SAFE-Trak models Eco STC150 Arborist STC16

SAFE-Trak models
Covering
Eco STC150
Arborist STC16-23
Arborist STC19-28
ChipmasterSTC220
Operators’ Manual
IMPORTANT NOTICE
TENSION OF MAIN
DRIVE FOR STC1623MT35 & STC150MT35
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.
SAFE-Trak
SECTION:
CONTENTS
1
1. Introduction and Purpose
2. Technical Specifications, Dimensions and Noise Level
3. Safety and Symbols
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Ensure!
Never!
Always!
Safety controls and switches
Control cut-outs
'No Stress' system
Tracking controls
Symbols
4. Machine Preparation
4.1
4.2
4.3
Fuelling and parking
Infeed chute
Discharge chute
5. Operation
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Pre-work checks
Starting machine
Moving machine
Starting Chipper
Stopping Chipper
Adjustable Feed roller control
Operating Hints
On Completion of Work
6. Maintenance
For Engine and Tracks please refer to separate manuals
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
Routine Maintenance schedule
Engine Oil
Coolant
Hydraulic Oil
Fuel level
Drive Belts
Disc Blades
Radiator
Steam Cleaning
Air Cleaner
Electrical Connections
©GreenMech Ltd
-1-
06/06
SAFE-Trak
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
CONTENTS
2
Battery
Bearings and pivots
Chipper Drive belt tension
Track Pump Drive Belts
Hydraulic connections
Mountings
Hydraulic Return Filter
Hydraulic Return Filter (Track Drive) STC220 only
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
Hydraulic Circuit
Electrical Circuits
Certificate of Conformity
Risk Assessment
©GreenMech Ltd
-2-
06/06
SAFE-Trak 1. INTRODUCTION AND PURPOSE
1-1
INTRODUCTION
This manual explains the proper 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
here the serial number and quote it in any communications. This is important when
ordering spares. Remember to include all numbers and letters.
Serial Number
STC150
(STC16-23, 19-28
similar)
Serial Number...................
Write in the number!
Serial
Number
STC220
This manual covers the following engine driven self-propelled SAFE-Trak models.
ECO STC150MT35, Arborist STC16-23, Arborist STC19-28MT50, ChipMaster
STC220MT55
If in doubt, always quote the serial number in any communications. Where instructions are
significantly different between models, the section may be designated with a letter a or b.
(for example: 6.14a)
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 wood and must not be
used for any other purpose. The machine should only be used by trained
operators who are familiar with the contents of this instruction manual. It is
potentially hazardous to fit or use any parts other than genuine GreenMech
parts. These Wood Chippers are for Off Highways use only. GreenMech
Ltd disclaims all liability for the consequences of such use, which in addition voids the
machine warranty.
©GreenMech Ltd
1-1
05/06
SAFE-Trak
2. SPECIFICATIONS
Fig 2.1 Eco STC150MT35 SAFE-Trak
2-1
Main features
Discharge chute
Track controls
Chipper disc cover
Control bar
Engine
cover
Reset bar
Infeed chute
Feed roller pivot
Track leg
TECHNICAL SPECIFICATION ECO STC150MT35 SAFE-Trak
Max capacity
150mm (6-inch) diameter
Infeed opening
800mm x 710mm
Throat size
155mm x 155mm
Chipping disc
500mm x 25mm
Speed
2400 rpm
Chipping disc-blades
2 Discs
Feed Rollers
2 x Hydraulic & Spring Tensioned
Power control
No-Stress Electronic Feed Roller Controller
Power unit
35hp water cooled diesel
Fuel capacity
45Lt
Hydraulic capacity
45Lt
Length (maximum in work position)
3990mm
Length (minimum for transport)
3200mm
Width over body
1300mm
Track width
1300mm - 2130mm
Track size
250mm x 1440mm
Height
2084mm - 2400mm
Weight
1350Kg
Ground pressure
0.28kg/cm2
©GreenMech Ltd
2-1
05/06
SAFE-Trak
2. SPECIFICATIONS
2-2
Fig 2.2 Arborist STC16-23MT35 SAFE-Trak
Discharge Chute
Tracking
Controls
Chipper Disc Cover
Engine
Cover
Control Bar
Reset Bar
Feed Roller Pivot
Infeed Chute
Track Leg
TECHNICAL SPECIFICATION
Max capacity
Infeed opening
Throat size
Chipping disc
Speed
Chipping disc-blades
Feed rollers
Power control
Power unit
Fuel capacity
Hydraulic capacity
Length (maximum in work position)
Length (minimum for transport)
Width over body
Track width
Track size
Height
Weight
Ground pressure
©GreenMech Ltd
2-2
Arborist STC16-23MT35 SAFE-Trak
150mm x 230mm (6inch x 9inch)
920mm x 820mm
160mm x 230mm
500mm x 25mm
2400 rpm
2/4 Discs
2 x Hydraulic & Spring Tensioned
No-Stress Electronic Feed Roller Controller
35hp water cooled diesel
37Lt
45Lt
3458mm
2377mm
735mm - 1090mm
736mm – 1589mm
250mm x 1440mm
2305mm – 2410mm
1400Kg
0.25kg/cm2
05/06
SAFE-Trak
2. SPECIFICATIONS
2-3
Fig 2.3 Arborist STC19-28MT50 SAFE-Trak
Discharge Chute
Chipper Disc Cover
Tracking
Controls
Engine
Cover
Control Bar
Reset Bar
Feed Roller Pivot
Infeed Chute
Track Leg
TECHNICAL SPECIFICATION
Max capacity
Infeed opening
Throat size
Chipping disc
Speed
Chipping disc-blades
Feed rollers
Power control
Power unit
Fuel capacity
Hydraulic capacity
Length (maximum in work position)
Length (minimum for transport)
Width over body
Track width
Track size
Height
Weight
Ground pressure
©GreenMech Ltd
2-3
Arborist STC19-28MT50 SAFE-Trak
190mm x 280mm (7.5inch x 11inch)
1200mm x 840mm
190mm x 280mm
600mm x 25mm
1500 rpm
4 Discs
2 x Hydraulic & Spring Tensioned
No-Stress Electronic Feed Roller Controller
50hp water cooled diesel
60Lt
50Lt
4100mm
3500mm
1320mm
1200mm – 2012mm
250mm x 1768mm
2390mm – 2720mm
1800Kg
0.26kg/cm2
05/06
SAFE-Trak
2. SPECIFICATIONS
Fig 2.4 Chipmaster STC220MT55 SAFE-Trak
2-4
Main Features
Discharge Chute
Chipper Disc Cover
Engine Cover
Control Bar
Reset Bar
Tracking Controls
Feed Roller Pivot
Infeed Chute
Track Leg
TECHNICAL SPECIFICATION CHIPMASTER STC220MT55 SAFE-Trak
Max capacity
220mm (9-inch) diameter
Infeed opening
1070mm x 870mm
Throat size
230mm x 230mm
Chipping disc
730mm x 30mm
Speed
1565 rpm
Chipping disc-blades
6 Discs
Feed rollers
2 x Hydraulic & Spring Tensioned
Power control
No-Stress Electronic Feed Roller Controller
Power Unit
55hp water cooled diesel
Fuel capacity
44Lt
Hydraulic capacity
44Lt
Length (maximum in work position)
4300mm
Length (minimum for transport)
3530mm
Width over body
1330mm
Track width
1600mm – 2590mm
Track size
250mm x 1768mm
Height
2470mm – 2800mm
Weight
1880Kg
Ground pressure
0.27kg/cm2
©GreenMech Ltd
2-4
05/06
SAFE-Trak
2. SPECIFICATIONS
2-5
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 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
All models have a central lifting point by the chipper disc cover and anchor points on the
corners of the chassis.
©GreenMech Ltd
2-5
05/06
SAFE-Trak
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 These Wood Chippers are for Off
Highways use only.
3.1.5 The machine is positioned with the
body level.
3.1.6(a) The infeed chute (bottom control
bar) at least 600mm (23.62 inches)above
ground level (fig 3.1) .
3.1.6(b) The infeed chute (top control bar)
no more than 600mm (23.62 inches) above
ground level (fig 3.1)
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.
3.1.12 Fire extinguisher is available on site.
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.
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.
©GreenMech Ltd
3-1
3-1
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 Stand between the tracks and the
chipper body.
3.2.10 Stand within 2 metres of the tracks
when the legs are being extended.
3.2.11 Extend legs to put the tracking
controls beyond reach.
3.2.12 Stop the engine or operate the
chipper when moving directly up or down a
slope.
3.2.13 Operate inside a building or
confined space.
3.2.14 Climb on the infeed chute.
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.
3.2.3 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 Adjust legs to keep the body level.
3.3.9 Check the route to the worksite for
gradients, undulations and obstructions.
3.3.10 Remove key before doing any
maintenance.
05/06
SAFE-Trak
3. SAFETY
3.4.1 Emergency Stop/Control Bar (fig
3.4.1(a) bottom type and 3.4.1(b) top type
In the event of an emergency, push the
emergency stop bar to STOP the feed
rollers. This will lock in position
Fig 3.4.1(a) Bottom Control Bar and
Reset Lever STC150, STC220,
STC19-28
Reset bar
3.4.1.1 Once the emergency has been
rectified the following sequence should be
carried out:
3.4.1.2 To restart rollers pull the reset lever
whilst pulling the control bar towards the
Feed In position. On STC 16-23 the control
bar will return automatically.
3.4.1.3 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.
3.4.1.4(a) To reverse (Feed Out) the rollers
on bottom bar machines push the control
bar into the middle detent. To regain
forward (Feed In) pull the control bar away
from the chipper. It is not necessary to use
the reset bar.
3.4.1.4(b) To reverse (Feed Out) the rollers
on top bar machine (STC16-23) pull the
control bar out towards the operator. The
bar will return to Feed In when released.
Control bar
Control Bar positions
(Nearside)
STOP
FEED OUT
FEED IN
(Offside)
FEED IN FEED OUT
STOP
Fig 3.4.1(b) Top Control Bar and
Reset Lever STC16-23
Control bar
CAUTION! Regularly check that the
bar locates in the 3 correct positions. At no
time may this system be removed, jammed,
disabled or otherwise impede from effecting
the infeed stop control.
Reset bar
Control Bar positions
(Nearside)
STOP
FEED IN
FEED OUT FEED IN
(Offside)
3-2
FEED OUT
Fig 3.1 Infeed Chute Height
STOP
Height
Bottom bar (as shown) 600mm (min)
Top bar (STC16-23)
600mm (max)
3.4 Safety Controls and Switches
©GreenMech Ltd
3-2
05/06
SAFE-Trak
3. SAFETY
Fig 3.4.2a Engine Stop
Switch STC150 and
STC220
3-3
3.4.2 Engine stop switch
3.4.2.1 To stop the engine, turn the start
key anticlockwise (fig 3.4.2 a or b).
