420Chipper - Gearmore, Inc.
Contents
1. GEARMORE INC WOOD CHIPPER Operation Service amp Parts Manual For Model 420 June 2008 Form 420Chipper indd TABLE OF CONTENTS PAGE General Information ANNE 1 2 PEE i 2 EE 2 SL 3 4 Technical PER NCS EE 5 E ann elle 6 Main 6 Identification EE 0 e EE 7 9 MONA i Krier EE 7 Safety in the 07 1806 O perator s REQUIFTEMENTS tree ee ENN 1 G eneral Sal 8 10 iii 11 12 Attachment to ETICO Ri 11 Driveline 0 12 3 1 0101418 U EPTO RO COCO PRES RCA 12 FOIS 13 Transport Eege 13 Modica 14 9 Maintenance 59006116 14 18 110 6 51 OTE e 1 15 EI 10 17 Belt LEE ME ee 18 Spare Parts ONE Lari 18 Torque Specifications 0000000 19 110115165100 MD EE 19 P P 8608 20 24 Chipper 7880010 20 22 Driveline Breakdowmn ENEE 23 4 EROI 25 GENERAL INFORMATION Dealer Stamp No part of this manual shall be reproduced copied or disseminated by any means without Gearmore s prior authorization in writing Gearmore reserves2. The operating times indicated in this manual have just an informative character and are referred to nor mal conditions of use they can thus undergo variations according to the type of service to the more or less dusty environment to seasonal factors etc MAINTENANCE SCHEDULE Every 10 Hours oF WORK At the end of every working day it is advisable that you clean accurately the machine so that its parts are always in good working condition Grease crosses on the PTO shaft Make a general inspection to verify possible hydraulic oil leaks or the presence of damaged parts when it applies Make sure the knives are in good condition sharpened and perfectly fixed by the tightening bolts Every 25 Hours oF WORK Grease the driveshaft crosses through the special lubricating zerks Grease the transmission shaft through the proper lubricating zerks Every 50 Hours Work Check to make sure that the belts are tightened Check that all bolts and nuts are correctly tightened MAINTENANCE INTERVENTIONS Before executing maintenance activities on the machine stop engine disengage PTO pull parking brake and place the equipment on the ground in horizontal position 14 MAINTENANCE Before injecting lubricating grease into the zerks clean them accurately to prevent mud dust or other foreign matters from mixing with the grease thus diminishing the lubrication effect GREASING Lubricate the machine regul
3. Stop Nut UNI 7473 M12 Nut UNI 5587 M10 screw M10 L 96 Belt Tensioner Spring Screw UNI 5739 M14 x 70 8 8 21 67210957 6363560 9642901 34106014 34120014 2020040 2002906 31514050 6384065 2402900 6330655 34129012 9892900 9932900 31508030 0812900 34120008 34121008 31508016 2002908 34108008 0132916 33108020 6320020 2226204 9782901 9002907 3132917 31508020 6363580 0642900 9302901 2020035 31512040 6350010 9302900 34120022 34106022 4301589 6351004 9002905 34106012 34100010 33710096 9215701 31514070 3 N Garman N N FFF PARTS LIST PART NO DESCRIPTION Screw M12 x 40 UNI 5931 8 Bearing UCFL Support Bearing UCFL Shield AX4 480 733 1024010 1504260 CP SS Stop Nut M10 DIN 985 6 Deflector Tie Rod D eflector D eflector Adjusting Lever Exit Chute Knob M10 X 20 Grease Nipple M10 x 1 5 UNI 7663 A Washer UNI 6592 M10 Screw UNI 5739 M10 x 35 8 8 Washer UNI 6592 M16 Bushing Stop Nut UNI 7473 M10 Bushing Screw UNI 5739 M10 x 30 8 Chipper Cover Screw UNI 5739 M10 x 25 8 Shaft Shield Circlip External 135 DIN 471 Screw UNI 5739 M14 x 45 8 Screw UNI 5739 M14 x 55 8 Chipper Box Screw UNI 5933 M12 x 35 8 8 Screw UNI 5739 M12 x 30 8 8 Screw UNI 5739 M12 x 35 8 8 Washer UNI 6592 M12 Chipper Support Washer UNI 1751 M12 Knocker Tie Rod Stop Nut M8 x 1 25 DIN 6927 8 Screw UNI 5731 M10 x 25 Stop Nut UNI 7473 M8 K nocker Chipper Chute Screw UNI 5739 M8
4. action by constantly paying attention to one s own actions and their effects If potentially dangerous situations are known accidents can be prevented OPERATOR S REQUIREMENTS All operators using the equipment must be competent and necessarily meet the following features Physical good eyesight coordination and capability of carrying out all functions required for the machine s use Mental Capable of understanding and applying the established rules and safety precautions Users must pay attention and be sensible for their own and other people s safety Training users must have read and studied this manual any enclosed graphs and schemes and its identification and danger plates They must be skilled and trained on any use or maintenance activities 7 SAFETY Work CLOTHING When working and especially when executing repair or maintenance activities it is necessary to wear the following clothing and safety accessories Overalls or other comfortable clothing not too loose to prevent the possibility that parts of them might be caught in the moving parts Protective gloves for hands Protective glasses or faceplate to protect eyes and face Protective helmet for the head Ear protections to safeguard hearing Wear only personal safety accessories in good condition eee Sec Lila and complying with the rules in force GENERAL SAFETY RULES ALWAYS CONSIDER THE FEATURES OF THE AREA WHERE WORK IS TAKING P
