SAFE-Trak 19-28 Mk2 Operators' Manual
Contents
1. R R 4 70 1290 LONG 1 11 2 1 220102 _____ i3 15161928119 COS ECP 2 HYD TANK ASSY 1 7 RETURN FILTER ASSY ____ uer 200 6 001 7 ROLLER SOLENOID VALV Uc quick release EON 44 571928 MANIFOLD _____ 47 10 APTS 1 1 2 R21 SI Xv0 1290 LONG 1 oY ae Dat 0122 22222200 4 TE 2217 2202 1 NAME SIGNATURE DATE DEBJRAND TOLERANCES TOLERANCES FINISH am DRAWN RVMR EDGES MACHINED PARTS 0 025mm BGG FABRICATED PARTS 1 0mm GreenMech Ltd MATERIAL TITLE Hy dL ay OUT The Mill Industrial Park Inc Emergen um ee Eger cester WEIGHT DWG NO A3 MODIFICATION DRN APPO MK2 511928 Hydraulics 2 3 1 1 SCALE 1 50 SHEET 1 OF 2 DO SCALE REV IF IN DOUBT ASK MODIFICATION DRN APPD DATE 121 1ST ANGLE PROJECTION DIMNS IN MM FINISH NAME NFRUR ANT 110 09 DGES HOG GreenMech Ltd MATERIAL The Mill Industrial Park Kings Coughton Alcester WEIGHT warks 52 Tel 01789 400044 BREAK SHARP PROGRAM No TOLERANCES MACHINED PARTS 0 025mm FABRICATED PARTS 1 0mm TITLE MK2 ST1922. 4 1 3 5 CG _ _ Sum 031 nau 44DA J43S5821v uoiuBnoj 5604 440g 10141 41 68210 euoug 205 45 5 H3dU 119 HD 331953701 pug pa 2 4 JD ro CO gt Wo or ct e E PoC Blitz s uz ENGINE TEMA 5 np izat PPEZZURE SWITCH j re 1 HD C2002 0e BONNET HICPOSWITC t THROTTLE L EH Aq paubisag pul NZNSI 8261 134 5 ZAW WIPJHE JUNCTION XU Hw PDS Box REVERSE 4 v M THPDTTLE FOPWARD SDLENDII 2DLEHDII eom l PT 512003 u E eran esl FUEL r 1 PT HD 5120096 O FUEL UM uy CONTROL SDLEHOII Pu CHIP TRACE SWITCH HYDPAULIC PUMP CLUTCH 5460714 3 FOP TRACK TC22010c 1 IG FLOW DIVEPTEF SIL ei je QUU 200908 1 PT Taggy
3. RIGHT EXTENSION SWITCH LEFT TRACH EXTENSIDN SWITCH ato uw ss un 271001 LEFT PIGHT SOLENOID PIGHT TRACH QUT SDLEHDII LEFT TPAC OUT SULEHUJT LEFT TRACH SOLENDIL TPACK EMERGENCY TRACKING 31925 0 181008 NP 4 BATTERY PT 512000 PT 1120 8 1001 a OF eO NUILO3CDNd 151 ONEAWad SNOISN SAIC PT HD C200908 PELAt PT ND C1 50018 71 PT 3TLJ22uieg PT 190812 wi 40114425 ag 19483108
4. e Hearing protection complying with EN352 where noise level exceeds 85 dB A see HSE pocket card INDG363 Protect your hearing or lose it Page Gloves 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 is 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 as 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 10 1 m 12 13 14 THE MACHINE Ensure the infeed hopper 18 clear of any materials Noise warning signs are in place For machines driven by a power take off PTO shaft before starting ensure The
5. 0 26kg cm OGreenMech Ltd 2 1 12 09 SAFE Trak 19 28 Mk2 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 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 Two lifting point are on each side of machine and tie down anchor points are on each corner of the chassis fig 2 2 Fig 2 on Sides of utellus T 2 lt Lift points Tie down points GreenMech Ltd 2 2 12 09 SAFE Trak 19 28 2 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 Appropriate Personal Protective Equipment PPE is worn including non snag clothing gloves eye and hearing protection 3 1 5 These Wood Chippers are for Off Highways use only 3 1 6 The machine 16 positioned with the body level 3 1 7 The infeed chute bottom
6. 4 01609 1003 22212722 90540 HD BOLT REAR FLAP 15 PART NUMBER DESCRIPTION 1 170 541 2 170 5 2 DISCHARGE FLAP 3 4 170 5 3 2 170 5 4 DISCHARGE CHUTE m T 91 20015 RUBBERRADMOUN 4 STC1928960 s 5 2 4 1 1 1928960 RAD HOSE 5 51 1928959 BOTTOM RAD HOSE 4 TC 1928965 EXPANSION BOTTLE 7 200920 1 CONVOLUTED HOSE 220215 THROTTLE CABLE EC1928103 RUBBER REDUCER a EC1523634 1 11 EX 2 1 203122 0 SPRING INSIDE HOUSING ES simus v 14 120032 THROTTLE SOLENOID 15 200340 2 JUBILEE CLIP 220623 RAD SCREEN 16 17 KUBOTA ENGINE PART NUMBER DESCRIPTION en MK2 ST1928 1 CUTAWAY CHASSIS 2 1928636 SILENCER 1 1 Be 120021 EXHAUST GASKET 4 51192855 SUPPORTBKT Er EB B 2 ES 4 571928638 CLOTH HEAT SHIELD 51 1928639 JUBILEE 2 EXHAUST FLEXI MK2 STC1928 6 25K 10 12 13 200333 EXHAUST WRAP 200340 JUBILEE CLIP ES EXHAUST SYSTEM INSIDE BATTERY BOX f 1 OPTIONAL EXTRA PART NUMBER NO DESCRIPTION 511928 1 99 WINCHPLATEFABR
7. 90830 M8x30bot ___ 22 90803 M8 SPRING WASHER 257 2 1 212720 M12 Boss Insert 26 9290 12 2 27 29104 MI2SHAKEPROOF WASHER MK2 EC 130 2 22 29 910100 set M10 x 100 set 91235CH M12 CAPHEAD x 35 NO 4 Torque to 100 plus locktite CHIPPER CHAMBER SHEARBARS WHERE FITTED 65 Ox TORQUE TO MEM PART NUMBER DESCRIPTION lary BENE 7160 Ml nyocnuf 14 50 oll MI DO 10 HMKZSII92 228 Tensoner amm yong 1 J 2 X 551 91428 Mi folwaner 8 55 1 5 1928961 1 V BEII 155 20 56 Cl3 2 24 FLYWHEEL WASHER 57 1523200 58 539 324 l T O ECAR T 4 13 62 9120245 45 DIA WASHER 3 928116 1 063 6 MK2 130 2 22 65 STC1928911 66 MK2 ST1928 6 46 Blanking plate 2x 35 ____ 2 Yoke bush I 1 29 2 0 1 Tensioner 1 25 9281 16 tullcoil spring 2 24 1928114 long clevis EN 25 91270 x 70 26 91201 2 1272 29 SIC1928957 Crank extension 1 _ 30 X 9 X 104 x ey 31 EC1928
8. confirm that the engine 18 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 1s switched off start key removed and dangerous parts have come to a stand still Maintenance 4 Knives must be changed reversed if damaged or blunt Knives must be scrapped when reduced to the minimum size specified by the manufacturer 42 When new sharpened knives are fitted ensure that there is the recommended clearance between the knives and the anvil MOVING THE MACHINE 43 Stop the engine and remove the start stop key 44 Lock the chipping components 45 Secure the infeed hopper and the chip discharge chute in the transport position 46 Check the towing bracket attach then lift and secure the jockey wheel 47 Connect the electrics and the safety chain s to the towing vehicle 48 Ensure that the load is secure and that people are in a safe position before moving off For further leaflets and reading see HSE web site www hse gov uk Further HSE Reading Mechanical roadside processing AFAG605 Emergency planning AFAG802 Training and certification AFAG805 First aid at work Your questions answered INDG214 Managing health and safety In forestry INDG294 Protect your hearing or lose it INDG363 Page 4 Further reading Continued Power fed mobile woo