Key
CAUTION! Do not restart engine until
hazard has been removed.
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. Refer to GreenMech in an
emergency.
3.5.4 Engine cover opening is protected by
a microswitch to shut off the fuel solenoid.
3.5.5 Clutch disengagement changes
engine throttle from operating speed to idle
speed.
Fig 3.4.2b Engine stop
switch STC16-23 and
STC19-28
Key
©GreenMech Ltd
3-3
05/06
SAFE-Trak
3. SAFETY
3-4
3.6 No Stress system
3.6.1 Speed sensor in alternator disables
feed roller FEED IN mode when engine
speed is below factory pre-set value.
LED light glows Green at normal operating
speed, Red at overload and idle and Red
Flash when start switch turned on.
Fig 3.7.1 Tracking controls
Levers
Switches
3.7 Tracking Controls (Fig 3.7.1 & 3.7.2)
3.7.1 A two position toggle switch selects
either tracking or chipping. In track mode
the No Stress system will not allow the feed
rollers to operate. In chip mode the legs
cannot be extended and the drive to the
track pumps is disconnected. (Fig 3.7.2)
3.7.2 A three position toggle switch
controls each extending leg. Out to extend.
In to retract.
3.7.3 Lever controls operate the drives to
the tracks. Push for forward motion. Pull
for reverse motion.
3.7.4 A hand throttle is fitted for use only
when the machine is being tracked, not
when chipping.
Note: On STC150, STC16-23 and STC1928 there is no chipper clutch. The chipper
disc runs whenever the engine is running.
Fig 3.7.2 Switches
Switches
Centre – Chip/track
Outer - Legs
CAUTION! STC16-23: When
traversing slopes track with legs at least
50% extended whenever possible.
©GreenMech Ltd
3-4
05/06
SAFE-Trak
3. SAFETY
3-5
3.8 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
©GreenMech Ltd
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
3-5
05/06
SAFE-Trak
3. SAFETY
3-6
Important Safety Information
Caution!
Do NOT drive up or down
slopes of more than 25°
Caution! Beware Crushing
hazard!
Caution!
Do NOT operate or traverse
on slopes of more than 35°
Do NOT work or park
directly up or down slope.
Caution! Beware crushing
hazard
Caution! Beware of thrown
object hazard
Action: Do NOT stand in area
between machine body and
tracks
Action: Keep away from fast
discharge chute
Caution!
Caution!
Do NOT operate with infeed
chute at less than 600mm from
ground. (bottom bar machines)
Do NOT operate with infeed
chute at greater than 600mm
from ground. (top bar machines)
©GreenMech Ltd
3-6
05/06
SAFE-Trak
3. SAFETY
3-7
Safety Information (continued)
Caution! Beware of thrown
object hazard
Transport Lock
Sound level
Ear defenders must
be worn
Action: Stand to side of infeed
chute, NOT in centre.
Lift Point
Lock this component before
moving machine
Maintenance Information
Diesel Filler
Hydraulic Filler
Grease point
40 hours / weekly
Radiator cleaning
8 Hours
Check
radiator
screen
©GreenMech Ltd
High temperature
grease 40 hours
40 Hours
Blow out
radiator
core
3-7
05/06
SAFE-Trak
3. SAFETY
3-8
Operating Information
Track drive and throttle controls
Track – Chip controls
Track legs
Outer switches – legs extend - retract
Centre switch – Up to chip: Down to drive
Discharge chute control
Left lever
LH track: forwards – backwards
Right lever
RH track: forwards – backwards
Lever with red knob
Engine throttle slow - fast
Green is UP
Blue is DOWN
Reset lever: Left hand shown
No Stress indicator
Pull to reset
Bottom type Control Bar. Left hand shown
Push to STOP : Centre-feed out : Pull–feed in
Green is ON: Red is OFF
Top type Control Bar. Left hand shown
Push to stop: Centre-feed in: Pull–feed out
©GreenMech Ltd
3-8
05/06
SAFE-Trak
4. MACHINE PREPARATION
4-1
4.1 Initial Fuelling and Parking
4.1.1 Fill the fuel tank with diesel. See
section 6.
4.1.2 Top up the hydraulic tank if
necessary, with the correct oil. See Section
6.
4.1.3 Position the machine body level and
adjust until the infeed chute is in correct
position - 600mm min (bottom bar) or max
(top bar) from the ground according to
control bar type. (see fig 3.1)
Fig 4.2 Infeed chute catch, bottom
bar models.
Catch (transport)
4.2 Infeed Chute unfolding (bottom bar
models only)
4.2.1 Remove the transport pin for the
infeed chute catch, release the catch (fig
4.2)
4.2.2 Using the tubular edge as a handle,
lower the infeed chute to the work position
and reset the catch.
4.2.3 Measure the height of the infeed
chute and readjust the legs as required.
4.2.4 Pull the reset lever to release the
control bar for use.
Catch
(work)
Fig 4.3 Discharge chute
CAUTION! The infeed chute must be
positioned correctly above the ground. (fig
3.1)
Flap lever
CAUTION! Before travelling, always
fold up and secure the infeed chute.
4.3 Discharge Chute (Fig 4.3)
4.3.1 Release the swivel clamps and point
the chute in the desired direction.
4.3.2 Set the flap at the desired height and
tighten the clamp.
Swivel clamp
CAUTION! When travelling, lock the
the discharge chute pointing away from the
driver.
©GreenMech Ltd
4-1
05/06
SAFE-Trak
5. OPERATION
5-1
5.1 Pre-Work Checks:
5.1.1 Check machine is stationary, start
key removed,
5.1.2 Check that machine is level and
infeed chute is 600mm minimum from
ground (fig 3.4.3).
5.1.3 Check engine oil level (Refer to
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.
5.1.6.1 Raise or remove engine cover.
5.1.6.2 Remove the bolt retaining chipper
disc cover. (Fig 5.1.1) Note: Two bolts on
STC19-28. (Fig 5.1.2)
5.1.6.3 Using discharge chute handle as a
lever, swing back cover onto stop to expose
chipper disc and blades. (fig 5.1)
5.1.6.4 Carefully rotate chipper disc to
check tightness of disc blade bolts and
condition of blades.
5.1.6.5 Remove any loose wood material.
5.1.6.6 If any bolts are loose, refer to
maintenance section for further action.
5.1.6.7 Replace chipper disc cover and
tighten bolt(s) securely.
5.1.7 Remove any loose material and dust
from radiator and engine bay.
5.1.8 Replace engine cover.
5.1.9 Check discharge chute is in desired
position and all clamps are tight. (see
Section 4.3)
5.1.10 Check infeed chute (fig 4.2) is
locked in position with catch.
5.1.11 Check work area and erect signs
and cone off discharge area if necessary.
5.1.12 Check ALL safety procedures have
been followed.
Fig 5.1 1 Chipper Disc Cover
Disc Cover
locating bolt
Fig 5.1.2 Disc Cover (STC16-23 &
19-28)
Bolts
CAUTION! Always work with the
chipper level across a slope, preferably with
the infeed direction slightly down the slope
to minimise the risk of material falling back
out.
©GreenMech Ltd
5-1
05/06
SAFE-Trak
5. OPERATION
5-2
5.2 Starting Machine:
5.2.1 STC150 and STC220: Put throttle
control toggle switch into up IDLE/START
position (fig 5.2.1)
5.2.2 Check all other personnel are clear
of machine.
5.2.3 Check that feed roller control bar is
pushed to the FEED OUT or STOP
position, to make the machine safe.
5.2.4 STC220 only: Check that clutch is
disengaged (fig 5.5)
5.2.5 Turn start key to pre-heat position
and depress low oil pressure override
button for 5 seconds. Note: STC19-28
override is automatic. Follow prompts.
5.2.6 Keeping override button depressed,
turn key to START position.
5.2.7 When the engine starts, keep
override button depressed until red warning
light goes out.
5.3 Moving the Machine
5.3.1 At tracking controls, (fig 5.3.1) select
Track. (Centre switch down)
5.3.2 Extend legs as required, keeping
body level. (fig 5.3.2)
5.3.3 Push both levers together to start
forward movement.
5.3.4 Open hand throttle to increase
speed. Close to decrease speed.
5.3.5 Push left or right lever to steer.
5.3.6 At work site adjust legs to level the
body and to position infeed chute at 600mm
min. height.
5.3.7 Close hand throttle to slow engine.
Note: When extending or retracting legs
it is advisable to track the machine.
Fig 5.2 1 Engine control STC150 &
STC220
Switch
Key
Oil
override
Fig 5.2.2 Control unit STC 16-23 &
19-28
Disc Speed
Run
Key
Fig 5.3.1 Tracking Controls
Motion levers
Hand
throttle
Switches
CAUTION! When extending legs, do
not force track against solid objects. This
may dislodge track.
Fig 5.3.2 Track Legs
Body level
CAUTION! Avoid static turns on hard
surfaces. This will rapidly wear the tracks
CAUTION! Point the discharge chute
away from the driver. Over long journeys,
engage the chipper drive to blow out build
up of exhaust gas.
CAUTION! Do not drive directly up
slopes exceeding 20 degrees. Slopes up to
35 degrees may be traversed with care.
©GreenMech Ltd
5-2
05/06
SAFE-Trak
5. OPERATION
5-3
fig 5.4 Clutch On (STC220 only)
5.4 Starting the Chipper
5.4.1 At tracking controls, select CHIP.
(Centre switch up)
5.4.2 STC220 only: Engage the clutch (fig
5.4). Note: On STC150 and STC19-28
chipper disc is always engaged.
5.4.3a STC150 and STC220: Press the
throttle control switch down to RUN position
to increase the speed to operating speed.
The green No Stress light will come on.
5.4.3b STC19-28: Press RUN on control
unit (fig 5.2.2).
5.4.4 Pull the reset lever to release the
control bar for work.
Clutch On
Fig 5.5 Clutch Off (STC220 only)
5.5 Stopping the Chipper
5.5.1 Push the control bar to STOP
position.
5.5.2a STC150 and STC220: Select
throttle switch (fig 5.2.1) up to START/IDLE
position and allow chipper disc to slow
down.
5.5.2b STC19-28: Press IDLE on control
unit and allow chipper disc to slow down.
5.5.3 STC220 only: Disengage the clutch.
(fig 5.5)
5.5.4 Switch start key to OFF to stop the
engine (fig 5.2).
5.5.5 Wait for chipper disc to stop.
Clutch Off
Fig 5.6(a) Adjustable feed roller
control (STC220 shown)
Control
Knob
CAUTION! The chipper disc will take
several minutes to stop due to its inertia.
STC19-28 location below
Control knob settings
Material
up to 150mm
turns)
150mm to 250mm
©GreenMech Ltd
5.6 Adjustable Speed Feed Roller
Control
When chipping wood sizes larger than
150mm diameter it is necessary to reduce
the feed roller speed to suit the material
being chipped.
