Safe Trak 16-23 Operators' Manual
Contents
1. 5 2 Pull hand throttle lever to increase speed to operating speed 5 3 Stopping Machine 5 3 Tracking TR 5 3 1 Push control bar to STOP position 5 3 2 Push hand throttle to idle and allow LSS SS chipper flywheel to slow down fig 5 3 5 3 3 Press red STOP button to stop throttle engine Ai 5 3 4 Switch ON OFF key to position 0 5 3 5 Wait for chipper disc to stop e N caution Chipper disc will take T several seconds to stop due to its inertia OGreenMech Ltd 5 2 11 12 Safe Trak16 23 Fig 5 4 1 Tracking Controls dt 5 OPERATION 5 3 Motion levers pru o B Pew OGreenMech Ltd Hand throttle 5 3 5 4 Moving the Machine 5 4 1 Attracking controls fig 5 4 1 select Track Centre switch down 5 4 2 Extend legs as required keeping body level fig 5 4 2 5 4 3 Push both levers together to start forward movement 5 4 4 Open hand throttle to increase speed Close to decrease speed 5 4 5 Push left or right lever to steer 5 4 6 At work site adjust legs to level the body and to position infeed chute at 600mm min height 5 4 7 Close hand throttle to slow engine Note When extending or retracting legs it is advisable to track machine CAUTION When extending legs do not force track against solid objects This may dislodge track CAUTION Avoid static turns on hard surfaces This will rapidly wear tracks AN CAUTION Point discharge2. Ltd 6 4 11 12 Safe Trak16 23 Fig 6 7 1 Chipper flywheel cover OGreenMech Ltd 3 s wha s T 1 2 5 4 4 Uu um gt 3 Torque to Tm Q 150Nm 6 5 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 Raise engine cover and check any rotation has stopped 6 7 3 Remove the bolt s retaining chipper flywheel cover fig 6 7 1 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 flywheel and blades 6 7 5 Current best practice is to lock chipper flywheel 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 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 1 101lb ft 6 7 9 Check condition and security of shear bars Rotate or replace if required Do not regrind N 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 e
3. THIRD Face injuries source whilst machine in system PARTY motion Very slow speed Plan and inspect safety of route to work place FALLING FROM OPERATOR Spinal or broken 3 POSSIBLE 3 Trained operator Very STAND ON slow speed Plan and PLATFORM inspect Safety of route to WHEN IN work place MOTION Key rating by the likelihood rating Final revised risk score acceptable to the Disability 4 Probable 4 QJ companyis 10 or less If higher further Very serious broken E e NN LN controls are required limbs Important 3 day Remotely possible Final revised likelihood score must be 2 or accident less Noticeable first aid Improbable 2 4 GreenMech Turner Company WARRANTY POLI CY PERI OD OF WARRANTY All new machinery is supplied with a 2 year warranty from original date of purchase excluding CS100 which has a 1 year warranty from original date of purchase LI MITATI ONS This warranty applies only to manufacturing defect and does not cover repairs or costs due to Normal wear and tear Routine maintenance or adjustment Damage caused by improper handling abuse misuse or neglect Lack of lubrication Overheating due to lack of maintenance Damage due to fittings fasteners becoming loose detached through lack of maintenance Damage caused by cleaning with water Machines serviced or repaired by non authorised GreenMech dealers Machines incorrectly assembled or adjusted Damage cau
4. Those likely injury Rating Of incident Rating C Risk to be affected hazard ati ain Score Stand at side of machine Trained operator OPERATOR BROKEN LIMB BRUISES Trained operator Keep other persons away from OPERATOR BROKEN LIMB BRUISES B B machine Out feed chute must be pointed to rear of closing machine MANUAL THIRD Back problems POSSIBLE Trained operator Keep HANDLING PARTY Damaged other persons away from Lowering outfeed tendons machine Out feed chute chute muscles etc must be pointed to rear of machine Key Consequence Score Likelihood Score To find risk Score multiply consequence rating by the likelihood rating Very likely 5 Final revised risk score acceptable to the Disability Very serious broken limbs Important 3 day accident Noticeable first aid Improbable Probable Possible company is 10 or less 4 controls are required If higher further Final revised likelihood score must be 2 or less Remotely possible P m GreenMech Lt Risk Assessment Company GreenMech Activity ChipMaster SAFE Trak AtRisk Consequence Likelihood L Final Those likely Likely injury Rating Of incident Rating C Risk to be affected from hazard Score EJECTION OPERATOR Penetration of POSSIBLE Trained operator Cutters PENETRATION skin Bruising isolated from power Failure of hydraulic