5. discharge tube open the hopper cover e Accurately select the wooden material to be chipped and do not exceed the maximum cutting diameter of 4 Small branches can be kept together and put in simultaneously with their butt end turned towards the g entrance e Absolutely avoid pushing the branches down the hopper slide using your hands Use other pieces of wood and 11 necessary use proper pusher device Before putting parts to be chipped into the hopper remove parts different from wood so that knives are not damaged ROAD TRANSPORT While transporting the machine it is very important to follow the road traffic code of the area where you operate SET ASIDE STORAGE If the chipper will not be used for a long period of time we advise to 1 Wash the machine accurately and dry it 2 Check out all equipment and replace damaged or worn parts 3 Tighten strongly all bolts and nuts See torque specifications chart Make an accurate greasing and at last protect the whole machine with a tarpaulin in a building Store it in a dry place Following the instruction will allow you to find the chipper always in good conditions whenever you use it 13 MAINTENANCE Maintenance 15 a fundamental operation to extend life and performances of any agricultural implement taking care of the machine grants you not only a good work condition but also a longer life of the equip ment and greater safety in the workplace
6. in design or changes in specification at any time without incurring any obligations to owners or units previously sold GEARMORE INC 13477 Benson Ave Chino CA 91710 Always refer to and heed machine operating warning decals on machine The serial number of this product is stored in our computer database thus submitting a warranty registration card is not required CUSTOMER INFORMATION NAME PURCHASED FROM DATE OF PURCHASE MODEL NUMBER SERIAL NUMBER 25
7. the user Do notuse the machine indoors in order to prevent smoke poisoning from the engine combustion Foreign bodies such as pieces of metal or stones must be removed before starting the machine Remove protection cover only when the machine 15 completely stopped from inertia motion and after having disconnected the drive shaft and removed the key from the engine Use the chipper only when wearing proper clothing and after having worn suitable protection for hands eyes ears and head During transporting chipper blower discharge tube must be oriented so that it does not stretch out from the outline of the machine When transporting chipper strictly comply with regulations of the area where you operate The manufacturer declines all responsibility for a lack of compliance with these instructions 10 SET UP ATTACHMENT TO THE TRACTOR It is advisable to read carefully this Operator s Manual as well as the instruction manuals of the tractor and the PTO shaft manufacturers All Gearmore chippers have been manufactured to be attached to any tractor provided with hydraulic lift and universal 3 point hitch Before attaching the equipment to the tractor set both on a flat and smooth ground and make sure that nobody is standing between them e Approach slowly the chipper with the arms of the lift and connect first the lower arms and then attach the upper third point hitch The chipper is equipped with attach
8. which there are specific tools Do not use tools in bad condition or inappropriately for instance pliers rather than wrenches etc When maintenance or repairs are completed check out that no tools wiping rags or other materials are left inside spaces or guides with moving parts While using the equipment it is forbidden to make more than one person give directions and make signals The eventual directions and signals relating to the load handling must be given by one person only Do not unexpectedly call an operator while he is working if not necessary it is forbidden as well to frighten or throw objects at the operator even if just for fun Watch out for those who are present especially the children Always make sure that no people stand within the equipment s ray of action Do not make people get on the machine When the equipment is not needed stop the vehicle s engine park it on flat ground with first speed and parking brake on with the machine rested on the ground and PTO disengaged Do not clean lubricate repair or adjust with the engine running and the machine lifted Do not stretch your hands into the chipper while it is working Short wooden parts must be pushed towards knives using longer wooden parts or by means of proper pusher device SAFETY Small wooden fragments must be pushed in slowly and longitudinally in order to avoid that splinters of wood or other material are thrown against