5.6.1 Turn the valve control knob (fig 5.6)
clockwise until valve is closed.
5.6.2 Turn the knob anticlockwise to the
recommended setting in the table.
Setting
Fully open (3
1/2 to 3/4 turn
5-3
05/06
SAFE-Trak
5. OPERATION
5.7 Operating Hints
5.7.1 Check chip/track switch is set to
CHIP.
5.7.2 STC220 only: Engage clutch slowly
(fig 5.4)
5.7.3a STC150 and STC220: Check that
chipper disc is at full speed with green light
showing on No-Stress control (fig 5.7.1).
5.7.3b STC16-23 and 19-28: Check disc
speed on control unit is 1470rev/min
minimum or more (fig 5.7.2).
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.
5.7.4 Select START/IDLE to reduce speed
to idle whilst further material is collected for
chipping.
5.7.5 Take care when feeding wood into
the machine to allow for awkward shapes to
“KICK” when contacting the feed rollers.
5.7.6 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.
Fig 5.6(b) Feed control STC16-23
location by roller pivot
Knob
Fig 5.7.1 No Stress light (if fitted)
No Stress
Light
Green
Red
overloaded
Red flash
Normal
Rollers stopped -
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. 4.3).
Engine START on
CAUTION! Keep working area around
the machine clear at all times and check
only authorised personnel are present.
Fig 5.7.2 Control unit STC16-23 &
STC19-28
5.8 On Completion Of Work
5.8.1 Check that engine has stopped and
chipper disc is stationary.
5.8.2 Remove surplus material from infeed
chute and machine surfaces.
5.8.3 Fold infeed chute to transport
position using control bar, secure with lock
and fit locking pin. (except STC16-23)
5.8.4 Set discharge flap into lowest
position and tighten clamp.
5.8.5 Release clamps, turn discharge
chute to straight position away from
tracking controls, tighten clamps.
Disc speed
1470 minimum
©GreenMech Ltd
5-4
5-4
05/06
SAFE-Trak
5. OPERATION
5-5
CAUTION! Do not leave machine
parked directly up or down slope.
©GreenMech Ltd
5-5
05/06
SAFE-Trak
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
Check condition of tracks
Check track gear, nuts, rollers and bearings
6.2 – 6.3
6-6
6.4
6-6
6.5
6-7
6.6
6-7
6.7
6-8
6.8
6-9
3.4
3-2
Refer to track manual
Refer to track manual
FIRST 50 HOURS
Check battery levels
Check drive belt tensions
Check hydraulic connections
Check all mountings
Check feed roller control bar function
Service engine
6.12
6-10
6.14
6-10, 6-11
6.16
6-12
6.17
6-12
3.4
3-2
Refer to engine manual
WEEKLY in addition to Daily actions
Grease all bearings, pivots and slide pads
Blow out radiator core with air line
Steam clean machine
Clean air cleaner
Check electrical connections
Check battery levels
Check chipper and pump drive belt tensions
Check hydraulic connections
Check all mountings
Check feed roller control bar function
6.1, 6.13
6.8
6.9
6.10
6.11
6.12
6.14, 6.15
6.16
6.17
3.4
250 hours in addition to Daily and Weekly actions
Check condition of bearings and pivots
Check all fluid levels
Service engine
Check track gear units, rollers and bearings
Replace return filter element(s)
6.1, 6.13
6-5, 6-10
6.2, 6.3, 6.4
6-6
Refer to engine manual
Refer to track manual
6.18, 6.19
6-13
1000 hours in addition to 250 hour actions
Change hydraulic oil when replacing filter element
6.20
©GreenMech Ltd
6-1
Section
Page
6-5, 6-10
6-6
6-9
6-9
6-9
6-10
6-10, 6-11
6-12
6-12
3-2
6-14
05/06
SAFE-Trak
6. MAINTENANCE
6-2
DIESEL ENGINE MAINTENANCE
REFER TO ENGINE MANUAL
TRACK MAINTENANCE
REFER TO TRACK MANUAL
Recommended lubricants
Hydraulic Oil
Grease
Engine
Specification
ISO 32
Complex grease EP2
SAE 15W-40 APICD
(high temperature)
6.1 Lubrication Points (see also 6.13)
Fig 6.1.1 Lubrication points STC150
6.1.3
6.1.4
6.1.5
6.1.2
6.1.7
6.1.1
6.1.9
6.1.8
©GreenMech Ltd
6-2
05/06
SAFE-Trak
6. MAINTENANCE
6-3
Fig 6.1.2 Lubrication points STC16-23
6.1.3
6.1.4
6.1.5
6.1.2
6.1.8
6.1.1
6.1.9
Fig 6.1.3 Lubrication points STC19-28
6.1.3
6.1.4
6.1.2
6.1.7
6.1.1
6.1.9
©GreenMech Ltd
6-3
6.1.8
05/06
SAFE-Trak
6. MAINTENANCE
6-4
Fig 6.1.4 Lubrication Points STC220
6.1.3
6.1.2
6.1.4
6.1.5
6.1.7
6.1.6
6.1.8
6.1.1
6.1.9
Fig 6.1.5 STC19-28 Rear chipper disc bearing
Rear bearing
grease nipple
in disc
©GreenMech Ltd
6-4
05/06
SAFE-Trak
6. MAINTENANCE
6-5
Grease except where stated
6.1.1
Track legs STC19-28 and STC220
2 nipples each leg
STC150 extend leg, smear with grease and retract/extend.
6.1.2
Top Feed roller pivot
1 nipple
6.1.3
Top Feed roller bearing
1 nipple
6.1.4
Chipper Disc bearings
1 nipple each bearing
Note: STC19-28 rear disc bearing is greased through disc. (fig 6.1.4)
6.1.5
Chipper Disc labyrinth seal
1 nipple
6.1.6
Clutch lever STC220 only
1 nipple
6.1.7
Infeed chute hinges
Oil
6.1.8
Mechanical reset mechanism
Clean and grease
6.1.9
Bottom 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
©GreenMech Ltd
6-5
05/06
SAFE-Trak
6. MAINTENANCE
6-6
6.2 Engine Oil
6.2.1 Check daily (fig 6.2). Refer to
engine manual to refill.
Fig. 6.2 Engine dipstick (typical)
6.3 Coolant
6.3.1 Check daily, both radiator and
overflow tank (fig 6.3). Refill as required.
Check antifreeze.
Dipstick
CAUTION! Do not remove cap when
engine is hot.
6.4 Hydraulic Oil
For location see respective pictures:
STC150
(fig 6.4.1)
STC16-23 & STC19-28
(fig 6.4.2)
STC220
(fig 6.4.3)
Fig.6.3 Coolant (typical)
Filler
6.4.1 Check daily. If below mark check
for leaks and refill to correct level.
6.4.2 1000 hours. Remove drain plug,
Drain tank and refill with clean oil of correct
specification. Replace filter (6.18, 6.19 if
applicable)
Expansion filler
Fig 6.4.1 Hydraulic Filler/Filter
STC150
Filler/Filter
Fig 6.4.2 Hydraulic Filler/Filter
STC19-28 (STC16-23 similar)
Fig. 6.4.3 Hydraulic Oil STC220
Hydraulic Oil
Filler/filter
©GreenMech Ltd
6-6
05/06
SAFE-Trak
6. MAINTENANCE
6-7
6.5 Fuel
For location see respective pictures
STC150
(fig 6.5.1)
STC16-23 (fig 6.5.2)
STC19-28 (fig 6.5.3)
STC220
(fig 6.5.4)
Fig 6.5.1 Fuel STC150
Fuel Filler
6.5.1 Check daily before work and fill with
diesel as required.
CAUTION! Use clean diesel fuel only.
If in doubt, use a funnel with a filter.
Fig 6.5.2 Fuel STC16-23
Fuel Filler
CAUTION! Do not use any form of
synthetic fuel.
Fig 6.5.3 Fuel STC19-28
Fuel Filler
6.6 Drive Belts
Check daily, before work, the condition of
all drive belts and replace if worn. See
section 6.14 and 6.15
STC150: CHECK TENSION AFTER FIRST
2-3 HOURS. See section 6.14a.
Fig 6.5.4 Fuel Tank STC220
Fuel filler
©GreenMech Ltd
6-7
05/06
SAFE-Trak
6. MAINTENANCE
6-8
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 Raise engine cover, and check any
rotation has stopped.
6.7.3 Remove the bolt(s) retaining chipper
disc cover (fig 6.7.1 or fig 5.1.2).
Fig 6.7.1 Chipper disc cover
Bolt
CAUTION! Take care. Blades are
extremely sharp.
6.7.4 Using discharge chute handle as a
lever, swing back cover on to stop to
expose chipper disc and blades.
6.7.5 Current best practice is to ‘lock’
chipper disc with timber or similar in desired
position when slackening or tightening
blade bolts to 150NM.
6.7.6 Slacken disc blade retaining bolt,
remove disc, clean mounting face and
location (fig 6.7.2 or fig 6.7.3).
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.
Fig 6.7.2 Chipper disc and disc
blades
Disc
Torque to
150Nm
Fig 6.7.3 Chipper Disc STC19-28
CAUTION! Disc blades must only be
sharpened by grinding the angled back face
on a suitable 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.
Torque to
150Nm
All blades must be sharpened in “sets” with
equal amounts removed to maintain
balance.
See section 6.23 for disc grinding details
©GreenMech Ltd
6-8
05/06
SAFE-Trak
6. MAINTENANCE
6-9
6.8 Radiator
Daily
6.8.1 STC150 and STC220: Lift out
radiator screen, clean and replace (fig
6.8.1).
50 hours
6.8.2a STC150 and STC220: In addition to
above, blow out radiator core from rear with
suitable airline and clear from front.
6.8.2b STC19-28: Blow radiator core from
front. (fig 6.8.2)
Fig 6.8.1 Radiator Screen STC16-23
Screen
CAUTION! A build up of debris risks
overheating of the engine and a risk of fire.
Fig 6.8.2 Radiator STC19-28
6.9 Steam Cleaning
50 hours
6.9.1 Check all covers are fitted and
closed.
6.9.2 Steam clean machine surfaces.
6.9.3 Clean electrical components with a
damp rag, spray with WD40 and then wipe
with dry rag.
Blow from
rear
CAUTION! Do not steam clean
directly on to electrical components, e.g.
control boxes.
Fig 6.10 Air Cleaner
6.10 Air Cleaner
50 hours
6.10.1 Release wingnut or clip and
remove cover (fig 6.10).
6.10.2 Release wingnut, slide out element
and either blow out with air-line or gently
tap on smooth ground to release debris. If
badly contaminated replace element.