5. chute away from 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 5 5 Starting the Chipper 5 5 1 At tracking controls select CHIP Centre switch up 5 5 3 Move hand throttle lever to increase speed to operating speed 5 5 4 Pull reset lever to release the control bar for work 5 6 Stopping the Chipper 5 6 1 Push control bar to STOP position 5 6 2 Set hand throttle lever to Idle 5 6 3 Press STOP to stop engine fig 5 2 5 6 4 Switch start key to OFF 5 6 5 Always wait for chipper flywheel to Stop 11 12 Safe Trak16 23 chipper cover GreenMech Ltd iL Feed roller cover 5 OPERATION 5 4 5 5 Blockages CAUTION Beware sharp edges and dust Wear protective gloves and eye shield 5 5 1 Stop engine and REMOVE key to secure place 5 5 2 Open chipper chamber See 5 1 Pre work checks CAUTION Chipped material is inflammable Expect large volume and prevent from falling into engine compartment All material must be removed 5 5 3 Rotate discharge chute to accessible position for cleaning 5 5 4 Clean out discharge chute thoroughly with a suitable rod to pass around bends as necessary 5 5 5 Check if chipper disc is free to rotate Pull top of disc in operating direction of rotation If so proceed to 5 5 11 below CAUTION Beware sh
6. clockwise until valve is closed 5 6 2 Turn knob anticlockwise to the recommended setting in the table 5 7 Operating Hints 5 7 1 Check chip track switch is set to CHIP 5 3 Check disc speed on control unit is 1470rev min minimum or more fig 5 7 NOTE The No Stress system will only allow FEED IN Forwards operation of feed rollers when 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 machine to allow for awkward shapes to KICK when contacting feed rollers 5 7 6 Position end of larger sections of wood inside infeed chute and then support other end whilst pushing the wood into feed rollers CAUTION Do not release discharge chute clamps when chipping is in progress Elevation of the discharge is altered by means of adjustable flap fig 4 3 CAUTION Keep working area around machine clear at all times and check only authorised personnel are present 11 12 Safe Trak16 23 5 OPERATION 5 6 5 8 On Completion Of Work 5 8 1 Check that engine has stopped and chipper disc is stationary 5 8 2 surplus material from infeed chute and machine surfaces 5 8 4 Set discharge flap into lowest position and tighten clamp Fig 5 2 1 b RDS control box 5 8 5 Release clamps turn discharge STC16 23 chute away from tracking controls tighten clamps CAUTION Do not leave m
7. four wheel drive emergency service vehicles In urban areas street names are essential Know the location details before they are needed in an emergency OPERATION 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 Set the engine speed and set the stress control if fitted to obtain optimum performance Check that material to be chipped 1 free from stones metal and foreign objects Stand to one side of the infeed rollers to avoid being hit by ejected material Let material go as soon as it is engaged in the infeed rollers or chipping components Page 2 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 27 28 29 30 31 32 Ji 34 35 36 Do not put any part of your body including hands or feet into the infeed hopper while the machine 1 running Always follow the manufactures instructions for dealing with blockages on the machine Keep the area of ground in front of the infeed hopper free from debris to prevent any tripping hazard Remove the engine start key when the machine 15 left unattended or when undertaking any maintenance FUELLING Stop engine and if necessary allow the machine to cool before refuelling Petrol vapour is invisible and can flow considerable distances from spillage or fu
8. out towards the operator Bar will return to Feed In when released CAUTION Regularly check that control 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 Engine Stop 3 4 2 1 Press STOP button and wait for engine to stop or turn key to OFF fig3 4 2 3 4 2 2 To disable machine remove key CAUTION Do not restart engine until hazard has been removed CAUTION Chipper flywheel may take several minutes to stop due to its inertia 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 engine oil pump There is a manual override to enable starting Refer to GreenMech in an emergency 3 5 3 Engine cover opening is protected by microswitch to shut off fuel solenoid 11 12 Safe Trak 16 23 Fig 3 7 1 Tracking controls Throttle B gt om d owitches Centre Chip track Outer Legs OGreenMech Ltd 3 SAFETY 3 3 3 3 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 3 7 Tracking Controls Fig 3 7 1 amp 3 7 2 3 7 1 A two position toggle switch selects either tracking or chipping In track mo
