropriate to prevailing weather conditions. Highvisibility clothing (complying with EN471) should be worn when the risk assessment identifies that it is needed. 2. Each person should carry a personal firstaid kit including a large wound dressing (see HSE leaflet INDG214 first aid at work; Your questions answered). 3. Hand cleaning material such as waterless skin cleanser or soap, water and paper towel should be readily available. THE MACHINE 4. Before working with a machine, check it has been properly converted from any transport mode. 5. Ensure guards for dangerous parts (e.g. belts, pulleys, shafts etc) are secure and undamaged. 6. Ensure protective devices, such as the infeed control bar (incorporating the stopping device), are working correctly (see HSE leaflet AI S 38 Power-fed mobile wood chippers: Operator protection at infeed chutes). 1. Use the following PPE • • • A Safety Helmet, complying with EN 397, if identified as required in the risk assessment. Eye Protection (a mesh visor complying with EN1731 or safety glasses to EN166) Hearing protection (complying with EN352) where noise level exceeds 85 dB(A) (see HSE pocket card INDG363 Protect your hearing or lose it!) • Gloves. 7. Ensure any lock for the chipping components has been disengaged; 8. Ensure the infeed hopper is clear of any materials. 9. Ensure Noise warning signs are in place. 10. For machines driven by a power take-off (PTO) shaft, before starting ensure: Page 1 PDF Compressor Pro • • • The PTO shaft is fitted with a suitable guard complying with EN1152, that encloses the shaft along its full length from tractor to machine. The guard is correctly fitted and in effective working order (see AS24(rev) Power take-offs and power take-off drive shafts); The PTO speed is suitable for the machine. SELECTING THE WORK AREA 11. Select as firm a surface as possible and stabilise the machine 12. Ensure ventilation is adequate and any exhaust fumes are vented into open air if working in an enclosed space. 13. Where appropriate, if the chipper is detached from the tow vehicle, apply the handbrake and, if necessary, chock the wheels. 14. On all reasonably foreseeable approaches to the worksite, erect warning and prohibition signs conforming to the Health and Safety (Safety Signs and Signals) Regulations 1996, indicating a hazardous worksite and that unauthorised access is prohibited. In areas of very high public access, a risk assessment may indicate that additional controls (e.g. barrier tape, barriers, extra manning) are required. 15. Ensure all operations near to highways are adequately signed with the appropriate notices as specified in the DTLR Code of Practice Safety at street works and road works (available from The Stationary Office ISBN 0 11 551958 -0) 16. Ensure that the discharge chute is positioned to prevent chips being blown onto the highway during roadside operations, or in any direction where they can affect colleagues or members of the public. 17. Position the chipper so that operators do not have to stand on embankments/slopes when feeding material into the machine EMERGENCY PROCEDURES 18. Ensure a designated and responsible person knows the daily work programme and agree with them a suitable emergency contact procedure. Where reasonably practicable use a mobile phone or radio and pre-arrange call-in system. 19. Ensure the operators can provide the emergency services with enough detail for them to be found in the event of an accident, e.g. the grid reference, the distance from the main road, the type of access (suitable for car/four-wheel drive/emergency service vehicles). In urban areas street names are essential. Know the location details before they are needed in an emergency. (Also see AFAG leaflet 802 Emergency planning) OPERATION 20. Make sure the cuffs of gloves are close fitting or tucked into you’re sleeves to stop them being caught on material as it is fed into the chipper. 