9. 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 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 uneven ground tree roots obstructions and type of materials being fed into the machine 3 2 3 Feed from the side 3 3 4 Keep clear of discharge area 3 3 5 Have a second trained operator within easy reach of the machine 3 3 6 Maintain strict discipline at all times 3 3 7 Service machine at specified periods see Section 6 Routine Maintenance 3 3 8 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 9 Adjust legs to keep the body level 3 3 10 Check the route to the worksite for gradients undulations and obstructions 3 3 11 Remove key before doing any maintenance 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 2 Fig 3 4 1 Bottom Control Bar Reset Knob and emergency Stop 3 4 Safety Controls and Switches 3 4 1 Emergency Stop Control Bar fig 3 4 1 Reset knob In the event of an emergency push the both sides emergency stop bar to STO
10. 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 6 16 4 prevent spillage on hose removal close the tank valve fig 4 1 CAUTION Ensure any residual pressure is released before dismantling CAUTION Ensure hoses are refitted free of twists and kinks CAUTION Ensure that hydraulic tank valve Fig 4 1 is set and locked to Open before starting machine Failure to do so will damage components Adjuster bolts 6 17 Mountings 50 hours then 250 hours 6 171 Check that all mounting bolts are tight aL 6 18 6 18 Hydraulic Return Filter Fig 6 18 250 hours 6 18 1 Check oil is cool 29 6 18 2 Unscrew the filter cover there is i Filler filter spring under the cover and carefully lift out the element it may require gentle prising out discard safely see section 8 6 18 3 Fit a new filter element to the correct specification and replace the cover and spring CAUTION Do not overtighten OGreenMech Ltd 6 7 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 8 6 19 Track removal A support leg fig 6 19 enables individual Fig 6 19 Support leg track removal track assemblie
11. 6 12 Check feed roller control bar function 3 4 3 2 service 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 5 6 10 Check all fluid levels 6 2 6 3 6 4 6 6 service engine Refer to engine manual Check track gear units rollers and bearings Refer to track manual Replace return filter element s 6 18 6 19 6 13 1000 hours in addition to 250 hour actions Change hydraulic oil when replacing filter element 6 20 6 14 GreenMech Ltd 6 1 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 2 DIESEL ENGINE MAINTENANCE REFER TO ENGINE MANUAL TRACK MAINTENANCE REFER TO TRACK MANUAL Recommended lubricants Specification Hydraulic ISO 32 Grease Complex grease EP2 high temperature Engine SAE 15W 40 APICD 6 1 Lubrication Points see also 6 13 Fig 6 1 D points SAFE 19 28 Mk2 Toiv Tx 1 28 AY Track legs 2 nipples each leg Top Feed roller pivot 1 nipple Top Feed roller bearing 1 nipple Chipper Disc front bearing 1 nipple Chipper Disc rear b
12. ASSY eB Mi flail washer ela D p CAP HD BOLT 2 FOR ASSEMBLY DETAIL 55 gt SEE PIVOT ARM EXPLODED DRAWING ROLLERS AND ROLLERBOX LEMNO NUMBER 00 ROLLER 3 2123065 CLAMPING BOLT BOTTOM ROLLER PARTNUMBER DESCRPTON 2 ECI928 3 bush 3 Oilite bush __ GREASE NIPPLE __5 CI928340 _ ______ _____ 7 19287 infernal circlip 8 internal circlip 9 External circlip 19283 24 n 928380 Top roller spacer 22212 MK2 EC1928 3 36A pivot arm guard EC1928107 SPHERICAL BEARING 14 EC1523200 SPHERICAL BEARING TOP ROLLER amp PIVOT ARM PART NUMBER DESCRIPTION MK2 ST1928 1 43 Fuel tankl ES 1 2 ST1928 1 44 6 Access plate gasket 1 Diesel filler neck MK2 ST1928 1 200 STC 1928 122 Fuel gauge FITTING 1 4 BANJO 1 4 BLEEDPIPE 1 4 BLEED K2 511928 1 200 2 1 4 1 4 hose FITTING 17 3 4 reducer FITTING 3 8 5 16 HOSE TAIL 5 16 FEEDPIPE SUCTION PIPE FITTING 1 4 1 4 MNN BANJO FITTING 1 4 5 16 HOSE TAIL 5 15 Hose clamp FITTING BONDED WASHER FITTING 3 3 3 8 MM FITTING 3 8 5 16 hose tail PIPE 5 16 Hose 90630 M bolt x 30 1
13. M Front grill 3 Bonnet stiffener 4 90625BH M 6x25 Button head 5 90602 flat washer amp 90801 Nyloc DESCRIPTION NO PART NUMBER 7 50012 BONNETHANDE 90825 90802 M8Hatwaser i0 9 801 M8Nylocnut 11 130 1 105 Micro SwITC 114 0801P M8 plain nut 15 ST1928 1 41 Bonnet side guard BONNET PARTNUMBER DESCRIPTION 1 25119281 113 CONSOLE 1 2 39120238 380dx12 7id x 3 14thk 4 3 91275 2 75 0 1 2 91202152 WASHER 45 DIA 2 221 X 9120 __ 1 6 2511928 1 62 12 7 5119281 127 1 ___ 2 181 519804 LONGCLEVS _ 6 9 LONG CLEVIS PIN INCLUED WITH ABOVE 8 9989 P PLAIN NUT 8 11 2 11928 1 125 VALVEROD 21 12 5204 THROTTLELEVER __ 13 51928976 2 14 QC160 9 1005 ___ I 15236961 ___ 4 51 1928952 TOGGLE SWITCH 2 ST1928 1 53 Centre link bracket STC 192896 160dx12 2id x 17 ST1928 1 122 Linkage pivot ELEC EMERGENCY TRACKING SWITCH 90616BH M xl mmB H 90602 M flatwasher 90603 M6 S WASHER 905208 5 20mm B HEAD 90502 MS WASHER ___ POSOI NYLOC M
14. bolts are loose refer to maintenance section 6 for further action 5 1 6 7 Replace chipper disc cover and tighten bolt s securely 5 1 7 Remove any loose material and dust from radiator and engine bay 5 1 8 Replace engine cover 5 1 9 Check discharge chute is in desired position and all clamps are tight see section 4 3 5 1 10 Check infeed chute fig 4 2 15 locked in position with catch 5 1 11 Check work area and erect signs and cone off discharge area if necessary 5 1 12 Check ALL safety procedures have been followed CAUTION Beware sharp edges of discs 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 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 9 2 59 5 2 1 Key and battery isola Il 1 8 i L V Batterv Isolator Fig 5 2 2 RDS control box OGreenMech Ltd efi 27 5 2 5 2 Starting Machine RDS Control 5 2 1 Check all other personnel are clear of 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 Check that battery isolator fig 5 2 1 is ON 5 2 4 Turn the ignition key to ON position 5 2 5 When 0000 appears enter PIN code at RDS box fig 5 2 2 as below Note This feature may not be enabled Please consu