9. 12 Safe Trak 16 23 3 SAFETY 3 6 Safety Information continued Caution Beware of thrown Transport Lock Sound level object hazard Ear defenders must be worn Action Stand to side of infeed Lift Point chute NOT in centre Lock this component before moving machine Maintenance Information Diesel Filler Hydraulic Filler Grease point L OIL Radiator cleaning High temperature grease 40 hours High Temp Grease Check Blow out radiator radiator screen core Operating Information GreenMech Ltd 3 6 11 12 Safe Trak 16 23 3 SAFETY 3 7 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 Green is UP Blue is DOWN Engine throttle slow fast Reset lever Left hand shown Control Bar Left hand shown Pull to reset Push to stop Centre feed in Pull feed out OGreenMech Ltd 3 7 11 12 Safe Trak16 23 4 MACHINE PREPARATION 41 _ Fig 4 3 Discharge Chute Flap Lever OGreenMech Ltd Swivel clamp 4 1 4 1 Initial Fuelling and Parking 4 1 1 Fill fuel tank with diesel See Section 6 4 1 2 Top up hydraulic tank if necessary with correct oil See Section 6 4 1 3 Position machine body level and adjust until infeed chute is
10. ED HEARING NOISE Guaranteed sound pressure level of Lwa 120dB LOSS OPERATOR BROKEN OR POSSIBLE BRUISED LIMB VIBRATION movement of machine STABBING OPERATOR EYE INJURIES PUNCTURE CUTS TO FACE When operating THIRD handle to raise PARTY engine residue from exhaust chute Key Consequence queen qoem Fatality 5 _ 5 Disablty n n 4 Probabe 4 4 Very serious broken 3 Possible 3 limbs Important 3 day LEN Remotely possible accident Noticeable first aid Improbable Scam 2 POSSIBLE 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 Final C Risk i ain Score 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 2 1 2 Operator to wear head and face protection P m GreenMech rt Risk Assessment Company GreenMech Activity ChipMaster SAFE Trak AtRisk Consequence Final Those likely Likely injury rs incident Scam C L Risk to be affected from hazard Rati
11. 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 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 11 12 Safe Trak 16 23 3 SAFETY 3 2 Fig 3 4 1 Control Bar and Reset Lever Control bar Control Bar positions Left hand side STOP FEED IN FEED OUT FEED OUT FEEDIN STOP Right hand side Fig 3 4 2 Chute height Fig 3 4 3 Engine STOP RDS Controller OGreenMech Ltd 3 2 3 4 Safety Controls and Switches 3 4 1 Emergency Stop Control Bar fig 3 4 1 In the event of an emergency push emergency stop bar to STOP feed rollers This will lock in position 3 4 1 1 Once emergency has been rectified carry out the following sequence 3 4 1 2 To restart rollers pull reset lever Control bar will return automatically to Feed In position 3 4 1 3 Should stop bar be tripped accidentally in normal working conditions i e NOT an emergency then rollers can be recovered by performing above sequence 3 4 1 4 To reverse Feed rollers pull control bar
12. OVING THE MACHINE Stop the engine and remove the start stop key Lock the chipping components Secure the infeed hopper and the chip discharge chute in the transport position Check the towing bracket attach then lift and secure the jockey wheel Connect the electrics and the safety chain s to the towing vehicle Page 3 48 Ensure that the load 1s secure and that people are in a safe position before moving off Further Reading Noise Don t lose your hearing INDG363 rev2 HSE Books 2012 www hse gov uk pubns indg363 htm First aid at work Your questions answered Leaflet INDG2114 rev1 HSE books 2009 www hse gov uk pubns indg214 htm Safety signs and signals The Health and Safety Safety Signs and Signals Regulations 1996 Guidance on Regulations L64 Second edition HSE Books 2009 ISBN 978 0 7176 6359 0 www hse gov uk pubns books 164 htm Power fed mobile wood chippers Operator protection at infeed chutes AIS38 HSE 2013 www hse gov uk pubns ais38 htm Power take offs and power take off drive shafts AIS40 HSE Books2012 www hse gov uk pubns ais40 htm Treework webpages www hse gov uk treework Page 4 Hisk Assessment Company Name GreenMech Ltd Likelihood L AtRisk Consequence Those likely Likely injury Rating Of incident Rating to be affected from hazard ENTANGLEMENT OPERATOR FATALITY Nn I With cutter in base i of CHIPPER 35 find risk Score mu
13. Safe Trak 16 23 1 xy th 6 1 Operators Manual IMPORTANT NOTICE TENSION OF MAIN DRIVE FOR STC16 23M T35 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 Trak16 23 CONTENTS SECTION 1 Introduction and Purpose 2 Technical Specifications Dimensions and Noise Level 3 and Symbols 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 Pre work checks Starting machine Stopping Machine Moving machine Starting Chipper Stopping Chipper Blockages Adjustable Feed roller control Operating Hints 5 10 On Completion of Work 5 11 RDS Control Display 6 Maintenance For Engine and Tracks please refer to separate manuals Routine Maintenance schedule Engine Oil Coolant Hydraulic Oil Fuel level Drive Belts Disc Blades Radiator OGreenMech Ltd 1 11 12 Safe Trak16 23 6 9 7 1 7 2 CONTENTS Steam Cleaning Air Cleaner Electrical Connections Battery Bearings and pivots Chipper Drive belt tension Pump Drive Belts Hydraulic connections Mountings Hydraulic Return Filter Hydraulic Oil change Fuses and No Stress system Fault f