6.10.3 Replace and tighten wingnut fingertight.
6.10.4 Replace cover.
Cover screw
Fig 6.10 Air Cleaner STC16-23
6.11 Electrical connections
50 Hours
6.11.1 Check all wiring loom connections
are secure.
CAUTION! Poor connections will
affect engine security cut-outs and may
prevent starting.
Cover screw
©GreenMech Ltd
6-9
05/06
SAFE-Trak
6. MAINTENANCE
6-10
6.12 Battery
50 hours
(fig 6.12.1, fig 6.12.2, fig 6.12.3, fig 6.12.4)
6.12.1 Remove metal cover, check
electrolyte level and top up if required
6.12.2 Replace cover.
Fig 6.12.1 Battery STC150
Battery
CAUTION! Gases are explosive.
Electrolyte is corrosive. Avoid sparks and
spillage.
6.12.3 Removal of battery
6.12.3.1 First disconnect negative (-)
cable.
6.12.3.2 Disconnect positive (+) cable.
6.12.3.3 Remove clamp and carefully lift
out battery.
6.12.3.4 Replace by connecting positive
cable before negative.
Fig 6.12.2 Battery STC16-23
Battery
cover
Fig 6.12.3 Battery STC19-28
6.13 Bearings and Pivots
50 hours
See section 6.1 for routine lubrication.
250 hours
6.13.1 Check rotating components for
excessive movement and noise in
operation.
6.13.2 Replace as required.
Battery
Fig 6.12.4 Battery STC220
Battery
6.14a Chipper Drive belt tension
50 hours
STC150
6.14a.1 : Check tension. If belts are
slack, adjust at tensioning nuts (fig
6.14a.1).
6.14a.2 To replace belts, slacken off
tensioner pulley and remove belts.
Fig 6.14a.1 Chipper drive belt
tension STC150, STC16-23
Tension nut
©GreenMech Ltd
6-10
05/06
SAFE-Trak
6. MAINTENANCE
6-11
Fig 6.14b.1 Drive Belt Tension
STC220
6.14b Chipper Drive belt tension (cont.)
50 hours
STC220
6.14b.1 Check tension by engaging the
clutch with engine stopped. If belts are
slack, undo tensioning nut (fig 6.14b.1)
sufficiently to transfer engine weight onto
belts. If nut is less than three threads from
end, replace belts.
6.14b.2 STC220: Belt Replacement
6.14b.2.1 Jack up engine cradle to release
tension.
6.14b.2.2 Remove lower belt wrap (fig
6.14b.2).
6.14b.2.3 Remove all belts and replace.
6.14b.2.4 Replace lower belt wrap.
Adjustment
nut
Fig 6.14b.2 Lower Belt Wrap
STC220
Belt Wrap
6.14c STC19-28
Tensioning is automatic and does not
require any routine attention.
Belt Replacement
6.14c.1 Screw special bar through side of
machine (fig 6.14) to engage idler pulley
bracket.
6.14c.2 Continue to screw to push back
bracket against spring force until the belts
are sufficiently slack to remove.
6.14c.3 Remove all belts and discard.
6.14c.4 Fit new set of belts ensuring they
lay snugly in grooves of all three pulleys.
6 14c.5 Carefully unscrew bar and stow.
6.14c.6 Check alignment and tension
before starting chipper.
Fig 6.14c Belt tension release
bar STC19-28
Belt bar
©GreenMech Ltd
6-11
05/06
SAFE-Trak
6. MAINTENANCE
6-12
6.15 Track pump drive belts
50 hours
STC150 and STC220
6.15.1a Check tension. If belts are slack
tighten using adjuster bolt accessed from
underneath machine. (fig 6.15.1a)
STC16-23 and STC19-28
6.15.1b Check tension. If belts are slack,
tighten using adjuster bolt. (fig 6.15.1b)
Note: Spare belts may have been fitted
over pump to reduce delay in emergency
replacement.
Fig 6.15 1a Track Pump Drive
Belts STC150 and STC220
Adjuster
bolt
6.16 Hydraulic connections
50 hours then 250 hours
6.16.1 With the aid of the circuit diagram
to follow the hose routings, check all hoses
and connections for leaks and damage.
6.16.2 Replace any worn or damaged
hoses with the correct type and length.
6.16.3 Before removal, check routing and
ensure replacement hose is fitted free of
strains, twists or kinks.
Fig 6.15.1b Track Pump Drive Belts
STC16-23 and STC19-28
Adjuster
bolts
CAUTION! Ensure any residual
pressure is released before dismantling.
CAUTION! Ensure hoses are refitted
free of twists and kinks.
6.17 Mountings
50 hours then 250 hours
6.17.1 Check that all mounting bolts are
tight.
©GreenMech Ltd
6-12
05/06
SAFE-Trak
6. MAINTENANCE
6-13
6.18a Hydraulic Return Filter
STC150 and STC19-28
(Fig 6.18.1 and fig 16.18.2)
250 hours
6.18a.1 Check oil is cool.
6.18a.2 Unscrew the filter cover (there is a
spring under the cover) and carefully lift out
the element, it may require gentle prising
out, discard safely).
6.18a.3 Fit a new filter element to the
correct specification and replace the cover
and spring.
Fig 6.18.1 Hydraulic Filter STC150
Filter
Fig 6.18.2 Hydraulic filter
STC19-28 (STC16-23 similar)
CAUTION! Do not overtighten.
Filter
6.18b Hydraulic Return Filter (main)
STC220 only.
250 hours & 500 hours
6.18b.1 Check oil is cool.
6.18b.2 With a drip tray underneath,
unscrew the filter element and discard
safely (fig 6.18.3).
6.18b.3 Fit a new filter to the correct
specification.
Fig 6.18.3 Hydraulic Return Filter
STC220(main)
CAUTION! Do not overtighten.
6.19 Hydraulic return filter (track drive)
STC220 only
250 hours & 500 hours
Located beside engine
6.19.1 Check oil is cool.
6.19.2 With a drip tray underneath,
unscrew the filter element and discard
safely (fig 6.19).
6.19.3 Fit a new filter to the correct
specification.
Hydraulic
filter
Fig. 6.19 Hydraulic Filter (Track
drive) STC220 only
CAUTION! Do not overtighten.
Note: There is no separate track drive
filter on STC150 and STC19-28 models
Filter
©GreenMech Ltd
6-13
05/06
SAFE-Trak
6. MAINTENANCE
6.20 Hydraulic Oil change
1000 hours
6.20.1 Remove hydraulic oil with suction
pump at filler, or via drain plug on underside
of tank and replace with new oil of correct
specification.
6.20.2 Replace suction filter.
6.20.3 Dispose of waste oil according to
local authority environmental procedures.
6-14
6.21 Fuses and No Stress system
There are two fuses.
6.21.1 A 40 amp in-line fuse protects the
engine pre-heat and start circuit.
6.21.2 A 20 amp fuse protects the No
Stress system.
Note The engine operating speeds for the
No Stress system are factory set for
particular machine builds and must not be
readjusted.
6.22 Fault finding
Fault
Engine will not start
Engine not at correct speed
No stress light not on
Blade disc will not start
Feed rollers do not turn
Feed will not reverse
Discharge does not flow
Wood unevenly chipped
Machine unsteady
Unusual noise(s)
Track legs do not extend
Tracks do not drive
©GreenMech Ltd
Check
Battery
Fuel
Oil pressure
Thermal cut-out
Fuses
Clutch cut-out
Fuses, cut-outs
Clutch
Drive belts
Chip/Track switch
Control bar
Hydraulics
Control bar
Hydraulic valve
Discharge chute
Blade disc
Blade condition
Track legs
Blade disc and bearings
Chip/Track switch
Chip/Track switch
Pump drive belts
Hydraulics
6-14
Action
Recharge
Fill tank
Check Oil level
Check operation
Check
Check operation
Check operation
Adjust (STC220 only)
Replace
Select 'Chip'
Reset and check
Check solenoid valve
Reset and check
Check operation
Check for blockage
Check for blockage
Replace with sharp
blades
Set to correct position
Check and replace
Select 'Track'
Select 'Track'
Check and adjust
Check operation
05/06
Page
6-10
6-7
6-6
3-2
6-14
5-3
6-14
6-11
6-10
5-3
3-2
3-2
5-1
5-1
6-8
5-2
6-8
5-2
5-2
6-12
SAFE-Trak
6. MAINTENANCE
6-15
6.23 Chipper Disc Re-grinding
6.23.1 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.
6.23.2 Always regrind the worst damaged
disc first, as this will establish the target
weight for the other discs.
6.23.3 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.
6.23.4 Chips may be repaired by grinding a
cutting edge around the damaged area using
a bench grinder.
6.23.5 With chipper disc mounted on a mandrel re-grind remainder of cutting edge at 43º as
shown.
6.23.6 Re-grind in increments of approximately 0.01mm (0.004") until sharp edge is restored.
6.23.7 Re-grinding must not go below 90mm diameter or the disc must be scrapped.
6.23.8 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).
©GreenMech Ltd
6-15
05/06
SAFE-Trak
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 Fold up infeed chute. Note: STC16-23 infeed chute can be removed and stowed
on top of machine to reduce length.
7.2
Removal from Storage
7.2.1 Charge battery and refit
7.2.4 Carry out machine preparation as necessary
©GreenMech Ltd
7-1
Refer to 6.10
Refer to Section 4
05/06
CM220 SAFE-Trak
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. Tracks.
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.
©GreenMech Ltd
8-1
05/06
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.
x
Gloves.
x
Safety Boots with good grip and ankle
support (complying with EN345-1)
It does not cover a combination of machines
working within each other’s risk zones (see
AFAG leaflet 605 Mechanical roadside
processing)
x
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.
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)
2. Each person should carry a personal
first-aid 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.
1. Use the following PPE
x
A Safety Helmet, complying with EN
397, if identified as required in the risk
assessment.
x
Eye Protection (a mesh visor complying
with EN1731 or safety glasses to
EN166)
x
Hearing protection (complying with
EN352) where noise level exceeds 85
dB(A) (see HSE pocket card INDG363
Protect your hearing or lose it!)
Page 1
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).
7. Ensure any lock for the chipping
components has been disengaged;
that additional controls (e.g. barrier tape,
barriers, extra manning) are required.
THE MACHINE
8. Ensure the infeed hopper is clear of any
materials.
9. Noise warning signs are in place.
10. For machines driven by a power take-off
(PTO) shaft, before starting ensure:
x
x
x
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
Page 2
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)
fuelling sites. Maintain a safe distance
from any source of ignition at all times.
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 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.
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.
34. Replace the fuel cap securely.
24. Let material go as soon as it is engaged
in the infeed rollers or chipping
components.
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.
FUELLING
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
Page 3
35. Keep fuel from contacting the skin. If
fuel gets into the eyes wash out with
sterile water immediately and seek
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.
Further reading Continued
Maintenance
41. Knives must be changed or reversed if
damaged or blunt. Knives must be
scrapped when reduced 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.