15. control bar at least 600mm 23 62 inches above ground level fig 3 1 3 1 8 All guards are fitted and in good condition 3 1 9 Blades are in good condition and secure 3 1 10 All blades are sharpened or replaced in Sets 3 1 11 All fasteners are checked regularly for tightness 3 1 12 Only WOODEN materials free of nails etc are fed into the machine 3 1 13 Correct First Aid Kit including large wound dressing is available on site 3 1 14 Fire extinguisher is available on site 3 2 NEVER 3 2 1 Work on the machine until the chipper disc is stationary and engine or PTO has stopped 3 2 2 Operate the machine without protective clothing Eye protection Earmuffs and Gloves or high visibility clothing when working on roadside 3 2 3 Operate with loose articles of clothing including loose cuffs on gloves 3 2 4 Work under a raised component without adequate safety support OGreenMech Ltd 3 1 3 1 3 2 5 Operate the machine with untrained personnel or with individuals present who are not involved in the chipping operation 3 2 6 Leave the machine unattended with engine running at full operating speed See section 4 3 2 7 Put any part of your body into the infeed chute while the machine is running 3 2 8 Operate the machine whilst under the influence of alcohol or drugs 3 2 9 Stand between the tracks and the chipper 3 2 10 Stand within 2 metres of the tracks when the legs are being extended 3 2
16. less Noticeable first aid Improbable Risk 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 1 A Turner Company Assessment 001 4 Activity SAFE Trak AtRisk Consequence C Likelihood L E sm Final Those likely injury Rating Of incident Rating Risk to be affected at 22 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 l GreenMe
17. slopes of more than 25 Caution Beware crushing hazard Action Do NOT stand in area between machine body and tracks Caution Do NOT operate with infeed chute at less than 600mm from ground bottom bar machines GreenMech Ltd Caution Beware Crushing Caution hazard Do NOT work or park Do NOT operate or traverse directly down slope on slopes of more than 35 Caution Beware of thrown object hazard Action Keep away from fast discharge chute Ear defenders must Face shield must be worn be worn Wear ear protectors Wear face shield when operating this machine 3 5 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 6 Safety Information continued Sound level Caution Beware of thrown Transport Lock 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 Caution Caution Infeed chute trapping e r Do not climb into infeed chute Keep hands clear Do not climb in Maintenance Information Radiator cleaning Diesel Filler Grease point SA o DIESEL 40 hours weekly Hydraulic Filler High temperature grease 40 hours __ x 40Hrs HYDRAULIC a lt OIL vi Blow out radiator radiator screen core High Temp SS GreenMech Ltd 3 6 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 7 Operating Information Trac
18. 0 90602 M flat washer 11 1 4 3 90603 6 S WASHER 3511925109 LOCKEABLE CAP 511228207 STEEL FILTER 91651929775 NON RETURN VALVE EN EN EN EN EN EN 21 4 EN BENE ETC Bice EN 5 12 18 14 15 17 18 20 21 22 23 24 25 26 27 28 2 3 3l 32 FUEL INSIDE TANK 10 NO PART NUMBER DESCRIPTION Exploded GTY MK 2STI928 1 44A HYD TANK a ERE STC1928112 TANK GAUGE ER OE 90602 6 flat washer 6 90603 7 M S WASHR 7 90625BH M x25 Button head 8 51 1926967 91 51192811 O 1 4 Extension 1 4 BSP HYDRAULIC TANK 1 2 5 4 4 B NOT SCALE IF IN DOUBT ASK IST ANGLE PROJECTION f sy PART NUMBER DESCRIPTION T O OWN PUMP ASSY ______ s e 7 X 90 ZSO LONG 1 ZN 320 LONG __ __ __ 12 x 32 A HFZU 3 8 9 HPO3 U4 NIIT SEX BANIO 2700 LONG W HPO O IZE RIT ST X BANJO 2050 LONG 1 74 45 ___ 22 45 11 23 A2 A GBU LONG 44 HP23 2 2 ST X BANJO 1150 0404451 1 _ J6 O T 175 62151 1500 LONG 27 C20020 7 IT ROLLER MOTOR 11 28 200207 18 BOOM ROLLER MOTOR 1 9 1 378
19. 108 Oilte bush 32 511928 2 50 FLYWHEEL 36 252120 Internal 35 CRS 18040 6 4 39 511928 2 60 Bearing housing 40 1 10 0209105 0 1 0 75 84 127 4 51 1928262 Sphenal beanng 420 511928 2 61 Bearing clamp 43 TM XB bo 45 71001 P 4 47 30 17 51 32 2 112 ___ T 5 7 EN CHIPPER DISC AND DRIVE i ITEM NO PART NUMBER DESCRIPTION p p T MK2 ROLLERBOX 2 DAOS OR CO csk T 4 19 91009 MIOBWASPER 180 ITEM 24 SHOULD BE FITTED TO Dur eren MO NY Ko ToU oad CENTRALISE THE ROLLER 5 Bottom roller motor pit 1 THEY CAN BE ALL ONE SIDE OR L__6 20007 1 Boltomrolermotor 2 EITHER SIDE OF PIVOT ARM GENE Z8 27 2851 od L8 90 14 18 NN 220 MIZCAPHD 2 REMOVING 10 NEN L 1 1 i803 0 18 1 035 Side bush 139 eee nylon washer 2 18 22 2 2 908 WASHER _ BO PVOTARMSPRNG A gens IMMSHM 2 PIVOT ARM PIVOT ARM
20. 1s fitted with a suitable guard complying with 1152 that encloses the shaft along its full length from tractor to machine The guard 18 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 select as firm a surface as possible and stabilise the machine Ensure ventilation 1s adequate and any exhaust fumes are vented into open air if working in an enclosed space Where appropriate if the chipper 15 detached from the tow vehicle apply the handbrake and if necessary chock the 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 1s prohibited In areas of very high public access a risk assessment may indicate Page 2 19 16 17 18 19 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 DTLR Code of Practice Safety at street works and road works available from The Stationary Office ISBN 0 11 551958 0 Ensure that the discharge chute 1s positioned to prevent chips being blown onto the highway during roadside operations or in any directio
21. 5NYLOCNUT MK2ST1928 1 77A PIVOTUNK MK2ST1928 1 107A ______ 512192950 ROCKER SWITCH 51219295 _____ SIC 19 28953 SEALING HOOD TOGGLE SWITCH 17 00 e 7 e SH CONSOLE 04114 433 9 4014340 261 1 826115 ZAW 4 1 120091 3 961 1 826115 Nid HONAT 5 8 OLW DOTAN 9W Ol 9W HOF 08 x 9Lw LAN DOAN JOYSOM 9 LN yoy og 2 N Co lt T T ES Ls 655 505 6 956826121 8261 LSCAW x e3gwfN 092 34 a gear pv WalOJIV 1d 3W v3 14 4405 PART NUMBER DESCRIPTION 4 MK2 ST1928 2 17 Rear plate 1928 231 shear bar 12 19282279 Lower shear bar 13 200 231 Vertical shear bar 14 170 233 __ Shear bar pocket 15 5 170 2 37 SHEARBARIOCK Thin Nyloc 172 20724822 M12 x 40 fine thread 18 92202 Mlfltwasher 19 9120 MI2S WASHER 20 91240 HEXHEADBOLT 2