14. achine parked directly up or down slope 5 9 RDS Control Display Control displays chipper speed default feed roller status daily hours total hours and faults Fig 5 2 1 b 5 9 1 Press left hand menu button to scroll through display menu indicated by black triangle over symbol 5 9 2 Reset daily hours Scroll to daily hours pos 5 Press and hold Set Reset 5 9 3 Fault signals Refer to Maintenance section 6 23 CAUTION Bleep sounds Ten regular bleeps indicates engine service due Bleeps at other times may indicate a fault If in doubt consult dealer CAUTION Do not hang other keys with ignition key Weight can stop engine OGreenMech Ltd 5 6 11 12 osafe Trak16 23 6 MAINTENANCE 6 1 ROUTINE MAINTENANCE SCHEDULE AN CAUTION Always remove key and check for rotation before carrying out any maintenance Action Section Page DAILY Check engine oil level and coolant ref engine manual 6 6 4 Check hydraulic oil level 6 4 Check fuel level 6 4 Check all drive belts 6 4 Check condition of disc blades and retaining bolts 6 5 Clean radiator screen and around radiator 6 6 Check feed roller control bar function 3 4 3 2 Check condition of tracks Refer to track manual Check track gear nuts rollers and bearings Hefer to track manual FIRST 50 HOURS Check battery levels 6 12 6 7 Check drive belt tensions 6 14 6 7 6 8 Check hydraulic connections 6 16 6 8 Check all mountings 6 17 6 8 Check feed rolle
15. arp edges of blades and unexpected movement of disc due to resistance of engine If disc does NOT rotate freely proceed as follows 5 5 6 Remove feed roller cover Fig 1 to access chipper blades and shear bar 5 5 7 Carefully remove excess loose material from around chipper disc and note any obstructions 5 5 8 Carefully rotate chipper disc in reverse direction top away from operator by full revolution to release blocked material Use bar against paddle blades for aid 5 5 9 Carefully remove all material checking for obstructions Check rotation of chipper disc 5 5 10 Check condition of blades Note Always attempt to find reason for blockage e g blunt blades slack drive belts 5 5 11 Re assemble all covers with correct fasteners and check for security 5 5 12 Start engine as Operators Manual oection 5 2 and check operation Note If machine will not run repeat process or contact dealer for technical advice 11 12 Safe Trak16 23 5 OPERATION 5 5 Fig 5 6 Feed control location by roller pivot Control knob settings Material Setting upto 120mm Fully open 3 turns 120 150mm 1 2 3 4 turn Fig 5 7 2 RDS Control unit Disc speed p 1470 minimum OGreenMech Ltd 5 5 5 6 Adjustable Speed Feed Roller Control When chipping wood sizes larger than 150mm diameter it is necessary to reduce feed roller speed to suit material being chipped 5 6 1 Turn valve control knob fig 5 6
16. bolt s securely 5 1 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 work area and erect signs and cone off discharge area if necessary 5 1 11 Check ALL safety procedures have been followed CAUTION Beware sharp edges of blades and unexpected movement 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 OGreenMech Ltd 5 1 11 12 Safe Trak16 23 5 OPERATION 5 2 5 2 Starting Machine 5 2 1 Check all other personnel are clear of Fig 5 2 RDS control box machine 5 2 2 Check that feed roller control bar is pushed to the FEED OUT or STOP position to make the machine safe 5 2 3 Turn ignition key to power up Fig 5 2 5 2 4 Optional PIN Code if enabled Otherwise proceed at 5 2 5 Please consult your dealer for instructions to enable or disable PIN according to preference 5 2 4 1 When 0000 appears enter PIN code as below 5 2 4 2 Press and hold left hand menu button until first digit of PIN is displayed 5 2 4 3 Release button and repeat for second and remaining digits until code is entered 5 2 4 4 When code is correct press SET 5 2 5 Wait for the pre heat icon to disappear 5 2 6 Press and hold START button until engine 1 running
17. de No Stress system will not allow feed rollers to operate In chip mode legs cannot be extended and drive to track pumps is disconnected Fig 3 7 2 3 2 Athree position toggle switch controls each extending leg Out to extend In to retract 3 7 3 Lever controls operate drives to tracks Push for forward motion Pull for reverse motion 3 7 4 A hand throttle for engine speed is fitted for use when machine is being tracked and idle to run when chipping Note Chipper flywheel runs whenever engine 1 running CAUTION Take care operating tilt when standing on platform CAUTION When traversing slopes track with legs at least 50 extended whenever possible 11 12 Safe Trak 16 23 3 8 SYMBOLS on the MACHINE 3 SAFETY 3 4 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 Safet Caution Caution Read instruction manual Machine not level incorrect Machine level correct Important Operating Checks Notice Before use carry out daily the stated checks in the order shown see table GreenMech Ltd Every 8 Hours Daily checks 1 Check coolant level 4 Check machine is level 7 Check all guards are in place 10 Pull control bar to work p