9. x 25 8 8 Anchor Angular Chute Protection Anchor Plate Chute Cover O ptional Cover Hinge Gas Spring Chute Cover Kit O ptional Schnorr Washer M8 22 31712040 9132905 9132926 E AX 47048 8007 34108010 0332130 0002134 9832138 9002073 6601020 6960010 34120010 31510035 34120016 9032902 34106010 9032901 31510030 9002904 31510025 9132901 6320035 31514045 31514055 2002901 31912035 31512050 31512035 34120012 2002900 34121012 2002902 34129008 33010025 34106008 0832902 9002910 31508025 3135292 9782900 0832906 9002911 2002909 6615624 8800001 34026008 lt CO PARTS LIST PART NO DESCRIPTION Yoke Assembly Tractor E nd Push Pin Kit Cross Assembly O uter Tube Yoke Roll Pin 8 x 60 DIN 1485 Outer Tube O uter Tube Inner Tube Roll Pin 8 x 55 DIN 1485 Inner Tube Inner Tube Yoke Safety Device Free Wheel Tube Bearing O uter Tube Stiffening Ring Soft Standard Cone Safety Ring Safety Sleeve O uter Tube Shield Inner Tube Shield Tube Bearing Inner Tube Complete Protection Anti Rotation Chain O uter D ecal Inner D ecal User Manual 23 PART NO 1024010 1581038 1004020 1704027 6330860 1524034 1525034 63308955 1704029 1504260 1784710 1211733 1781723 1211735 1881709 1773026 1872026 1784711 96554026 1006065 1140001 1140003 1140910A E lt DRIVELINE
10. JJ m 4 EE DRIVELINE SAFETY DEVICE REF QTY PART NO DESCRIPTION 1 1 1504240 Outer Body for RF1 4 2 2 1326062 Key 3 2 1215001 Flat Spring 4 1 1506132 Hub 1 Z6 5 1 1706016 Push Pin 6 1 1215016 Push Pin Spring d 2 1133011 Closure Ring 6 1 6320075 Elastic Ring 9 1 6560006 Grease Z erk 10 1 1581038 Push Pin Kit 24 LIMITED WARRANTY GEARMORE INC warrants each new Gearmore product to be free from defects in material and workmanship for a period of twelve 12 months from date of purchase to the original purchaser This warranty shall not apply to implements or parts that have been subject to misuse negligence accident or that have been altered in any way Our obligation shall be limited to repairing or replacement of any part provided that such part is returned within thirty 30 days from date of failure to Gearmore through the dealer from whom the purchase was made transportation charges prepaid This warranty shall not be interpreted to render us liable for injury or damages of any kind or nature direct consequential or contingent to person or property This warranty does not extend to loss of crops loss because of delay in harvesting or any other expenses for any other reasons Gearmore in no way warranties engines tires or other trade accessories since these items are warranted separately by these respective manufacturers Gearmore reserves the right to make improvements
11. LACE Havingtoattach the equipment on the spot it is necessary to arrange a flat and compact area of sufficient dimensions When the equipment is running it 1s forbidden to stand within the field of action of the chipper or of the other accessories of which it is provided with PREPARE THE WORK Before and when working do not drink alcohol take drugs or any other substances which may alter your capability of working with machine tools Be sure to have sufficient fuel to prevent a forced stopping of the machine maybe during a critical movement Do not use the equipment under unsafe conditions For instance it is forbidden to execute makeshift repair activities just to start working it 1s forbidden to work at night with an insufficiently illuminated working area SAFETY VVHEN WORKING OR DURING THE MAINTENANCE ACTIVITIES IT IS NECESSARY TO REMEMBER The labels and stickers providing instructions and pointing out the dangers must not be removed hidden or made illegible Do not remove except in case of maintenance the safety devices and protective covers When it 15 necessary to remove them stop engine handle with care and reassemble them properly before restarting the engine and using the equipment Itis forbidden to lubricate clean and adjust the moving parts while they are running During maintenance or adjustment activities on the equipment it is forbidden to use hands for executing operations for
12. Y Distributed by Gearmore Inc Chino CA Model 420 Serial 000001 When asking for information or technical service always specify the machine type and width SAFETY ALLoweD USE Gearmore chippers taken into account in this instruction manual are equipments designed to chip wood s residuals from pruning and residuals from packaging or from other structures made of wood and free of nails Any other use jeopardizes the operator s safety and the machine integrity IMPROPER USE When using Gearmore Chippers it is particularly forbidden The attachment to tractors of unsuitable power or weight To assemble the machine without securing the adjustment links of the 3 point hitch of the tractor To chip materials different from wood To introduce pieces of wood of bigger dimensions compared to the machine s capacity To use the machine without having placed the relevant pins and cotter pins where required To lift the machine when the power takeoff is engaged To approach rotating parts when wearing inappropriate work clothing To get on the machine while it 1s being used or transported SAFETY SAFETY IN THE WORKPLACE Most of the accidents which take place while the operator 1s using the machine or the equipment or during their maintenance or repair are caused by a lack of compliance with the basic safety precautions It is necessary therefore to become more and more conscious of the potential risks of one s