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.
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
Page 4
Power-fed mobile wood chippers:
Operator protection at infeed chute AIS38
Power take-offs and power take-off
drive shafts
AS24
Risk Assessment
Company Name: GreenMech Ltd
Hazard
ENTANGLEMENT
With cutter in base
of CHIPPER
infeed chute
STABBING AND
PUNCTURE by
projectiles from
cutter. Wood,
stones, nails
rebounding back
out of infeed chute
GreenMech Ltd
Assessment No: G001
A Turner Company
Activity: ChipMaster SAFE-Trak
At Risk
Those likely
to be affected
OPERATOR
Consequence ( C)
Rating
Likely injury
from hazard
FATALITY –
5
LOSS OF LIMB
OPERATOR
Injuries to face,
eyes, head and
hands
3
Likelihood (L)
Of incident
Rating
Risk
Score
VERY LIKELY
5
25
PROBABLE
4
12
Controls
Revised
C
L
Reach area safety
distance to cutter complies
to latest HSE guidelines.
Fix safety stop rail to
upper and side perimeter
on 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
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
Probable
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: …………………………….
Risk Assessment
Company Name: GreenMech Ltd
Hazard
NOISE
Guaranteed sound
pressure level of
Lwa 120dB
VIBRATION –
movement of
machine
STABBING –
PUNCTURE
When operating
handle to raise
engine – residue
from exhaust chute
At Risk
Those likely
to be affected
OPERATOR
THIRD
PARTY
OPERATOR
OPERATOR
GreenMech Ltd
Assessment No: G001-2
A Turner Company
Activity: ChipMaster SAFE-Trak
Consequence ( C)
Rating
Likely injury
from hazard
NOISE
4
INDUCED
HEARING
LOSS
BROKEN OR
3
BRUISED LIMB
EYE INJURIES
CUTS TO FACE
2
Likelihood (L)
Of incident
Rating
Risk
Score
PROBABLE
4
16
POSSIBLE
3
9
POSSIBLE
3
6
THIRD
PARTY
Controls
Revised
C
L
Wear hearing protection to
BE EN 352-3.
Display mandatory ‘wear
hearing protection’ sign
Trained Operator.
Position machine on
sound ground, if on slope
must be across the slope
and less than 35° and no
possibility of land slip.
Cordon off collection point.
Operator to wear head
and face protection
Rating
Rating
4
2
Final
Risk
Score
8
3
2
6
2
1
2
Key:
Consequence
Score
Likelihood
Score
Fatality
Disability
Very serious (broken
limbs)
Important (3 day
accident)
Noticeable (first aid)
5
4
3
Very likely
Probable
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: …………………………….
Risk Assessment
Company Name: GreenMech Ltd
Hazard
ENTANGLEMENT
Branches with
clothing
STABBING AND
PUNCTURE –
Processed green
waste
STABBING AND
PUNCTURE –
Handling branches
A Turner Company
Activity: ChipMaster SAFE-Trak
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
GreenMech Ltd
Assessment No: G001-3
Likelihood (L)
Of incident
Rating
Risk
Score
POSSIBLE
3
15
1
POSSIBLE
3
3
2
QUITE
POSSIBLE
4
8
Controls
Revised
C
L
Rating
Rating
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 off exhaust chute
Cordon off collection point
5
2
Final
Risk
Score
10
1
1
1
Wear hardwearing gloves
with long cuffs that can be
tucked into sleeves.
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
Probable
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: …………………………….
Risk Assessment
Company Name: GreenMech Ltd
Hazard
IMPACT
Being struck by
branch when
feeding green
waste into cutters
CRUSH, IMPACT
Being caught
between tracks
when opening or
closing
MANUAL
HANDLING
Lowering outfeed
chute
GreenMech Ltd
Assessment No: G001-4
A Turner Company
Activity: ChipMaster SAFE-Trak
At Risk
Those likely
to be affected
OPERATOR
Consequence ( C)
Rating
Likely injury
from hazard
BROKEN LIMB
3
BRUISES
OPERATOR
BROKEN LIMB,
BRUISES
THIRD
PARTY
Back problems.
Damaged
tendons,
muscles etc
Likelihood (L)
Of incident
POSSIBLE
3
9
Stand at side of machine.
Trained operator
3
2
Final
Risk
Score
6
3
POSSIBLE
3
9
3
2
6
3
POSSIBLE
3
9
Trained operator. Keep
other persons away from
machine. Out feed chute
must be pointed to rear of
machine
Trained operator. Keep
other persons away from
machine. Out feed chute
must be pointed to rear of
machine.
3
1
3
Rating
Risk
Score
Controls
Revised
C
L
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
Probable
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: …………………………….
Risk Assessment
Company Name: GreenMech Ltd
Hazard
EJECTION,
PENETRATION
Failure of hydraulic
system
FALLING FROM
STAND-ON
PLATFORM
WHEN IN
MOTION
At Risk
Those likely
to be affected
OPERATOR
THIRD
PARTY
OPERATOR
GreenMech Ltd
Assessment No: G001-5
A Turner Company
Activity: ChipMaster SAFE-Trak
Consequence ( C)
Rating
Likely injury
from hazard
Penetration of
3
skin. Bruising.
Face injuries.
Spinal or broken
limb
3
Likelihood (L)
Of incident
Rating
Risk
Score
POSSIBLE
3
9
POSSIBLE
3
9
Controls
Revised
C
L
Trained operator. Cutters
isolated from power
source whilst machine in
motion. Very slow speed.
Plan and inspect safety of
route to work place.
Trained operator. Very
slow speed. Plan and
inspect Safety of route to
work place.
Rating
Rating
3
1
Final
Risk
Score
3
Key:
Consequence
Score
Likelihood
Score
Fatality
Disability
Very serious (broken
limbs)
Important (3 day
accident)
Noticeable (first aid)
5
4
3
Very likely
Probable
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: …………………………….
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
12
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
DISCHARGE
CHUTE
C
C
OPERATORS
CONSOLE
D
D
CHIPPER
CHAMBER
E
E
ROLLERBOX
F
F
INFEED CHUTE
G
G
DOCUMENT
CASE
H
H
J
J
PULLEY GUARD
K
K
BONNET
L
L
M
M
BATTERY BOX
N
HYDRAULIC TANK
N
NEARSIDE TRACK
P
P
FUEL TANK
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
OFFSIDE TRACK
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
13/12/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
OPERATORS PLATFORM
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
TITLE:
SAFETRACK 1928
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
26
24
C
1
23
23
25
E
32
4
24
PROGRAM No:-
A
35
D
23
14
A
2
22
DIMNS IN MM
1ST ANGLE PROJECTION
B
21
3
F
7
G
8
H
11
11
7
J
ITEM
NO. PART NUMBER
1 ST1928-4-1
2 CM170-4-71
3 CM170-4-14A
4 STARLOCK
5 CM170-4-171A
6 91280AT
7 C203120
8 CM170-4-59
9 C170427
10 CM170-4-79
11 91201P
12 C1704101
13 90802
14 60825
15 90801
16 90803
17 C170477
18 CM170-4-78
19 CM170-4-78L
20 91602
21 91601
22 91601T
23 91202
24 81240
25 91201
26 CM170-4-19
27 CM170-4-56
28 910170
29 91001
30 91002
31 ST1928-4-47A
32 C170409
33 C170107
34 C170107/1
35 STC1928129
DESCRIPTION
INFEED CHUTE
REAR FLAP
HINGE PIN
12MM STARLOCK FASTENER
PIVOT BKT ASSY
M12 X 80 L0NG ALLTHREAD
FIBRE FRICTION DISC
CLAMP PLATE
SAFETY BAR
SIDE PLATE
M12 PLAIN NUT
OIL-LITE BUSH
PLAIN WASHER
BUTTON HEAD BOLT
NYLOC NUT
SPRING WASHER
OPERATING ROD
RELEASE HANDLE
RELEASE HANDLE
PLAIN WASHER
NYLOC NUT
HALF NUT
PLAIN WASHER
C/SUNK HEAD SOCKET SCREW
NYLOC NUT
FLAP LATCH
DETENT GUARD
HEX HEAD BOLT
NYLOC NUT
PLAIN WASHER
CABLE BKT
DOCUMENT CASE
OPERATING CABLE
CLEVIS PIN
CURTAIN ASSY
QTY.
1
1
1
1
1
2
4
2
1
2
4
2
8
13
6
2
1
1
1
6
2
2
2
1
1
1
1
1
1
2
1
1
1
2
1
B
C
D
E
F
G
H
J
6
K
K
19
31
L
L
5
17
M
M
15
13
15
14
N
15
N
34
14
33
16
P
P
18
29
Q
30
Q
9
20
30
12
28
21
20
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
20
22
2
3
4
5
6
7
8
9
10
GreenMech
10
11
12
13
DRAWN
SIGNATURE
BGG
DATE
24/03/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
TITLE:
ST1928-4 EXPLODED
VIEW INFEED CHUTE
LTD
Tel 01789 400044
TOLERANCES
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
MOD
1
NAME
APPV'D
R
27
FINISH:
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 2
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
35
B
B
2
1
C
C
D
D
9
E
E
19
10
F
F
31
33
27
G
G
5
H
H
J
J
8
K
K
L
L
M
M
32
N
N
44
3
P
P
9
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
24/03/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
TITLE:
ST1928-4 EXPLODED
VIEW INFEED CHUTE
DWG NO.
SCALE:1:5
A0
SHEET 2 OF 2
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
ITEMS 29 (4 OFF) SHOULD BE FITTED TO
CENTRALIZE THE TOP ROLLER.
THEY CAN BE ALL ON ONE SIDE OR
EITHER SIDE OF THE PIVOT ARM.
CHECK FOR FACTORY FIT BEFORE REMOVING
C
C
1
D
22
25
24
D
23
18
19
29
29
19 11 21
14
E
E
29
29
F
F
15
16
ITEM PART NUMBER
NO.
1 EC1928-3
2 C180109
3 81045
4 91002
5 91001
6 EC1928105
7 81230
8 C170322
17
G
H
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
J
FOR ASSEBLY DETAILS SEE
PIVOT ARM EXPLODE DRAWING
K
13
L
12
11
26
9
27
10
20
M
8
28
DESCRIPTION
QTY.