18. elling sites Maintain a safe distance from any source of ignition at all times 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 Containers must be clearly labelled and have securely fitting caps Plastic containers must be designed and approved for use with petrol or diesel fuel Replace the fuel cap securely Keep fuel from contacting the skin If fuel gets into the eyes wash out with sterile water immediately and seek medical advise Maintenance Ensure the machine 1s carried out in accordance with the manufacture s handbook 37 38 39 40 41 42 43 44 45 46 47 Check chipping components and knives each day for damage and wear Wear gloves when handling knives Before working on knives confirm that the engine 1 switched off the start key removed and the chipping component is stationary 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 Knives must be changed or reversed if damaged or blunt Knives must be scrapped when worn to the minimum size specified by the manufacturer When new sharpened knives are fitted ensure that there 1s the recommended clearance between the knives and the anvil M
19. es and No Stress system 6 19 1 Remove hydraulic oil with suction pump at filler or via drain plug on underside Ful J of tank and replace with new oil of correct specification 6 19 2 Replace suction filter 6 19 3 Dispose of waste oil according to local authority environmental procedures Note The engine operating speeds for the No otress system are factory set for particular machine builds and must not be readjusted 6 21 Fault finding This machine is fitted with an RDS controller which can display various engine and machine faults Fig 6 23 RDS Engine Control 6 21 1 Engine faults Black arrow at position 1 read out COOL OIL or ALT Check relevant problem e g coolant and rectify as below 6 21 2 To reset read out press and hold SET RESET for 2 An Erone auns seconds Press STOP for 2 seconds Restart engine 6 21 3 If fault still present consult dealer Faut Check_ j Acion Page Engine will not start Battery Recharge 6 7 Thermal cut out Check operation Engine not at correct speed Hand throttle Check operation Engine stops Control display COOL Check level and clean core Engine stops Control display OIL Oil level Check and top up oil Engine stops Control display ALT Alternator belt Check and adjust tension un See engine manual No stress light not on Check operation Blade disc will not start Drive belts ss 7 Feed rollers do not turn Hydraulics Check s
20. hine 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 The company disclaims all liability for the consequences of such use which in addition voids the machine warranty OGreenMech Ltd 1 1 11 12 Safe Trak16 23 2 SPECIFICATIONS 2 1 Fig 2 2 Arborist STC16 23MT35 Safe Trak Discharge Chute Tracking Controls PCR SW Chipper Disc Cover Cover 4 Control Bar i Engine controls mm n UL DE Heset Bar J Feed Roller Pivot 40 Infeed Chute Track Leg Max capacity 150mm x 230mm 6inch x 9inch 1400Kg GreenMech Ltd 2 1 11 12 Safe Trak16 23 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 chi
21. ight of discs within a set must not vary by more than 1gm 0 0302 The weight of each disc must not be less than 560gm 2002 OGreenMech Ltd 6 10 11 12 Safe Trak 7 STORAGE 7 1 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 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 Refer to 6 10 7 2 4 Carry out machine preparation as necessary Refer to Section 4 GreenMech Ltd 7 1 11 12 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 OGreenMech Ltd 8 1 11 12 Safety Guides and Checklist as Transcribed from and Advised by Arborculture amp Forestry Advisory Group and Issued as Leaflet AFA604 rev1 by HSE issued 04 14 INTRODUCTION This leaflet covers the safe working practices to be followed when operating a wood chipper It does not cover a combination of machines wo
22. in correct position 600mm max from ground see fig 3 1 4 2 Infeed Chute 4 2 4 Pull the reset lever to release the control bar for use CAUTION The infeed chute must be positioned correctly above the ground fig 3 1 4 3 Discharge Chute Fig 4 3 4 3 1 Release swivel clamps and point chute in desired direction away from infeed 4 3 2 Set at desired height 4 3 3 Tighten all clamps CAUTION When travelling lock discharge chute pointing away from driver 11 12 Safe Trak16 23 5 OPERATION 5 1 5 1 Pre Work Checks 5 1 1 Check machine is stationary start key removed Fig 5 1 1 Disc Cover 9 1 2 Check that machine is level and infeed chute is correct height 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 two bolt retaining chipper flywheel cover Fig 5 1 1 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 flywheel 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 flywheel cover and tighten