21. Set the engine speed (and set the stress control if fitted) to obtain optimum performance. 22. Check that material to be chipped is free from stones, metal and foreign objects. 23. Stand to one side of the infeed rollers to avoid being hit by ejected material. 24. Let material go as soon as it is engaged in the infeed rollers or chipping components. Page 2 PDF Compressor Pro Maintenance 25. Use a push stick at least 1.5 metre long, for both short produce and for the last piece of produce to be chipped. 26. Do not put any part of your body (including hands or feet), into the infeed hopper while the machine is running. 27. Always follow the manufactures’ instructions for dealing with blockages on the machine. 28. Keep the area of ground in front of the infeed hopper free from debris to prevent any tripping hazard. 29. Remove the engine start key when the machine is left unattended or when undertaking any maintenance. 36. Ensure the machine is carried out in accordance with the manufacture’s handbook. 37. Check chipping components and knives each day for damage and wear. 38. Wear gloves when handling knives. 39. Before working on knives, confirm that the engine is switched off, the start key removed, and the chipping component is stationary. 40. Before opening any guard/cover or reaching into the infeed hopper or discharge chutes make sure that the engine is switched off, start key removed and dangerous parts have come to a stand still. FUELLING Maintenance 30. Stop engine and, if necessary allow the machine to cool before refuelling. 31. Petrol vapour is invisible and can flow considerable distances from spillage or fuelling sites. Maintain a safe distance from any source of ignition at all times. 32. Store fuel to avoid vapour ignition from any source such as fires, people smoking or the wood chipper. Select a site shaded from direct sunlight and away from watercourses and drains. 33. Containers must be clearly labelled and have securely fitting caps. Plastic containers must be designed and approved for use with petrol or diesel fuel. 41. Knives must be changed or reversed if damaged or blunt. Knives must be scrapped when worn to the minimum size specified by the manufacturer. 42. When new/sharpened knives are fitted, ensure that there is the recommended clearance between the knives and the anvil. MOVING THE MACHINE 43. Stop the engine and remove the start/stop key. 44. Lock the chipping components. 45. Secure the infeed hopper and the chip discharge chute in the transport position. 34. Replace the fuel cap securely. 35. Keep fuel from contacting the skin. If fuel gets into the eyes wash out with sterile water immediately and seek medical advise 46. Check the towing bracket, attach, then lift and secure the jockey wheel. 47. Connect the electrics and the safety chain/s to the towing vehicle. Page 3 PDF Compressor Pro 48. Ensure that the load is secure and that people are in a safe position before moving off. For further leaflets and reading see HSE web site: www.hse.gov.uk Further HSE Reading Mechanical roadside processing AFAG605 Emergency planning AFAG802 Training and certification AFAG805 First aid at work: Your questions answered INDG214 Managing health and safety In forestry INDG294 Protect your hearing or lose it! INDG363 Further reading Continued Power-fed mobile wood chippers: Operator protection at infeed chute AIS38 Power take-offs and power take-off drive shafts AS24 Page 4 PDF Compressor Pro 2 *,-.% !"#$% &'(% )%'' * *,-.% &! *# )%'' * + / 0 1 1 1 1 1 / / 3 PDF Compressor Pro "*14!"2 56 ")/"2 56 77, 8"2 1("!.9" .