ROLLERBOX
1
BOTTOM ROLLER
1
BEARING
C/S HD BOLT
4
FLAT WASHER
8
NYLOC NUT
8
BOTTOM ROLLER
1
C/S HD BOLT
1
BOTTOM ROLLER
1
WASHER
BOTTOM ROLLER MOTOR
EC1928-3-11A
1
PLATE
C200207/1
BOTTOM ROLLER MOTOR 2
FLAT WASHER
5
91202
SPRING WASHER
2
91203
71240
CAPSCREW
2
EC1928338
PIVOT ARM PIN
1
FLAT WASHER
1
91602
91603
SPRING WASHER
1
HEX HD BOLT
1
916240
C170345
SLIDE BUSH
3
N91630
NYLON WASHER
6
EC1928-3-28A
PIVOT ARM ASSY
1
91201
NYLOC NUT
3
EC1928-3-15MK2
TOP COVER
1
FLAT WASHER
2
90802
90803
SPRING WASHER
2
HEX HD BOLT
2
90825
HEX HD BOLT
1
91250
C220325
PIVOT ARM STOP BOSS
1
28 C180119
29 EC1928-3-67
N
PIVOT ARM SPRING
1MM SHIM
G
H
J
K
L
M
1
4
N
5
4
P
P
6
7
5
Q
Q
4
3
2
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
10.02.06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
ROLLERBOX EXPLODED
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:5
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
13
12
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
3
4
14
2
C
C
D
D
E
E
4
F
F
12
G
G
8
H
H
J
J
10
9
11
13
K
K
ITEM
NO.
1
2
3
4
L
1
5
M
6
7
5
6
7
8
N
9
10
11
12
13
P
14
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
PART
NUMBER
EC1928-3-28
EC1928113
C180114
GNS502
DESCRIPTION QTY.
PIVOT ARM
1
OILITE BUSH
1
OILITE BUSH
1
GREASE NIPPLE 2
SPHERICAL
EC1928107 ROLLER BEARING 1
EC1928-3-421
END PLATE
1
EC1928-3-422
SHIM
1
INTERNAL
EC1928117
1
CIRCLIP
INTERNAL
C252120
1
CIRCLIP
EXTERNAL
C180351
1
CIRCLIP
SPHERICAL
EC1523200
1
ROLLER BEARING
EC1928104
TOP ROLLER
1
TOP ROLLER
EC1928-3-80
1
SPACER
EC1928-3-36A PIVOT ARM
1
GUARD
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
10.02.06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
N
P
Q
TOLERANCES
MACHINED PARTS - +/- 0.025mm
TITLE:
PIVOT ARM EXPLODED
LTD
Tel 01789 400044
M
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
L
WEIGHT:
DWG NO.
SCALE:1:5
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
13
12
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
9
A
A
B
B
C
C
52
D
D
1
E
E
49
29
F
F
G
G
42
H
44
34
40
H
28
33
53
40
J
51
39
J
K
K
L
L
M
M
24
N
N
24
25
25
P
P
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
7/11/05
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
17
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
TITLE:
LTD
Tel 01789 400044
WEIGHT:
CHIPPER DISC &
DRIVE ASSY
ST1928-2-50A
DWG NO.
SCALE:1:5
SHEET 1 OF 2
A0
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
B
18
1
17
18
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
45
D
E
22
11
28
27
13
3
48
4
2
5
28
11
27
25
6
10
12
24
25
9
11
35
15 1-2BSW
1-2"W X 1/1-2"LONG
3
16 EC1928110
TAPERLOCK PULLEY
1
17
18
19
20
21
22
23
24
ECCENTRIC COLLAR
BEARING
GREASE NIPPLE
GRUBSCREW
PULLEY
SPB DRIVE BELT
TAPERLOCK BUSH
IDLER PULLEY
2
2
3
4
1
3
1
1
DOUBLE ROW AC BALL BEARING
2
TENSIONER ARM
FLAT WASHER
M12 X 35 BOLT
YOKE
TENSIONER EYE
TENSIONER BAR
HALF COIL SPRING
FULL COIL SPRING
TENSIONER CLEVIS
CLEVIS FASTENER
M12 X 70 ALLTHREAD
PART OF ITEM 42
PART OF ITEM 42
PART OF ITEM 42
PART OF ITEM 42
PART OF ITEM 42
SHOCK ABSORBER
1
3
2
1
1
1
1
2
1
1
1
2
2
2
4
4
1
TAPERLOCK BUSH
1
SPA 2 GROOVE PULLEY
V-BELT
CRANK EXTENSION
KEY
OILITE BUSH
1
2
1
1
1
44
45
46
47
48
33
36
33
37
24
PROGRAM No:-
QTY.
1
4
4
4
4
1
1
1
1
1
3
1
1
1
C150206/1
C150206
GNS502
1-2inch
EC1928111
EC1928112
C150208
EC1928643
ST1928-2-28
91202/H
91235
EC1928270
EC1928269
ST1928284
EC1928116
EC1928116
EC1928114
EC1928114
91270AT
91201P
STARLOCK
SNUT
BUSH
CUP
C170632
43 C151003
26
27
M
23
DESCRIPTION
FLYWHEEL FABRICATION
CHIPPING DISC
NYLOC NUT
FLAT WASHER
C/SUNK HD CAPSCREW
SHAFT WASHER
FLYWHEEL CENTRE BEARING
CIRCLIP (INTERNAL)
SPACER SHIM
STUB SHAFT HOUSING
SPRING WASHER
M12 X 50 BOLT
SHAFT KEY
TAPERLOCK BUSH
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
J
K
PART NUMBER
STC1928-2-50B
C202503
91601
91602B
81650
EC1523224
EC1523200
C252120
EC1523248
EC1523231
91203
91250
KS14980
EC1928109
25 C252121
H
7
22
A
17
F
21
DIMNS IN MM
C
8
20
15
14
A
L
19
1ST ANGLE PROJECTION
16
G
18
TC220112
STC1928103
TC220216
KS149104
EC1928108
B
C
D
E
F
G
H
J
K
L
M
46
47
N
N
TORQUE TO
100NM
44
31
43
32
P
P
20
29
42
Q
21
20
TORQUE TO
150NM
41
40
R
23
Q
30
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
2
3
4
5
6
NAME
DRAWN
40
7
SIGNATURE
BGG
DATE
7/11/05
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
41
39
GreenMech
8
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
38
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
DATE
19
MACHINED PARTS - +/- 0.025mm
TITLE:
CHIPPER DISC &
DRIVE EXPLODED
LTD
Tel 01789 400044
TOLERANCES
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
MOD
1
FINISH:
WEIGHT:
ST1928-2-50A
DWG NO.
SCALE:1:5
SHEET 2 OF 2
A0
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
12
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
C
C
17
4
7
2
D
D
16
23
E
E
3
1
7
F
F
6
G
G
H
2
20
5
H
J
J
4
3
K
K
L
L
20
23
M
M
N
N
P
P
FRONT PANEL OF CHIPPER CHAMBER
REMOVED FOR CLARITY
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
28/02/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
TITLE:
SHEARBARS AND
EXHAUST
LTD
Tel 01789 400044
WEIGHT:
DWG NO.
SCALE:1:5
A0
SHEET 1 OF 2
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
1
7
B
B
C
15
9
17
C
16
D
D
9
4
15
E
E
F
F
ITEM
NO.
1
2
3
4
5
6
7
8
G
11
12
3
18
H
9
21
12
J
PART
NUMBER
LOWER CC1
CM220231
EC1928229
EC1928231
C170237
C170233
EC1523231
71230
DESCRIPTION
LOWER CHIPPER CHAMBER
VERTICAL SHEARBAR
LOWER SHEARBAR
TOP SHEARBAR
SHEARBAR LOCK
SHEARBAR CLAMP
FLYWHEEL BEARING HOUSING
CAPSCREW
QTY.
1
1
1
1
1
1
1
2
FLAT WASHER
8
M12 SHAKEPROOF WASHER
2
HEX HEAD BOLT
SPRING WASHER
M10 THIN NUT
HEX HEAD BOLT
SPRING WASHER
HEX HEAD FINE THREAD BOLT
HEX HEAD BOLT
OVAL EXHAUST GASKET
SQUARE EXHAUST GASKET
SILENCER
FLAT WASHER
PLAIN NUT
FLEXIBLE EXHAUST PIPE MT VERSIONS
FLEXIBLE EXHAUST PIPE SAFETRACK VERSION
8
10
1
1
6
2
4
1
3
1
8
2
1
1
91202/C
10 SHW12
22
15
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
17
K
19
2
20
L
23
M
12
90830
90803
91001/T
910100
91203
91240FP
91240
S120020
S120021
EC1523611
90802
90801P
EC1928637
STC1928637
G
H
J
K
L
M
8
21
10
9
N
11
19
19
N
FRONT PANEL OF CHIPPER CHAMBER
REMOVED FOR CLARITY
6
P
P
11
12
24
Q
13
Q
5
14
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
28/02/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
SHEARBARS AND
EXHAUST
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 2 OF 2
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
12
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
C
C
1
D
D
4
9
E
5
6
E
10
F
F
2
G
G
H
H
ITEM
PART
NUMBER
NO.
1 ST1928-1
J
K
11
L
5
DESCRIPTION
QTY.
CHASSIS
1
2
3
4
5
STC1928636
ST1928-6-35
S120021
60825
SILENCER
SUPPORT BKT
GASKET
BUTTON HD BOLT
1
1
4
6
6
7
8
9
10
11
90802
90801
ST1928637
90803
90801P
90835
FLAT WASHER
NYLOC NUT
FLEXIBLE PIPE
SPRING WASHER
PLAIN NUT
HEX HD BOLT
16
2
1
12
12
4
J
K
L
4
M
M
3
4
N
N
9
10
10
6
9
P
P
4
8
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
04/08/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
SAFETRACK EXHAUST
21/7/06 ON
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
13
12
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
44
A
A
43
32
33
26
B
49
47
10
5
7
6
C
29
11
B
30
33
8
C
3
32
9
14
D
D
39
28
2
E
2
28
4
13
F
E
F
G
G
37
38
24
39
H
H
21
42
38
INSIDE TANK
13
J
J
8
3
K
K
9
19
16
21
L
248.5380
15
20
17
0.0000
M
L
24
256.7132
39
2
18
31
M
30
26
N
27
N
25
22
41
23
40
12
25
P
P
28
37
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
28/10/05
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
HYD LAYOUT
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 4
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
44
B
B
43
49
C
C
22
23
39
D
D
21
24
E
E
36
F
32
29
F
28
33
G
G
H
H
35
34
25
J
41
26
12
20
19
13
14
40
J
20
K
17
30
18
27
31
K
2
L
M
L
M
37
38
N
N
P
P
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
28/10/05
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
HYD LAYOUT
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:20
A0
SHEET 2 OF 4
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
52
22
23
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
A
21
44
A
B
B
43
C
C
ITEM
NO.