23. inding chart Blade sharpening 7 Storage Storage Removal from storage 8 Disposal 9 Appendix 9 1 Hydraulic Circuit 9 2 Electrical Circuits 9 3 Certificate of Conformity 9 4 Risk Assessment OGreenMech Ltd 11 12 16 23 1 INTRODUCTION amp PURPOSE 11 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 Serial Number Write in the number This manual covers the engine driven self propelled Safe Trak STC16 23 If in doubt always quote the serial number in any communications 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 mac
24. ltiply consequence infeed chute uence Likelihood by the likelihood rating Fatality Very likely Final revised risk score acceptable to the Disability Probable company is 10 or less If higher further a are ue I Remotely possible LOSS OF LIMB STABBING AND PUNCTURE by projectiles from cutter Wood stones nails rebounding back chute OPERATOR Injuries to face eyes head and hands Very serious broken limbs Important 3 day accident Noticeable first aid Improbable rt Final revised likelihood score must be 2 or less Assessment No GOOI Activity ChipMaster SAFE Trak GreenMech L A Turner Company EE Final C Risk ain Score 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 Hisk Assessment Company Name GreenMech Ltd Assessment No G001 2 P m GreenMech rt A Turner Company Activity ChipMaster SAFE Trak AtRisk Likelihood L Those likely Likely injury Rating i incident to be affected from hazard m o B OPERATOR NOISE INDUC
25. nary 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 3 2 5 Operate the machine with untrained personnel or with individuals present who are not involved in the chipping operation OGreenMech Ltd 3 1 3 SAFETY 3 1 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 2 15 Impede or obstruct the Stop control 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
26. ng Score ENTANGLEMENT OPERATOR Drawn into und nbl Wear snug fitting clothes 5 2 10 Branches with cutters No ties scarves etc clothing FATALITY oame controls as for LOSS OF previous hazard of LIMBS entanglement with cutters Wear gloves with long cuffs which can be tucked into sleeves STABBING AND PUNCTURE Processed green waste STABBING AND OPERATOR CUTS TO 2 QUITE 4 Wear hardwearing gloves 2 2 4 PUNCTURE HANDS POSSIBLE with long cuffs that can be Handling branches tucked into sleeves OPERATOR THIRD PARTY EYE INJURIES POSSIBLE Trained operator 1 1 1 CUTS TO FACE Lock off exhaust chute Cordon off collection point Key Consequence Score Score To find risk Score multiply consequence rating by the likelihood rating Fatality 5 Verylikely 5 Final revised risk score acceptable to the 4 Probable 4 company is 10 or less If higher further Very serious broken 3 Possible controls are required limbs Important 3 day Remotely possible Final revised likelihood score must be 2 or accident less Noticeable first aid Improbable Hisk Assessment Company Name GreenMech Ltd IMPACT Being struck by branch when feeding green waste into cutters CRUSH IMPACT Being caught between tracks when opening or GreenMech L A Turner Company Assessment No G001 4 Activity ChipMaster SAFE Trak AtRisk Consequence C Likelihood L BEEN a Final
27. olenoid Feed will not reverse Hydraulic valve operation Discharge does not flow Discharge chute Check for blockage Check for blockage Tracks do not drive Pump drive belts Check andadjust_ 6 8 Hydraulics Check operation OGreenMech Ltd 6 9 11 12 Safe Trak16 23 6 MAINTENANCE 6 10 6 22 Chipper Disc Re grinding RE GRIMD THIS FACE ONLY 6 22 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 FACE A FACE A DO NOT RE GRIND DU RE GRIND DAMAGE MUST NOT BREAK INTO 900 DIAMETER 6 22 2 Always regrind the worst damaged disc first as this will establish the target weight for the other discs dune di ig odor 6 22 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 22 4 Chips may be repaired by grinding a cutting edge around the damaged area using a bench grinder 6 22 5 With chipper disc mounted on a mandrel re grind remainder of cutting edge at 43 as shown 6 22 6 Re grind in increments of approximately 0 01mm 0 004 until sharp edge is restored 6 22 7 Re grinding must not go below 90mm diameter or the disc must be scrapped 6 22 8 After re grinding the we
28. osition 3 4 2 Check engine oil level 5 Check brakes are on 8 Check infeed chute is clear of debris 11 Start engine Do NOT REMOVE KEY start engine ae Beware Beware Brakes trapping off hazard hazard hazard incorrect Wear Wear Brakes helmet amp on visor p clothes correct NENNEN Beware Beware Beware flying flying exposed innl object object drives Caution hazard hazard hazard Position ders and lock Fit all Keep id ay discharge guards nuts tight chute Remove key stop engine 3 Check hydraulic oil level 6 Check chipper disc is clear of debris 9 Lock discharge chute 12 Increase from idle to Run 11 12 Safe Trak 16 23 3 SAFETY 3 5 Important Safety Information Caution Beware Crushing Caution Caution hazard Do NOT drive up or down slopes of more than 25 Do NOT operate or traverse on slopes of more than 35 Do NOT work or park directly up or down slope Caution Beware crushing Caution Beware of thrown Caution hazard object hazard Do not climb into infeed chute Action Do NOT stand in area Action Keep away from fast between machine body and discharge chute tracks Caution Caution Infeed chute trapping hazards Do NOT operate with infeed chute at greater than 600mm Keep hands clear Do not climb in from ground top bar machines OGreenMech Ltd 3 5 11