+" ).(" ,""! ") **3" 21:1).+1 !* .+" 14 /2 " 1(( !23*+,1.( .,/- 1!4* ()"*+",- .,/* '& 0 !" # $%& '###'' 34 + ! 21+1 ! ""+ PDF Compressor Pro Eco-Combi With Isuzu 35hp engine Parts Manual PDF Compressor Pro Fig 1 2 PDF Compressor Pro Main Chassis Fig No Part Number Description 1 2 3 4 C200322/I/1 C150104/I/1 EC151042 C150118 C150123 C150124 EC150061 EC150060 N/A EC151011 EC151006 ECM151006/1 C200345/3 EC150019 ECM151002 N/A N/A N/A EC35-6-15 EC15054 SI20111 EC150007/1 EC150013 ECM151005 ECM151004 EC150013 EC150002 EC151044 ECM5009/A C202503 C202503 81660 81660 91601 EC150030 C200613 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Quantity Tow Hitch Jockey Wheel Fuel Tank Battery Positive Battery Lead Negative Battery Lead Fuel Cap & Gauge Fuel Tank Strainer Filter 1 1 1 1 1 1 1 1 Bonnet Side Panel LEFT HAND Side Panel RIGHT HAND Wheel & Tyre Mud Guard Axle 1 1 1 3 2 1 Exhaust Exhaust Down Pipe Manifold Gasket Drive Pulley Taper Lock Bush Drive Belts Driven Pulley Taper Lock Bush Front Flywheel Bearing Rear Flywheel Bearing Flywheel Disc Blades (Chipper) Disc Blades (Shredder) Blade Bolts (Chipper) Blade Bolts (Shredder) Disc Blade Nut Discharge Chute Clamp Bolt 1 1 1 1 1 3 1 1 1 1 1 4 22 4 22 26 1 2 3 PDF Compressor Pro Fig 2 4 PDF Compressor Pro Fig 2 Fig No Part Number Description 1 2 3 4 5 6 6a 9227 C170433 EC151029/1 EC150021/1 EC151041 ST20004 ST20003/1 Quantity Rubber Handle Grip Lighting Board Hydraulic Return Filter Lynch Pin Hydraulic Tank Throttle Lever Throttle Cable 5 2 1 1 2 1 1 1 PDF Compressor Pro Fig 3 6 PDF Compressor Pro Fig 3 Fig No Part Number Description 1 2 3 3a 4 5 6 7 8 8a 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ECM151004 EC150013 EC150002 EC151044 EC150002/1 N/A N/A N/A EC151052 C170112 ECM151005 EC150007/1 EC150013 C200206 HYD – 2 C251813 C251808 EC1523255 C200224 ECM151008 C200207/1 EC150036 C180109 EC151026 C200207/1 Quantity Driven Pulley Taper Lock bush Front Flywheel Bearing Rear Flywheel Bearing Locking Collar 1 1 1 1 2 Hydraulic Pump 3CD/CE Hydraulic Pump 3CB Drive Belts Drive Pulley Taper Lock Bush Micro Switch Manual Valve Hydraulic Control Valve Solenoid Valve (NO-Stress) Pivot Pin Pivot Bush Pivot Arm Top Infeed Roller Hydraulic Motor Spring Roller Bearing Bottom Infeed Roller Motor Plate Hydraulic Motor 1 1 3 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 7 PDF Compressor Pro Fig 4 8 PDF Compressor Pro Fig 4 Fig No Part Number Description 1 2 3 4 5 N/A ECM15009/A ECM15002 C200207/1 EC150003 Quantity Rotor/Flywheel c/w Cutters Combi Shredder Infeed Roller Shredder Infeed Roller Motor Shredder Infeed Roller Bearing 9 1 1 1 1 PDF Compressor Pro Other Parts not Illustrated in Manual Part Number Description SI20103 Engine Oil filter 3CD/CE 1 SI20104 Engine Fuel Filter 3CD/CE 1 SI20003/2 Air Filter Element 1 C170103/1 Suction Filter Element 1 C180118 Short Control Cable 1 ECM15003 Long Control Cable 1 ECM15045/1 Rubber Infeed Flap SI20001 Engine Oil Filter 3CB 1 SI20002 Engine Fuel Filter 3CB 1 10 Quantity (Shredder Chute) 1 PDF Compressor Pro Risk Asse ssm e nt Company Name: GreenMech Ltd Hazard ENTANGLEMENT with cutter in base of CHIPPER and SHREDDER infeed chutes STABBING AND PUNCTURE by projectiles from cutter. Wood, stones, nails rebounding back out of infeed chute GreenMech Ltd Assessment No: R026 A Turner Company Activity: ECO- COMBI (ECM.150/35.D) At Risk Those likely to be affected OPERATOR Consequence ( C) Rating Likely injury from hazard FATALITY5 LOSS OF LIMB Likelihood (L) Of incident VERY LIKELY 5 25 OPERATOR Injuries to face, eyes, head and hands PROBABLE 4 12 3 Rating Controls Risk Score Reach area safety distance to cutter complies to latest HSE guidelines. Fix safety stop rail to lower perimeter