22. 8 Hydraulics ST1928 1 73A NEARSIDE TRACK ASSEMBLY 811928 1 72 OFFSIDE TRACK ASSEBLY 4 51220 1 113 ADJUSTABLE WEAR PAD 512201171 TOP CYLINDER FIXING PIN 7 81220170 CYLINDER SPACER ST1928 1 58 INNER LEG ASSEMBLY 2 91645F __ 16 FINE THREAD HEX HD BOLT 91640F MI6FINE THREAD HEX HD BOLT 5 SHAKEPROOF WASHER STC 1928107 HYDRAULIC CYLINDER 15 7 17 2201172 CYLINDER LOWER FIXING RP102 8 X 40 ROLLPIN 51220102 NYLON WEAR PAD HYDRAULIC TRACK AND CYLINDERS MK2ST1928 4 1 INFEED CHUTE ER emna STC1928129 INFEEDRUBBERSCREEN 1 91202 FLAT WASHER EX 812508 C SUNKHDBOL 1 mes i ES 5 2 2 170 4 19 FLAP LATCH 9 12045 STARLOCK WASHER INFEED CHUTE 14 Exploded able ITEM NO PART NUMBER DESCRIFTION 1 25 1928 4 FLAP FABRICATION 2 62903010 3 5161928 48 60 4 5 908505712 M8 allthreadx50 y GU ashe 080IP_ p STC 1928400 M8 SHORT CLEVIS 160 4 17 RearFap 170 4 69 arge Friction Washer 12 2 CM170 4 59 y OU L 91201 51 1928954 1413 SENSUS 15 BENE 33 90825BH ___ 908084227 35 MK2ST1928 4 7 REAR SW COVER p
23. ICATION 1 ea a HOO MK2 QTY rm C a ER ER EE E I A ER EE 10 Eg 8 emon ST1928 1 104 RETUR ICEL HYDRAULIC FILTER OLE TWIN PUMF lohe 2600 rev PUMP XV IP 17cm3 REV H1 DRALL IC RELIEF VALVE HS TRACK DS IRAC SOLENOIL 2 x E E ES CT TT ER gt HYDRAULIC 20 RDLLEF FLOV CONTROL CONTROL LEVEF ROLLER 376 SDLEMIII VALVE 25100 HYDRAULIC SCHEMATIC iugis 12193191 51444 3H H MI 14110 6310 2404 Aq 2 a gt 3unu 3 j 1 5 191913373 826115 _ _ t 1j a 2 1 ES gt a cy Lose PI NU LAT nus 1 Bice pg A
24. If fault still present consult dealer Engine will not start Battery Recharge Thermal cut out Check operation Fuses Check 6 14 Engine not at correct speed Clutch cut out 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 E oee engine manual Blade disc will not start Feed rollers do not turn Hydraulics ________ Check solenoid valve Feed will not reverse Hydraulic valve Check operation Discharge does not flow Discharge chute Check for blockage Check for blockage unevenly chipped _________ Blade condition Replace with sharpblades 6 8 Unusual noise s Blade disc and bearings Check and replace 68 Tracks do not drive Hydraulics Check operation GreenMech Ltd 6 9 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 10 6 23 Chipper Disc Re grinding RE GRIMD THIS FACE ONLY 6 23 1 Examine set of chipper discs for damage If front face A is worn the disc must be scrapped If chips have broken off the cutting edge they can be re dressed provided that they do not go inside the 90mm diameter FACE FACE A DO NOT RE GRIND DU RE GRIND DAMAGE MUST NOT BREAK INTO 900 DIAMETER 6 23 2 Always regrind the worst damaged disc first as this will establish th
25. P the feed rollers 3 4 1 1 Once the emergency has been Idle Run rectified the following sequence should be knob carried out 3 4 1 2 To restart rollers press either reset Control Bar positions knob Viewed towards right of chute 3 4 1 3 Should the stop bar be tripped FEEDIN FEEDOUT STOP accidentally in normal working conditions i e NOT an emergency then the rollers can Viewed towards left of chute STOP FEEDOUT EEEDIN be recovered by performing the above sequence 3 4 1 4 To reverse Feed Out the rollers push the control bar into the middle detent Fig 3 4 2 Engine STOP To regain forward Feed In pull the control RDS Controller _ bar away the chipper It is not tL necessary to use the reset knob CAUTION Regularly check that the bar locates in the correct positions At no time may this system be removed jammed disabled or otherwise impede from effecting the infeed stop control 3 4 2 Engine stop switch Press STOP button fig 3 4 2 and wait for engine to stop before turning key fig 3 4 3 to OFF CAUTION Do not restart engine until hazard has been removed Note Refer to Operation paragraph 5 5 for normal stopping procedure 3 4 3 Battery isolator fig 3 4 3 Turn switch to OFF OGreenMech Ltd 3 2 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 3 3 5 Control cut outs Cut outs are installed to stop and prevent restarting due to specific events 3 5 1 Engine overheat
26. Radiator 6 8 Radiator Daily 6 8 1 Blow radiator core from front fig 6 8 CAUTION A build up of debris risks overheating of the engine and a risk of fire Blow from roar 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 WG Cov 6 10 1 Release wingnut or clip and eA 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 eet f n A 4 I 4 v f 2 I6 2 D ve 4 6 11 Electrical connections 50 Hours 6 11 1 Check all wiring loom connections are secure CAUTION Poor connections will affect engine security cut outs and may prevent starting GreenMech Ltd 6 5 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 6 Fig 6 12 Battery 6 14 Belt tension release bar Belt bar GreenMech Ltd 6 6 6 12 Battery fig 6 12 50 hours 6 12 1 Turn isolator fig 5 2 1 to OFF 6 12 2 Check electrolyte level and t
27. SAFE Trak 19 28 2 4 Operators Manual SAFE Trak 19 28 Mk2 CONTENTS SECTION 1 Introduction and Purpose 2 Technical Specifications Dimensions and Noise Level 3 and Symbols Ensure B Never 3 3 Always 3 4 Safety controls and switches 3 5 Control cut outs 3 6 Stress system 3 7 Tracking controls 3 8 Symbols 4 Machine Preparation 41 Fuelling and parking 4 2 Infeed chute 4 3 Discharge chute 5 Operation 5 1 Pre work checks 5 2 Starting machine 5 3 Moving machine 54 Starting Chipper 5 5 Stopping Chipper 5 6 Adjustable Feed roller control 5 7 Operating Hints 5 8 On Completion of Work 6 Maintenance For Engine and Tracks please refer to separate manuals 6 1 Routine Maintenance schedule 6 2 Engine Oil 6 3 Coolant 6 4 Hydraulic Oil 6 5 Fuel level 6 6 Drive Belts 6 7 Disc Blades 6 8 Radiator 6 9 Steam Cleaning 6 10 Air Cleaner 6 11 Electrical Connections OGreenMech Ltd 1 12 09 SAFE Trak 19 28 Mk2 CONTENTS 6 12 Battery 6 13 Bearings and pivots 6 14 Chipper Drive belt tension 6 15 Track Pump Drive Belts 6 16 Hydraulic connections 6 17 Mountings 6 18 Hydraulic Return Filter 6 19 Track removal 6 20 Hydraulic Oil change 6 21 Fuses and No Stress system 6 22 Fault finding chart 6 23 Blade sharpening 7 Storage 7 11 Storage 7 2 Removal from storage 8 Disposal 9 Appendix 91 Hydraulic Circuit 9 2 Electrical Circuits 9 3 Certificate of Conformity 9 4 Risk Assessme