1
2
3
4
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
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
D
49
33
32
E
53
29
F
30
9
G
28
8
5
H
10
11
47
J
4
K
3
48
15
6
L
12
24
51
50
7
19
16
M
14
48
13
N
PART NUMBER
ST1928-1
C251813
C170112
HP12
HP16
HP15
HP01
HP04
HP05
HP06
HP07
HP28
HP11
HP27
HP21
HP22
HP19
HP20
HP03
HP02
HP17
HP26
HP25
HP18
HP24
HP23
HP13
HP14
C200207/1
C200207/1
HP08
HP09
HP10
27063
27039
27031
ST1928-1-72A1
ST1928-1-73A1
TC220111
STC1928114
ST1928-1-105A
STC1928121
ST1928-1-445
ST1928-111
91002
71020
C251808
TC220103
TC220102
TC220110
TC220217
TC204920
STC1928101
DESCRIPTION
CHASSIS
ROLLER DIRECTIONAL VALVE
ROLLER/RAM PUMP
1/2 R1T ST X 90 400 LONG
1/2 R2T ST X 90 250 LONG
1/2 R2T ST X 90 350 LONG
1/4 R1T ST X 90 550 LONG
1/4 R2T ST X C90 900 LONG
1/4 R2T ST X C90 900 LONG
1/4 R2T ST X C90 1300 LONG
1/4 R2T ST X C90 1300 LONG
3/4 ST HT X 90 HT 540 LONG
1/2 R1T ST X 90 850 LONG
3/4 ST HT X 45 HT 1100 LONG
3/8 R2T ST X ST 1830 LONG
3/8 R2T ST X ST 1830 LONG
3/8 R2T ST X ST 2010 LONG
3/8 R2T ST X ST 2010 LONG
1/4 R1T ST X BANJO 2700 LONG
1/4 R1T ST X BANJO 2050 LONG
1/2 R2T ST X 90 900 LONG
3/4 45 HT 380 LONG
3/4 45 HT 380 LONG
1/2 R2T ST X 90 1250 LONG
2" X 680 LONG
1" 90 HT X ST HT 2000 LONG
1/2 R1T ST X BANJO 1150 LONG
1/2 R2T ST X ST 1500 LONG
TOP ROLLER MOTOR
BOTTOM ROLLER MOTOR
3/8 R2T ST X 90 250 LONG
3/8 R2T ST X 90 1250 LONG
3/8 R2T ST X 90 1300 LONG
HOSE CLIP
HOSE CLIP
HOSE CLIP
COMPLETE O/S TRACK ASSY
COMPLETE N/S TRACK ASSY
TRACK VALVE
RETURN MANIFOLD
SUCTION MANIFOLD
SUCTION FILTER INSIDE TANK
HYD TANK ASSY
RETURN FILTER ASSY
WASHER
CAPSCREW
3/8 SOLENOID (NO STRESS)
RAM VALVE
CLUTCH
1/2 SOLENOID (TRACK/CHIP)
3/8 PRESSURE RELIEF VALVE
BREATHER
TWIN PUMP
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
6
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
D
E
F
G
H
J
K
L
M
N
P
P
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
28/10/05
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
HYD LAYOUT
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:20
A0
SHEET 3 OF 4
1
A
2
3
4
5
6
7
8
DO NOT SCALE - IF IN DOUBT ASK
9
10
11
12
13
15
14
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
16
A
B
B
C
C
RETURN
FILTER
STEEL HYDRAULIC TANK
SUCTION
FILTER
D
D
TOP ROLLER
MOTOR
MANUAL
CONTROL
VALVE
C251813
RELIEF
VALVE
SUCTION MANIFOLD
CONTROL
LEVER
MANIFOLD
FLOW
CONTROL
RETURN
TWIN PUMP
KV2P
14cc/REV
E
E
P
T
BOTTOM ROLLER
MOTOR
F
F
P
P
T
RELIEF
VALVE
CONTROL
LEVER
G
CONTROL
LEVER
RELIEF
VALVE
MANUAL
CONTROL
VALVE
ENGINE
MOUNTED
HYDRAULIC
PUMP
C170112
G
3/8" SOLENOID
VALVE
C251808
RELIEF
VALVE
N/S TRACK
MOTOR
H
O/S TRACK
MOTOR
H
DRAIN
1/2" SOLENOID
VALVE
A
A
B
B
P
T
SOLENOID
CONTROL
VALVE
J
RELIEF
VALVE
J
K
K
HYDRAULIC RAM
HYDRAULIC RAM
L
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH: xxxxxxxxxxx
DATE
NAME SIGNATURE
28/10/05
DRAWN BGG
CHK'D
APPV'D BGG
MATERIAL:
GreenMech Ltd
M
MOD
1
2
3
4
5
6
7
8
MODIFICATION
9
10
DRAWN
11
APPRD
DATE
12
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG Tel 01789 400044
WEIGHT:
DEBUR AND
BREAK SHARP
EDGES
TOLERANCES
MACHINED PARTS +/- 0.025mm
FABRICATED PARTS +/- 1.0mm
TITLE:
HYD LAYOUT SCHEMATIC
DWG NO.
SCALE:1:20
A1
SHEET 4 OF 4
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
ITEM PART NUMBER
NO.
1 ST1928-1
B
16
3
11
C
1
D
14
E
15
14
12
G
17
14
13
18
13
CHASSIS
1
ST1928-1-73A
NEARSIDE TRACK ASSEMBLY
1
3
ST1928-1-72A
OFFSIDE TRACK ASSEBLY
1
4
ST220-1-113
ADJUSTABLE WEAR PAD
4
5
91680
HEX HD BOLT
8
6
ST1928-1-75
TOP CYLINDER FIXING PIN
2
7
ST220-1-170
CYLINDER SPACER
4
8
ST1928-1-36
END COVER
2
9
90603
SPRING WASHER
4
HEX HD BOLT
4
11 ST1928-1-58
INNER LEG ASSEMBLY
2
12 ST1928-1-50
HOSE GUIDE
2
13 91645F
M16 FINE THREAD HEX HD BOLT
4
14 91640F
M16 FINE THREAD HEX HD BOLT
12
15 SH0116
SHAKEPROOF WASHER
16
16 STC1928107
HYDRAULIC CYLINDER
2
17 ST220-1-172
CYLINDER LOWER FIXING PIN
2
8 X 40 ROLLPIN
2
NYLON WEAR PAD
4
18 RP102
H
QTY.
2
10 90620
F
DESCRIPTION
19 ST220102
B
C
D
E
F
G
H
J
J
8
K
K
10
9
L
L
M
M
4
N
7
3
7
6
19
N
5
P
P
Q
Q
2
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
7/12/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
TITLE:
TRACK AND CYLINDER
EXPLODED
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
OPTIONAL EXTRA
B
ITEM
PART NUMBER
NO.
1 EC150018/1
DESCRIPTION
QTY.
12V RELAY
1
2
ST1928128
WINCH SOLENOID
1
3
ST1928127
WINCH ISOLATOR SWITCH
1
B
C
C
D
E
4
ST1928-1-99
WINCH MOUNTING PLATE
1
5
ST1928126-1
GUIDE PLATE
1
6
7
8
ST1928126
91235
91202
ELECTRIC WINCH
HEX HD BOLT
PLAIN WASHER
1
6
8
9
91203
SPRING WASHER
4
NYLOC NUT
HEX HD BOLT
PLAIN WASHER
2
4
4
SPRING WASHER
SENSOR
SENSOR/END CAP
4
2
2
10 91201
11 91030
12 91002
13 91003
14 C200908/1
15 ST1928-1-104
F
D
E
F
G
G
H
H
J
J
K
K
14
L
L
15
3
M
2
1
M
6
N
10
N
8
5
4
P
P
7
Q
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
12
8
7
GreenMech
8
11
MOD
1
2
3
4
5
6
7
8
9
10
11
12
11/12/06
DEBUR AND
BREAK SHARP
EDGES
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TOLERANCES
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
13
9
BGG
DATE
CHK'D
APPV'D
R
SIGNATURE
TITLE:
LTD
Tel 01789 400044
WEIGHT:
WINCH
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
B
C
D
E
DESCRIPTION
1
NYLOC NUT
THROTTLE LEVER
BUTTON HD BOLT
5
1
1
NYLOC NUT
4
PLAIN WASHER
HEX HD BOLT
PLAIN WASHER
HEX HD BOLT
SUMP GUARD
10
6
10
5
1
SPRING WASHER
BATTERY
THROTTLE CABLE
BATTERY COVER
2
1
1
1
15 60616
BUTTON HD BOLT
2
16 EC150006
METALASTIC BUSH
2
SPACER
2
18 91402/P
LARGE PLAIN WASHER
2
19 914110
20 91401
HEX HD BOLT
NYLOC NUT
2
2
PLATFORM
1
PLAIN WASHER
NYLOC NUT
HEX HD BOLT
TREADPLATE
6
2
2
1
PLATFORM STOP
2
91201
ST20004
60820
5
91001
6
7
8
9
10
91002
91030
91202
91240
ST1928-1-35
11
12
13
14
91003
EC1928119
EC1523634/1
ST1928-1-82
17 ST1928-1-126
F
21 ST1928-1-30
G
22
23
24
25
H
91602/B
91601
91655
ST1928-1-77-3
26 ST1928-1-98
J
15
16
17
18
19
20
21
22
23
24
PROGRAM No:-
DIMNS IN MM
QTY.
OPERATOR CONSOLE
2
3
4
14
1ST ANGLE PROJECTION
ITEM
NO. PART NUMBER
1 ST1928-1-113
A
13
12
27 ST1928-1-76
TRANSPORT PIN
1
28 EC150021/1
SPRINGPIN
1
29 C150124
- BATTERY LEAD
1
30 C150123/1
+ BATTERY LEAD
1
A
B
1
C
9
8
D
12
E
3
F
13
G
24
22
22 22 23
4
H
30
29
J
15
28
27
K
K
2 8
L
L
M
M
20
14
N
N
18
17
8
9
P
P
6
10
16 26
19
7
Q
Q
21
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
GreenMech
MOD
2
3
4
5
6
7
8
9
10
11
12/12/06
DEBUR AND
BREAK SHARP
EDGES
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
LTD
Tel 01789 400044
TOLERANCES
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
25
1
BGG
DATE
CHK'D
APPV'D
R
SIGNATURE
TITLE:
FRONT END EXPLODED
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 2
1
2
3
4
5
6
7
8
9
10
11
13
12
DO NOT SCALE - IF IN DOUBT ASK
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
1
ITEM
PART NUMBER
NO.
1 ST1928-1-113
B
C
8
8
D
7
30
32
E
4
3
F
31
7
2
6
G
H
9
2
24
J
33
24
2
4
5
16
15
K
26
14
L
12
26
2
3
4
N91204
91275
91202/N
5
91201
6
ST1928-1-62
7
8
9
ST1928-1-61-1
ST1928-1-127
ST1928-1-54
DESCRIPTION
QTY.
