ECOCOMBI ECM150MT35D Operator`s Manual

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ECOCOMBI
ECM150MT35D
Operator’s Manual
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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.
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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
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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
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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
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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
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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
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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
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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
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.
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 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.
3.4.1.5 To regain forward (Feed In) pull the
control bar away from the chipper. It is not
necessary to use the reset bar.
3.4.1.6 The Shredder control bar operates
in the same way, linked to the chipper
control bar. To restart, follow procedure
3.4.1.2 at the chipper infeed.
Fig 3.4.2 Engine Stop Switch - (start
key)
Key to stop
3.4.2 Engine stop switch
3.4.2.1 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
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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
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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
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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
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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
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06/06
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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
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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.
5.1.6.1 With shredder chute in work
position, raise engine cover. Check
nothing is rotating.
5.1.6.3 Remove the two bolts retaining
chipper disc cover.
5.1.6.4 Fold shredder chute back to
transport position and fit locking pin.
5.1.6.5 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 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.
5.1.6.6 Carefully rotate chipper disc to
check tightness of disc blade bolts and
condition of blades.
5.1.6.7 Remove any loose wood material.
5.1.6.8 If any bolts are loose, refer to
maintenance section for further action.
5.1.6.9 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
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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.
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5-2
06/06
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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
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06/06
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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
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06/06
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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
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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)
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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
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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
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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
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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
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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
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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
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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.
6.15.2.1 Chock machine, release
handbrake and check drawbar is fully
extended.
6.15.2.2 Jack up both wheels and support
on axle stands.
6.15.2.3 Turn brake adjuster clockwise
whilst rotating each wheel forwards until
tight (fig 6.13).
6.15.2.4 Check brake linkage is free from
slack.
6.15.2.5 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
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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
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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
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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
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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
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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
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•
•
•
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.
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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
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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
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2
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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
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Fig 4
8
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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
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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
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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: …………………………….
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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: …………………………….
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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: …………………………….
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