28. ch Lt Risk Assessment Company GreenMech Ltd Activity SAFE Trak AtRisk Consequence Likelihood Final Those likely Likely injury Rating Of incident Rating Risk to be affected from hazard _________ 22 Score EJECTION OPERATOR Penetration of POSSIBLE Trained operator Cutters PENETRATION skin Bruising isolated from power Failure of hydraulic 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 ___ company is 10 or less If higher further Very serious broken e controls are required limbs Important 3 day Remotely possible Final revised likelinood score must be 2 or accident less Noticeable first aid Improbable 2 511928 INDEX PAGES BONNET 1 OPERATOR CONSOLE 2 OPERATOR PLATFORM 3 SHEARBARS 4 CHIPPER DISC amp DRIVE 5 ROLLERBOX 6 8 FUEL TANK 9 HYDRAULIC TANK 10 HYDRAULIC LAYOUT 11 13 PAGES INFEED CHUTE 14 15 DISCHARGE CHUTE 16 KUBOTA ENGINE 17 EXHAUST SYSTEM 18 WINCH 19 HYDRAULIC SCHEMATIC 20 ELECTRICAL SCHEMATIC _ ELECTRICAL SCHEMATIC ISUZU 22
29. d chippers Operator protection at infeed chute AIS38 Power take offs and power take off drive shafts AS24 Risk Assessment Company Name GreenMech Ltd Activity SAFE Trak Likelihood L AtRisk 1 Those likely Likely injury Rating Of incident Rating to be affected from hazard ENTANGLEMENT OPERATOR FATALITY With cutter in base of CHIPPER 35 find risk Score multiply 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 Remotely possible 055 STABBING AND PUNCTURE by projectiles from cutter Wood stones nails rebounding back 2 chute OPERATOR Injuries to face eyes head and hands Very serious broken limbs Important 3 day accident Noticeable first aid Improbable Final revised likelihood score must be 2 less Assessment 0001 GreenMech 1 A Turner Company Risk at 22 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 on
30. d chute to transport position using control bar secure with lock and fit locking pin 5 8 4 Set discharge flap into lowest position and tighten clamp 5 8 5 Release clamps turn discharge chute to straight position away from tracking controls tighten clamps CAUTION Do not leave machine parked directly up or down slope 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 9 6 Fig 5 9 RDS control box Idle Fast speed Set GreenMech Ltd 5 6 5 9 RDS Control Display Control displays chipper speed default feed roller status daily hours total hours and faults Fig 5 9 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 02 11 SAFE Trak 19 28 Mk2 Options Winch and Lighting Post S 1 HAULAGE WINCH A winch for haulage is installed under the infeed chute and can be used with chute folded or unfolded Refer to winch instructions for safe use and maintenance LIGHTING POST Tap E eo oe Fig 1 Transport position post stowed Fig 2 Work position post raised Preparation see Figs 1 a
31. e chute 4n away from the driver Over long journeys engage the chipper drive to blow out build up of exhaust gas CAUTION Do not drive directly up slopes exceeding 20 degrees Slopes up to 35 degrees may be traversed with care Fig 5 3 2 Track Legs OGreenMech Ltd 5 3 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 5 4 Fig 5 4 RDS Control unit 5 4 Starting the Chipper display 5 4 1 At tracking controls select CHIP Centre switch up 5 4 3 Press Hare on control unit fig 5 2 2 1470 minimum or yellow button on infeed chute fig 3 4 1 1 to increase speed to operating speed 5 4 4 Push the reset knob to release the control bar for work Fig 3 4 1 5 5 Stopping the Chipper 5 5 1 Push the control bar to STOP position 5 5 2 Set hand throttle lever to Idle 5 5 3 Press SLOW tortoise on control unit and allow chipper disc to slow down 5 5 4 Press STOP to stop the engine fig 5 2 2 5 5 5 Switch start key to OFF to stop the engine Note Use of start key to OFF will require re entry of PIN code if enabled 5 5 6 Always wait for chipper disc to stop Fig 5 6 Adjustable feed roller control 5 6 Adjustable Speed Feed Roller Control When chipping wood sizes larger than 150mm diameter it is necessary to reduce the feed roller soeed to suit the material being chipped The control knob can be carefully accessed from inside the battery cover 5 6 1 Turn the valve control knob fig 5 6 clockwise until valve is clos
32. e target weight for the other discs dune di 6 23 3 If large chips exist over less than 30 of the circumference the disc may be re ground provided the large damaged area is not used for chipping 6 23 4 Chips may be repaired by grinding a cutting edge around the damaged area using a bench grinder 6 23 5 With chipper disc mounted on a mandrel re grind remainder of cutting edge at 43 as shown 6 23 6 in increments of approximately 0 01mm 0 004 until sharp edge is restored 6 23 7 Re grinding must not go below 90mm diameter or the disc must be scrapped 6 23 8 After re grinding the weight of discs within 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 02 11 SAFE Trak 19 28 Mk2 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 7 1 3 Fit replacement parts when available 7 1 4 Remove battery Refer to 6 10 7 1 5 Drain fuel 7 1 6 Fold up infeed chute Note 51 16 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 12 09 SAFE Trak 19 28 2 8 DISPOSAL 8 1 When the machine is finally scrapp