29. ours 6 15 1 Check tension If belts are slack tighten using adjuster bolt fig 6 15 6 15 2 To replace first remove chipper belts as 6 14 6 15 3 Fit new set of belts ensuring they lay snugly in grooves of all three pulleys 6 15 4 Check alignment and re tension 6 15 5 Replace chipper belts as 16 4 Note Spare belts may have been fitted over pump to reduce delay in emergency replacement 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 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 6 18 Hydraulic Return Filter Fig 6 18 250 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 CAUTION not overtighten 11 12 Safe Trak16 23 6 MAINTENANCE 6 9 6 19 Hydraulic Oil change 1000 hours 6 20 Fus
30. pping 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 single central lifting point by the base of the discharge chute CAUTION Lift with extreme care The machine may tilt because the single lifting point may not be directly over the centre of gravity OGreenMech Ltd 2 2 11 12 Safe Trak 16 23 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 The infeed chute no more than 600mm 23 62 inches above ground level fig 3 1 3 1 7 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 2 NEVER 3 2 1 Work on the machine until the chipper disc is statio
31. quipment 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 22 for disc grinding details 11 12 Safe Trak16 23 6 MAINTENANCE 6 6 Fig 6 8 1 Radiator Screen OGreenMech Ltd hi Screen 6 6 6 8 Radiator Daily 6 8 1 Lift out radiator screen clean and replace fig 6 8 50 hours 6 8 2 Blow radiator core from rear CAUTION A build up of debris risks overheating of the engine and a risk of fire 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 CAUTION Do not steam clean directly on to electrical components e g control boxes 6 10 Air Cleaner 50 hours 6 10 1 Release clips 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 finger tight 6 10 4 Replace cover 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 s
32. r control bar function 3 4 3 2 oervice engine 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 250 hours in addition to Daily and Weekly actions Check condition of bearings and pivots 6 1 6 13 6 3 6 7 Check all fluid levels 6 2 6 3 6 4 6 4 service engine Hefer to engine manual Check track gear units rollers and bearings Refer to track manual Replace return filter element s 6 18 6 8 1000 hours in addition to 250 hour actions Change hydraulic oil when replacing filter element 6 19 6 9 OGreenMech Ltd 6 1 11 12 Safe Trak16 23 6 MAINTENANCE 6 2 DIESEL ENGINE MAINTENANCE REFER TO ENGINE MANUAL TRACK MAINTENANCE REFER TO TRACK MANUAL Recommended lubricants Specification Hydraulic Oil ISO 32 Grease Complex grease EP2 high temperature Engine SAE 15W 40 APICD OGreenMech Ltd 6 2 11 12 Safe Trak16 23 6 MAINTENANCE 6 3 6 1 Lubrication Points see also 6 13 Fig 6 1 1 Lubrication points STC16 23 Rear bearing grease nipple in disc Grease except where stated Track legs 2 nipples each leg 6 1 2 Top Feed roller pivot 1 nipple 6 1 3 Top Feed roller bearing 1 nipple 6 1 4 Chipper Disc bearing
33. rking 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 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 1 Use the following PPE e A Safety Helmet complying with EN 397 if identified as required in the risk assessment e Eye Protection a mesh visor complying with EN1731 or safety glasses to EN166 e Hearing protection complying with EN352 where noise level exceeds 85 dB A see HSE pocket card INDG363 Protect your hearing or lose it e Gloves with long close fitting cuffs that can be tucked into sleeves 9 Safety Boots with good grip and ankle support complying with EN345 1 Non Snag Outer Clothing appropriate to prevailing weather conditions High visibility clothing complying with EN471 should be worn when the risk assessment identifies that it 1s needed 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 Hand cleaning material such a