of infeed chute. Operation of this emergency stop system should operate as recommended by HSE. Only appointed operators to use machine (competent) Trained operator. Check only green waste is fed into machine. Safety helmet to BSEN 397 Forestry visor Hard wearing gloves Revised C L Rating Rating 5 2 Final Risk Score 10 3 2 6 Key: Consequence Score Likelihood Score Fatality Disability Very serious (broken limbs) Important (3 day accident) Noticeable (first aid) 5 4 3 Very likely Quite Possible Possible 5 4 3 2 Remotely possible 2 1 Improbable 1 To find risk Score multiply consequence rating by the likelihood rating Final revised risk score acceptable to the company is 10 or less. If higher, further controls are required. Signed: …………………………… Date: ……………………………. Review Date: ……………………………. PDF Compressor Pro Risk Asse ssm e nt Company Name: GreenMech Ltd Hazard NOISE Guaranteed sound pressure level of Lwa 97 dB At Risk Those likely to be affected OPERATOR THIRD PARTY GreenMech Ltd Assessment No: R026-2 A Turner Company Activity: ECO- COMBI (ECM.150/35.D) Consequence ( C) Rating Likely injury from hazard NOISE 4 INDUCED HEARING LOSS Likelihood (L) Of incident Controls Risk Score Revised C L PROBABLE 4 16 Wear hearing protection to BS EN 352-3 Display mandatory ‘wear hearing protection’ sign 4 2 Final Risk Score 8 Trained operator Lock off with handbrake Chock wheels and secure stabiliser in place. Stand machine on sound, level ground. Cordon off collection point. Operator to wear head and face protection. 3 2 6 2 1 2 Rating VIBRATION – Movement of machine OPERATOR BROKEN OR BRUISED LIMB 3 POSSIBLE 3 9 STABBING – PUNCTURE When operating handle to raise engine – residue from exhaust chute OPERATOR Eye injuries, cuts to face 2 POSSIBLE 3 6 THIRD PARTY Rating Rating Key: Consequence Score Likelihood Score Fatality Disability Very serious (broken limbs) Important (3 day accident) Noticeable (first aid) 5 4 3 Very likely Quite Possible Possible 5 4 3 2 Remotely possible 2 1 Improbable 1 To find risk Score multiply consequence rating by the likelihood rating Final revised risk score acceptable to the company is 10 or less. If higher, further controls are required. Signed: …………………………… Date: ……………………………. Review Date: ……………………………. PDF Compressor Pro GreenMech Risk Asse ssm e nt Assessment No: R026-3 Company Name: GreenMech Ltd Hazard ENTANGLEMENT Branches with clothing STABBING AND PUNCTUREprocessed green waste STABBING AND PUNCTURE – Handling branches Activity: ECO- COMBI (ECM.150/35.D) At Risk Those likely to be affected OPERATOR Consequence ( C) Rating Likely injury from hazard 5 Drawn into cutters – FATALITY – LOSS OF LIMBS OPERATOR EYE INJURIES, CUTS TO FACE CUTS TO HANDS THIRD PARTY OPERATOR Ltd A Turner Company Likelihood (L) Of incident Rating Controls Risk Score POSSIBLE 3 15 1 POSSIBLE 3 3 2 QUITE POSSIBLE 4 8 Wear snug fitting clothes. No ties, scarves etc. Same controls as for previous hazard of entanglement with cutters. Wear gloves with long cuffs which can be tucked into sleeves Trained operator Lock of exhaust chute Cordon off collection point Wear hard wearing gloves with long cuffs that can be tucked into sleeves. Revised C L Rating Rating 5 2 Final Risk Score 10 1 1 2 2 2 4 Key: Consequence Score Likelihood Score Fatality Disability Very serious (broken limbs) Important (3 day accident) Noticeable (first aid) 5 4 3 Very likely Quite Possible Possible 5 4 3 2 Remotely possible 2 1 Improbable 1 To find risk Score multiply consequence rating by the likelihood rating Final revised risk score acceptable to the company is 10 or less. If higher, further controls are required. Final revised likelihood score must be 2 or less Signed: …………………………… Date: ……………………………. Review Date: …………………………….