33. eadjust the legs as required CAUTION The infeed chute must be positioned correctly above the ground fig 3 1 CAUTION Before travelling always fold up and secure the infeed chute 4 3 Discharge Chute Fig 4 3 4 3 1 Release the swivel clamps and point the chute in the desired direction always pointing away from the infeed 4 3 2 Setthe at the desired height and tighten the flap lever clamp CAUTION When travelling lock the discharge chute pointing away from the driver Fig 4 3 Discharge chute Flap lever GreenMech Ltd 4 1 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 9 1 Fig 5 1 Chipper Disc Cover GreenMech Ltd 5 1 5 1 Pre Work Checks 5 1 1 Check machine is stationary start key removed 5 1 2 Check that machine 15 level and infeed chute 1 set at correct height fig 3 1 5 1 3 Check engine oil level Refer to engine instruction manual 5 1 4 Check hydraulic oil level See section 6 5 1 5 Check fasteners for tightness and hydraulic connections for leaks 5 1 6 Check condition of disc blades 5 1 6 1 Raise or remove engine cover 5 1 6 2 Remove the bolts retaining chipper disc cover Fig 5 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 disc to check tightness of disc blade bolts and condition of blades 5 1 6 5 Remove any loose wood material 5 1 6 6 If any
34. earing 1 nipple Infeed chute hinges Oil Infeed roller mechanism Clean and grease Bottom Feed roller bearing 1 nipple Note Do not overgrease bearings as damage to seals may occur Note Use high temperature grease on chipper disc bearings GreenMech Ltd 6 2 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 3 Fig 6 2 Engine dipstick 2917 Fig 6 5 Fuel Filler Fuel Filler GreenMech Ltd b Filler filter 6 3 6 2 Engine Oil 6 2 1 Check daily fig 6 2 Refer to engine manual to refill 6 3 Coolant 6 3 1 Check daily both radiator and overflow tank 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 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 See section 6 14 and 6 15 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 4 Fig 6 7 Chipper Disc d GreenMech Ltd 6 4 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 switc
35. ed 5 6 2 Turn the knob anticlockwise to the recommended setting in the table 5 6 3 Close the cover and secure Control knob settings Material Setting upto 150mm Fully open turns 150 250mm 1 210 3 4 turn GreenMech Ltd 5 4 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 9 9 GreenMech Ltd 9 5 5 7 Operating Hints 5 7 1 Check chip track switch is set to CHIP 5 2 Check disc speed on control unit is 1470rev min minimum or more fig 5 4 NOTE No Stress system will only allow FEED IN Forwards operation of the feed rollers when the machine is running at FULL operating speed 5 7 4 Select IDLE to reduce speed from RUN to IDLE whilst further material is collected for chipping 5 7 5 Take care when feeding wood into the machine to allow for awkward shapes to KICK when contacting the feed rollers 5 6 Position the end of larger sections of wood inside the infeed chute and then support the other end whilst pushing the wood into the feed rollers CAUTION Do not release discharge chute clamps when chipping is in progress Elevation of the discharge is altered by means of the adjustable flap fig 4 3 CAUTION Keep working area around the machine clear at all times and check only authorised personnel are present 5 8 On Completion Of Work 5 8 1 Check that engine has stopped and chipper disc is stationary 5 8 2 Remove surplus material from infeed chute and machine surfaces 5 8 3 Fold infee
36. ed the following items should be disposed of only authorised waste disposal facilities Engine oil Hydraulic oil Antifreeze Battery Tracks If in doubt consult the Local Authority environmental department Major non ferrous items such as engine cover and hydraulic hoses may also be disposed of separately GreenMech Ltd 8 1 12 09 Safety Guides and Checklist as Transcribed from and Advised by amp 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 operators must have had appropriate training in how to operate the machine and how to carry out the tasks require see leaflet 805 Training and certification PERSONAL PROTECTIVE EQUIPMENT PPE 1 Use the following PPE Safety Helmet complying with EN 397 if identified as required the risk assessment e Eye Protection a mesh visor complying with EN1731 or safety glasses to EN166
37. gs before using the machine Important Safety symbols Take the correct action shown on the display below the stated hazard see table General Safet Caution Remove ke start engine 5 Caution ae trapping off h incorrect azard Read instruction manual Wear Brakes proper on clothes correct Wear helmet amp visor Wear ear protectors Beware flying object hazard Position and lock discharge chute Beware exposed drives hazard Beware flying object hazard Machine not level incorrect Caution Machine level correct Keep bystanders away Fit all guards Keep nuts tight Important Operating Checks Notice Before use carry out daily the stated checks in the order shown see table Every 8 Hours Daily checks Remove key stop engine GreenMech Ltd 1 Check coolant level 4 Check machine is level 7 Check all guards are in place 10 Pull control bar to work position 3 4 2 Check engine oil level 5 Check brakes are on 8 Check infeed chute is clear of debris 11 Start engine 3 Check hydraulic oil level 6 Check chipper disc is clear of debris 9 Lock discharge chute 12 Increase from Idle to Run 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 5 Important Safety Information Caution Do NOT drive up or down
38. he 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 l GreenMech Lt Risk Assessment Company GreenMech Ltd Activity SAFE Trak AtRisk Consequence Final Those likely Likely injury incident Risk to be affected from hazard Rating Score ENTANGLEMENT OPERATOR Drawn into Wear snug fitting clothes 5 2 10 Branches with cutters No ties scarves etc clothing FATALITY Same 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 115 Final revised risk score acceptable to the Disability 4 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