CONSOLE
1
M12 LARGE PLAIN WASHER
HEX HD BOLT
LARGE PLAIN WASHER
4
1
2
NYLOC NUT
1
CONTROL LEVER
2
LEVER ROD
KNOB
TOP LINK BKT
2
3
1
10 ST1928-1-54-1
SPINDLE SUPPORT
1
11 ST1928-1-52-1
FIXING TUBE
3
12 ST1928-1-116
PIVOT TUBE
1
13 ST1928-1-59
60MM BELL CRANK
6
14 ST1928-1-119
PIVOT TUBE
1
15 ST1928-1-120
16 ST1928-1-128
17 ST1928-1-52
PIVOT PIN
SPLIT PIN
NS LINK BKT
1
3
1
18 ST1928-1-53
OS LINK BKT
1
19 ST1928-1-118
PIVOT TUBE
1
20 ST1928-1-60
40MM BELL CRANK
2
21 ST1928-1-117
PIVOT TUBE
1
22 STC1928104
M8 LONG CLEVIS & PIN
12
23 STC1928104
M8 LONG CLEVIS PIN
12
24 ST1928-1-124
25 90801P
26 ST1928-1-123
TOP LINK ROD
PLAIN NUT
CENTRE LINK ROD
2
12
2
27 ST1928-1-122
PIVOT PIN
1
28 ST1928-1-121
PIVOT PIN
1
29 ST1928-1-125
30 ST20004
31 S460714/2
VALVE ROD
THROTTLE LEVER
TRACK-CHIP SWITCH
2
1
1
B
C
D
E
F
G
H
J
K
L
M
M
32 STM10016
TRACK IN-OUT SWITCH L&R
2
COVER
1
33 ST220-1-145
27
N
29
17
22
18
N
P
P
29
23
Q
28
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
21
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
12/12/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
19
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
TITLE:
OPERATOR
CONSOLE
LTD
Tel 01789 400044
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 2 OF 2
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
ITEM
PART NUMBER
NO.
1 ST1928-1-43
B
C
2
2
E
5
F
4
9
QTY.
STEEL FUEL TANK
1
2
3
4
5
ST1928-1-434
HOSE
STC1928120
STC1928122
FILLER NECK
2" HOSE X 500 LONG
63MM HOSE CLIP
CONTENTS GAUGE
1
1
2
1
6
STC1928109
LOCKABLE FILLER CAP
1
7
8
9
10
11
12
13
14
1-4-1-4 BANJO
PIPE
ECM15044/4
1-4-1-4M BANJO
1-4-516 HT
1bw
1-14R
5-16X150
I-4" BANJO X HOSETAIL FITTING
1-4" BLEED PIPE X 1350 LONG
12MM HOSE CLIP
1-4" X 1-4" MM BANJO
1-4" X 5-16" HOSETAIL
1" BONDED WASHER
1" X 1-4" REDUCER
SUCTION PIPE X 150 LONG
1
1
2
1
3
1
1
1
15 1-4-1-4MNN BANJO
1-4" HOLLOW MALE BANJO
1
14MM HOSE CLIP
5-16" SUCTION PIPE X 1000 LONG
4
1
6
D
DESCRIPTION
16 5-15HC
17 PIPE
B
C
D
E
F
8
G
G
FUEL BLEED
FROM ENGINE
7
H
H
3
9
J
J
K
K
17
L
L
13
12
11
11
15
4
M
M
16
N
N
11
16
10
P
P
14
TO FUEL FILTER
ON ENGINE
Q
16
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
12/12/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
TITLE:
SAFETRACK
FUEL TANK
LTD
Tel 01789 400044
MACHINED PARTS - +/- 0.025mm
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
TOLERANCES
WEIGHT:
DWG NO.
SCALE:1:5
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Item No
PT NO.
C200908/1
A
Part No
Material
PT NO.
C200908/1
LEFT
SENSOR
N
RIGHT
SENSOR
N
U
U
SAFETRACK 1928
ISUZU 4LE1
A
B
B
U
PT NO.
EC150018/1
WITH EITHER
U
EHB CONTROLLER
S
DRIVER RELAY
S
OR
RDS CONTROLLER
B
Description
16
DIMENSIONS IN MILLIMETERS
THIS DRAWING IS 1ST ANGLE PROJECTION
DO NOT SCALE - IF IN DOUBT ASK
No Off
15
B
N
PT NO.
STC1928128
N
B
ISOLATOR RELAY
N
R
PT NO.
C251808
PT NO.
SI20032
R
G
THROTTLE
SOLENOID
W
R B
PT NO.
SI20005
NO STRESS
SOLENOID
P
C
R
PT NO.
SI20006
FROM BATTERY
WINCH ISOLATOR
SWITCH
A
M
B
R
ALTERNATOR
STARTER MOTOR
PT NO.
STC1928126
WINCH
U
W
PT NO.
STC1928127
UW
C
NB
N
WR
N
N
W
PT NO.
ELEC17
40A
N
UY
20A
PT NO.
SI20008
PT NO.
ELEC18
HYDRAULIC PUMP CLUTCH
GR
B
FUEL
D
UY
FOR TRACK MOTORS
CONTROL
PT NO.
TC220102
B G
RW
SOLENOID
D
PT NO.
S460714/2
UW
CHIP / TRACK
PT NO.
SI20017
B
B
B
SWITCH
BR
B
FUEL PUMP
B
UB
B
FLOW DIVERTER
SOLENOID
PT NO.
TC220110
ENGINE EARTH
UW
LEFT TRACK
EXTENSION SWITCH
PT NO.
STM10016
LEFT TRACK
OUT SOLENOID
NU
UW
E
E
NG
R
GU
WN
PT NO.
C200206
BONNET
F
GLOW PLUGS
PT NO.
SI20007
ENGINE TEMP
PT NO.
SI20011
OIL PRESSURE
RIGHT TRACK
EXTENSION SWITCH
PT NO.
SI20010
UY
GU
MICROSWITCH
R
UW
UY
N
WR
NB
B
P
G
BR
J
PT NO.
EC1523695
B
H
PT NO.
EC1523696
3
A
1
2
C
G
EHB
BOX
RDS
JUNCTION
BOX
PT NO.
EC1523631
H
D
KEY
SWITCH
F
PT NO.
EC1523697
G
PT NO.
STC1928124
RED
BLACK
GREEN
BROWN
BLUE
YELLOW
PINK
PURPLE
WHITE
ORANGE
GREY
TOLERANCE ON ALL OPEN DIMENSIONS
Issue
Modifications
1
BGG
15/3/07
RDS CONTROLLER ADDED
Date
2
F
RDS
UNIT
MACHINED PARTS +/- 0.25mm
A
RIGHT TRACK
OUT SOLENOID
HARNESS
COLOUR CODE
=
=
=
=
=
=
=
=
=
=
=
WB
E
RW
R
B
G
N
U
Y
K
P
W
O
S
RIGHT TRACK
IN SOLENOID
UW
WN
G
PT NO.
STM10016
WG
R
N/O
LEFT TRACK
IN SOLENOID
3
Sig
FABRICATED PARTS
+/- 1.0mm
Chkd
4
5
6
7
10
11
Designed by
BGG
Checked byApproved
Filename
Date
xxx
xxx
27/04/05
BGG
GreenMech
LTD
The Mill Industrial Park, Kings Coughton
Alcester,Warks
B49 5QG
Phone 01789 400044
12
13
Scale
1/1
H
TITLE ST1928 ELECTRICAL
Issue Sheet
PART NO
A
1 OF 1
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
DO NOT SCALE - IF IN DOUBT ASK
13
14
15
16
17
18
19
20
21
22
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
A
A
B
B
9
C
C
D
D
16
E
E
1
F
F
5
G
G
8
7
6
H
H
14
11
J
13
14
3
J
K
K
L
L
6
M
M
ITEM
PART
NUMBER
NO.
1 EC151011
2 ST1928-1-40A
3 ST1928-1-41AO
4 ST1928-1-41AN
5 ST1928-1-39A
6 60625
7 90602
8 90601
9 EC150012
10 90825
11 90802
12 90801
13 EC130-1-105
14 90801P
16 BIGHEAD RIVET
N
P
Q
DESCRIPTION
QTY.
BONNET MOULDING
SAFETRACK FRONT GRILL
SIDE GRILL OFFSIDE
SIDE GRILL NEARSIDE
BONNET STIFFENER
BUTTON HD BOLT
PLAIN WASHER
NYLOC NUT
BONNET HANDLE
HEX HD BOLT
PLAON WASHER
NYLOC NUT
MICROSWITCH BUTTON
PLAIN NUT
MONEL POP RIVET
1
1
1
1
1
18
18
18
2
4
6
4
1
2
7
4
P
2
Q
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
FINISH:
NAME
DRAWN
SIGNATURE
BGG
DATE
10/4/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
APPV'D
GreenMech
MOD
2
3
4
5
6
7
8
9
10
11
12
13
14
15
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
TITLE:
SAFETRACK BONNET
LTD
Tel 01789 400044
TOLERANCES
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
R
1
N
WEIGHT:
DWG NO.
SCALE:1:5
A0
SHEET 1 OF 1
1
2
3
4
5
6
7
8
9
10
11
DO NOT SCALE - IF IN DOUBT ASK
12
13
14
15
16
17
18
19
20
21
22
7
A
24
PROGRAM No:-
DIMNS IN MM
1ST ANGLE PROJECTION
23
6
A
2
B
B
ITEM
PART NUMBER
NO.
1 CM170-5-1A
2 CM170-5-2A
3 N91204
4 CM170-5-3A
5 910150
6 91002
7 91001
8 CM170-5-4A
9 C180104
10 CM170-5-11
11 C200613
C
D
E
DESCRIPTION
DISCHARGE CHUTE
DISCHARGE FLAP
PLAIN NYLON WASHER
DIRECTIONAL HANDLE
HEX HD BOLT
PLAIN WASHER
NYLOC NUT
FLAP ADJUSTER ROD
TEE HANDLE
CLAMP RING
CLAMP BOLTS
QTY.
1
1
1
1
2
6
3
1
1
1
3
C
3
5
6
7
D
6
E
F
F
G
G
1
H
H
J
J
K
K
L
L
10
M
M
11
6
11
N
N
4
7
6
8
P
P
Q
Q
5
TOLERANCES:
LINEAR: 0.025mm
ANGULAR: 0.25
9
GreenMech
MOD
3
4
5
6
7
8
9
10
11
12
13
14
15
DRAWN
SIGNATURE
BGG
DATE
12/4/06
DEBUR AND
BREAK SHARP
EDGES
CHK'D
MODIFICATION
16
APPRD
DRN
17
18
The Mill Industrial Park
Kings Coughton
Alcester
Warks B49 5QG
DATE
19
MACHINED PARTS - +/- 0.025mm
TITLE:
DISCHARGE CHUTE
EXPLODED
LTD
Tel 01789 400044
TOLERANCES
FABRICATED PARTS - +/- 1.0 mm
BGG
MATERIAL:
6
2
NAME
APPV'D
R
1
FINISH:
WEIGHT:
DWG NO.
SCALE:1:10
A0
SHEET 1 OF 1
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