34. s 1 nipple each bearing Note Rear disc bearing is greased through disc fig 6 1 2 6 1 5 Chipper Disc labyrinth seal 1 nipple 6 1 6 Mechanical reset mechanism Clean and grease 6 1 7 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 OGreenMech Ltd 6 3 11 12 Safe Trak16 23 6 MAINTENANCE 6 4 Fig 6 2 Engine dipstick typical B T v 4 Dipstick EN A Ar Ay a 4127 joi 1 6 2 Engine Oil 6 2 1 Check daily fig 6 2 Refer to engine manual to refill Fig 6 3 Coolant _ 6 3 Coolant P Y 6 3 1 Check daily fig 6 3 Refill as required Check antifreeze CAUTION Do not remove cap when engine is hot 6 4 Hydraulic Oil 6 4 1 Check daily Fig 6 4 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 5 Fuel 6 5 1 Check daily fig 6 5 before work and fill with diesel as required CAUTION Use clean diesel fuel only If in doubt use a funnel with a filter CAUTION Do not use any form of synthetic fuel 6 6 Drive Belts 6 6 1 Check daily before work the condition of all drive belts and replace if worn Note Chipper drive belt must be checked and re tensioned after first 2 3 hours use See section 6 14 GreenMech
35. s waterless skin cleanser or soap water and paper towel should be readily available THE MACHINE Before working with a machine check it has been properly converted from any transport mode Ensure guards for dangerous parts e g belts pulleys shafts etc are secure and undamaged 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 Ensure any lock for the chipping components has been disengaged Ensure the infeed hopper is clear of any materials Ensure Noise warning signs are in place 10 For machines driven by a power take off PTO shaft before starting ensure Page 1 11 l 13 14 15 16 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 ordersee AIS40 Power take offs and power take off drive shafts The PTO speed is suitable for the machine SELECTING THE WORK AREA Select as firm a surface as possible and stabilise the machine Ensure ventilation is adequate and any exhaust fumes are vented into open air 1f working in an enclosed space Where appropriate 1f the chipper is detached from the tow vehicle apply the handbrake and if necessary chock the
36. sed by improper use of the machine 1 ltems considered as consumable parts are not normally covered by the warranty including but not limited to Blade and Blade Assemblies Belts Filters Clutch Assemblies Lubricants Wheels amp Tyres Batteries 12 Consequentialdoss damages or costs 22 du d dim Ens MAI NTENANCE Maintenance carried out during the warranty period should be carried out as per section 6 of the machine owner s manual and by an authorised GreenMech dealer ENGI NES This is covered by the manufacturer of the engine Please refer to the separate warranty conditions as supplied with the owner s manual All warranty repairs must be carried out by an authorised GreenMech dealer except for engines please refer to separate warranty terms supplied with the engine owner s manual GreenMech engineering for a greener environment Turner Engineering Celebrating GreenMech Ltd The Mill Industrial Park Kings Coughton Celebrating Alcester Warwickshire B49 5QG England YEARS _ _ _ YEARS 1993 2013 T 44 01 89 400044 44 011 89 400167 1863 2013 of chippers amp shredders E sales greenmech co uk W www greenmech co uk of innovative engineering Directors AL Turner FIAgrE Chairman JAE Turner BEng Managing GA Tum er Pages Ind Econ Mrs Rodd DA Turner MJ Lucas Sales Company Reg No 2810365
37. tarting 11 12 Safe Trak16 23 6 MAINTENANCE 6 7 6 12 Battery 50 hours fig 6 12 6 12 1 Remove engine cover check electrolyte level and top up if required T CAUTION Gases are explosive Battery Electrolyte is corrosive Avoid sparks and bid spillage 6 12 2 To remove battery remove metal cover fig 6 12 6 12 3 First disconnect negative cable 6 12 4 Disconnect positive cable 6 12 5 Remove clamp and carefully lift out battery 6 12 6 Replace by connecting positive ee eS cable before negative d E gt gt 6 12 7 Replace covers 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 6 14 Chipper Drive belt tension After first 2 3 hours then 50 hours 6 14 1 Check tension If belts are slack adjust at tensioning nuts fig 6 14 1 6 14 2 To replace belts slacken off tensioner pulley and remove belts 6 14 3 Remove all belts and discard 6 14 4 Fit new set of belts ensuring they lay snugly in grooves of all three pulleys 6 14 5 Check alignment and retension before starting chipper OGreenMech Ltd 6 7 11 12 Safe Trak16 23 6 MAINTENANCE 6 8 Fig 6 15 1b Pump Drive Belts iind Bolts TAM m TE exi y f I L3 Tensioner Fig 6 18 Hydraulic Filter GreenMech Ltd 6 8 6 15 Pump drive belts 50 h
38. wheels 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 1 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 Ensure all operations near to highways are adequately signed with the appropriate notices as specified in the Department of Transport s Safety at street works and road works A Code of Practice Ensure that the discharge chute 1s 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 18 19 20 21 22 23 24 Position the chipper so that operators do not have to stand on embankments slopes when feeding material into the machine EMERGENCY PROCEDURES 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 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
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