39. hed off and start key removed 6 7 2 Raise engine cover and check any rotation has stopped 6 7 3 Remove the bolts retaining chipper disc cover fig 5 1 and fig 6 7 CAUTION Take care Blades are extremely sharp CAUTION Beware sharp edges of discs and unexpected movement 6 7 4 Using discharge chute handle as a lever swing back cover on to stop to expose chipper disc and blades 6 7 5 Current best practice 16 to lock chipper disc with timber or similar in desired position when slackening or tightening blade bolts to 150NM 6 7 6 Slacken disc blade retaining bolt remove disc clean mounting face and location 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 CAUTION Disc blades must only be sharpened by grinding the angled back face on a suitable grinder Grinding of the front face will upset the gap which is factory set Do not sharpen with hand held equipment Note If any of the Disc Blades are worn below the flat annular section a complete set should be replaced Inspect condition of nuts and bolts and replace if any signs of wear All blades must be sharpened in sets with equal amounts removed to maintain balance See section 6 23 for disc grinding details 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 5 Fig 6 8
40. il 23 1 i 1 i T i r 4 tr pnr 5 5 zi Tox FALE Fa 5 PT NI FOF TPAD EE a iG 0 16 42 FLOS DIvEFTEF LIMIT mor il w dw PT NG TPAC EATEN FIGHT TRACE Uii 7 7 PIGHT TRAC E Dui 5 na mm Hl m SIC Heo LEFT Ar ESTEN ev LEFT TRACK 1 ooo 5 th te anit TACK i f 00 04 0 1 ee ee 1 BUS 11928955 Pl HU A MATO 1 z oe aaa n e T z 5 119259 4 E B 2 8 74 ipli Das PONS cre m z x
41. ing 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 3 5 3 Engine cover opening is protected by a microswitch to shut off the fuel solenoid 3 6 No Stress system 3 6 1 Speed sensor in alternator disables Fig 3 7 Track Controls feed roller FEED IN mode when engine Track speed is below factory pre set value controls LED light glows Green at normal operating speed Red at overload and idle and Red Flash when start switch turned on 0 3 7 Tracking Controls Fig 3 7 3 7 1 position toggle switch selects either tracking or chipping In track mode 7 the No Stress system will not allow the feed Chip Track rollers to operate In chip mode the legs cannot be extended and the drive to the track pumps 15 disconnected Fig 3 7 3 7 2 A three position switch controls each extending leg Press in desired direction 3 3 Lever controls operate the drives to the tracks Push for forward motion Pull for reverse motion 3 7 4 A hand throttle fig 3 4 2 is fitted for use only when the machine 15 being tracked not when chipping Note The chipper disc runs whenever the engine 15 running GreenMech Ltd 3 3 02 11 SAFE Trak 19 28 Mk2 3 SAFETY 3 4 3 8 SYMBOLS on the MACHINE These relate to operator safety correct use and maintenance of machine Check that all personnel understand and are familiar with meanin
42. k drive and throttle controls Left lever LH track forwards backwards Right lever RH track forwards backwards Lever with red knob Engine throttle slow fast Bottom type Control Bar Left hand shown 8 8 Push to STOP Centre feed out Pull feed GreenMech Ltd 3 Track Chip controls Track legs 200704 82 Outer switches legs extend retract Centre switch Up to chip Down to drive Discharge chute control Green is UP Blue is DOWN Reset lever Left hand shown Pull to reset 02 11 SAFE Trak 19 28 Mk2 4 MACHINE PREPARATION 41 _ Fig 4 1 Hydraulic tank 4 1 Initial Fuelling and Parking Hydraulic 4 1 1 Fill the fuel tank with diesel See tank valve section 6 4 1 2 Top up the hydraulic tank if necessary with the correct oil See Section 6 CAUTION Ensure that hydraulic tank valve Fig 4 1 is set and locked to Open Failure to do so will damage components 4 1 3 Position the machine body level and adjust until the infeed chute is in correct position 600mm min from the ground see fig 3 1 Fig 4 2 Infeed chute catch Catch t t q 4 2 Infeed Chute unfolding Ij 4 2 1 Remove the transport for the infeed chute catch release the catch fig Sh 4 2 4 2 2 Using the tubular edge as a handle lower the infeed chute to the work position and reset the catch 4 2 3 Measure the height of the infeed chute and r
43. lt your dealer for instructions to enable or disable PIN according to preference 5 2 5 1 Press and hold left hand menu button until first digit of PIN is displayed 5 2 5 2 Release button and repeat for second and remaining digits until code is entered 5 2 5 3 When code is correct press SET 5 2 6 Wait for the pre heat icon to disappear 5 2 Press and hold START button until engine 15 running 5 2 8 Increase speed to operating speed by slow fast to FAST hare switch or hand throttle lever if fitted 02 11 SAFE Trak 19 28 Mk2 5 OPERATION 9 3 Fig 5 3 1 Tracking Controls 5 3 Moving the Machine 5 3 1 At tracking controls fig 5 3 1 select Track Centre switch down 5 3 2 Extend legs as required keeping body level fig 5 3 2 5 3 3 Push both levers forwards together to start forward movement 5 3 4 Open hand throttle to increase speed Close to decrease speed Leg Switches 7 5 3 5 Push left right lever to steer Hand 5 3 6 At work site adjust legs to level the body and to position infeed chute at 600mm min height 5 3 7 Close hand throttle to slow engine Note When extending or retracting legs it is advisable to track the machine CAUTION When extending legs do not force track against solid objects This may dislodge track Ww CAUTION Avoid static turns on hard JUR My surfaces This will rapidly wear the tracks 41 CAUTION Point the discharg
44. ly green waste is fed into machine Safety helmet to BSEN 397 Forestry visor Hard wearing gloves Risk Assessment Company Name GreenMech Ltd Assessment No 001 2 Activity SAFE Trak AtRisk 1 Consequence Likelihood L Those likely Likely injury Rating i incident to be affected from hazard m B OPERATOR NOISE INDUCED 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 15 15 4 Probable 42 4 Very serious broken 3 Possible 3 limbs Important 3 day LEN Remotely possible accident Noticeable first aid Improbable 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 m GreenMech A Turner Company Final Risk 22 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 t
45. mation 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 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 09 13 SAFE Trak 19 28 2 2 SPECIFICATIONS 2 1 Fig 2 1 SAFE Trak 19 28 Mk2 IET T Ee zr e 4 au c e A T IA E DIL TR ae 4 nl a a WE jam Discharge Chut yc gm 23 59 7 7 Disc Cover Om eee 2 M T 3i Tracking a i INE n Controls TT o CES Jis 2 7 OMM n T 24 1 s iwi Mee s 1 i Pr 1 T 1 1 B a P 412 10 ge Reset Knob Feed Roller Pivot Track Leg Infeed Chute TECHNICAL SPECIFICATION SAFE Trak 19 28MT50 Mk1 1320mm Weight 2000Kg
46. n where they can affect colleagues or members of the public 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 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 m 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 Set the engine speed to obtain optimum performance Check that material to be chipped 18 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 Use a push stick at least 1 5 metre long for both short produce and for the last piece of produce
47. nd 2 1 1 Remove pin from support above engine cover 1 2 Using winch partially raise post to enable extension to clear control levers 1 3 Remove extension and extend post to full length 5 holes exposed Fig 2 taking care of cable and re insert pin to secure 1 4 Using winch Fig 3 raise post to vertical and secure upright with pin 1 5 completion of work reverse procedure and secure with all pins for transport Fig 1 Operation Turn switch on Fig 4 Fig 3 Lighting post installation Fig 4 Lighting post pins Maintenance Refer to component suppliers instructions GreenMech Ltd S 1 09 13 5 19 28 2 6 6 1 ROUTINE MAINTENANCE SCHEDULE CAUTION Always remove key and check for rotation before carrying out any maintenance All covers except engine cover are secured closed with bolts requiring a spanner Action Section Page 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 3 4 3 2 Check condition of tracks Refer to track manual Check track gear nuts rollers and bearings Refer to track manual FIRST 50 HOURS Check battery levels 6 12 6 10 Check drive belt tensions 6 14 6 10 6 11 Check hydraulic connections 6 16 6 12 Check all mountings 6 17
48. nt GreenMech Ltd 2 12 09 SAFE Trak 19 28 2 1 INTRODUCTION AND PURPOSE 1 1 INTRODUCTION This manual explains the proper operation of your machine Read these instructions thoroughly before operating and maintaining the machine Failure to do so could result in personal injury or equipment damage Consult your GreenMech supplier if you do not understand the instructions in this manual CAUTION This symbol indicates important safety messages in this manual When you see this symbol be alert to the possibility of injury to yourself or others and carefully read the message that follows We recommend that you keep this manual with the machine in the box provided Note here the serial number and quote it in any communications This is important when ordering spares Remember to include all numbers and letters Serial Serial Write in the number B Number This manual covers the following engine driven self propelled SAFE Trak models SAFE Trak 19 28 Mark2 Optional winch and optional Lighting post see supplement sheet for instructions 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 machine in your possession please contact your GreenMech dealer for up to date infor
49. op up if required 6 12 2 Turn isolator to ON CAUTION Gases are explosive Electrolyte is corrosive Avoid sparks and Spillage 6 12 3 Removal of battery 6 12 3 1 First disconnect negative cable 6 12 3 2 Disconnect positive cable 6 12 3 3 Remove clamp and carefully lift battery 6 12 3 4 Replace by connecting positive cable before negative 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 Tensioning is automatic and does not require any routine attention Belt Replacement 6 14 1 Screw special bar through side of machine fig 6 14 to engage idler pulley bracket 6 14 2 Continue to screw to push back bracket against spring force until the belts are sufficiently slack to remove 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 614 5 Carefully unscrew bar and stow 6 14 6 Check alignment and tension before starting chipper 02 11 SAFE Trak 19 28 2 6 MAINTENANCE 6 7 6 15 Track pump drive belts 50 hours 6 15 1 Check tension If belts are slack tighten using adjuster bolt fig 6 15 1 Fig 6 15 1 Track Pump Drive Belts Note Spare belts may have been fitted over pump to reduce delay in emergency replacement 6 16 Hydraulic connections
50. s to be removed for servicing 6 19 1 Extend both track legs 6 19 2 Remove foot from parked position and fit to base of support leg 6 19 3 Remove pin and reposition leg on side to be removed with foot on firm ground side 6 19 4 Carefully retract track leg until clear of ground to remove 6 19 5 Refer to track manual for servicing Leg each 6 20 Hydraulic Oil change 1000 hours 6 20 1 Remove hydraulic oil with suction pump at filler or via drain plug on underside of tank and replace with new oil of correct specification 6 20 2 Replace suction filter 6 20 3 Dispose of waste oil according to local authority environmental procedures 6 21 Fuses and No Stress system There are two fuses 6 21 1 A 40 amp in line fuse protects the engine pre heat and start circuit 6 21 2 A20 amp fuse protects the No Stress system Note The engine operating speeds for the No Stress system are factory set for particular machine builds and must not be readjusted GreenMech Ltd 6 8 02 11 SAFE Trak 19 28 Mk2 6 MAINTENANCE 6 9 6 22 Fault finding This machine 1 fitted with an RDS controller which can display various engine and machine faults Fig 6 23 RDS Engine Control 6 22 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 22 2 To reset read out press and hold SET RESET for 2 seconds Press STOP for 2 seconds Restart engine 6 22 3
51. to be chipped Do not put any part of your body including hands or feet into the infeed hopper while the machine is 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 is 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 Page 3 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 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 Maintenance 36 Ensure the machine 15 carried out accordance with the manufacture handbook 37 Check chipping components and knives each day for damage and wear 38 Wear gloves when handling knives 39 Before working on knives
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