13. arly with a high quality lithium based grease to keep it efficient and extend its life and performance Grease the following areas every 25 hours or sooner 11 operated in extreme conditions taking care to not over grease bearings which could damage the seals A B Picture 1 Transmission shaft supports C D Picture 2 3 Flywheel shaft supports E Picture 4 Blower discharge tube base Picture 1 Picture 2 ges fi i 8 Picture 3 15 MAINTENANCE BLADES CHECK To assure a perfect functioning of the chipper check often that its blades are in good conditions sharpened and perfectly fixed by the locking bolts To inspect the rotor and the blades condition please proceed as described below e Stop the machine e Disengage the PTO shaft and remove the tractor ignition key Remove the locking screw of the flywheel housing Grab the top half of the housing by the handles and slowly open the cover to maximum open position Carefully rotate the flywheel checking the condition of every single blade SHARPENING AND REPLACEMENT OF BLADES A poor performance of the chipper usually depends on its blades wear To disassemble the blades please proceed as follows e Repeat previous point regarding check Rotate flywheel until blade screws are accessible Remove fixing screws and pull out the blade e Sharpen or replace the blades e Install the new blades with the hardware that was incl
14. dealer After installation secure safety imum guards both to the tractor and the machine using the special chains fe DS and make sure that they pivot freely If the PTO shaft is equipped n tr _ 7 with other safety devices such as a slip clutch be sure to install 1 them on the working machine side As for the PTO use and TT maintenance refer to the relevant booklet These operations shall be made only on working ground and only after having stopped the engine disengaged the PTO and pulled the parking brake If necessary lift the machine from the ground but in order to avoid risks for people place it on supports thus preventing any injuries that might be caused by its sudden fall CHECKS PRIOR TO STARTING UP Before starting the chipper check the following gt The machine is properly connected gt It is firmly rested on the ground gt The chipper is parallel to the ground in order to avoid major stress on the PTO gt The knives are sharpened gt The discharge tube is correctly mounted and positioned STARTING UP OF THE CHIPPER When all setting up operations are completed your machine is ready to be used At this point it is possible to engage the PTO and work the machine at full capacity 12 SET UP Use the power take off only at 540 rpm MATERIAL FEEDING SYSTEM AND CHIPPING Before starting to chip make sure the unit has reached 540 rpm PTO speed e After having correctly E oriented the blower
15. important information It draws the operator s attention to situations which can jeopardize people s safety It draws the attention to situations which jeopardize the machine efficiency but not people s safety It highlights general information which does not d endanger people s safety or the efficiency of the parts SAFETY LABELS SAFETY LABELS The safety labels and the information on the machine listed in the following table must be necessarily carried out failure to carry out these warnings can cause death or severe injuries Make sure that the labels are always present and legible should this not be the case contact your nearest Gearmore dealer to replace the missing or illegible ones Note Shown with optional hopper extension Danger of hands injuries do not open or remove the safety protections while the machine is operating Attention Read carefully all instructions and safety rules before using the machine Stop engine and remove key before maintenance or repair works Wear eyeglasses or face guard for eyes and face protection and head guard to protect hearing ROTATING DRIVELINE Contact can cause death KEEP AWAY Do not operate without eAll driveline guards tractor and equipment shields in place Driveline securely attached at both ends Driveline guards that turn freely on driveline KEEP AWAY THROWN OR FLYING OBJECTS To prevent serious injury or death Do not operate if a
16. ipper vibrates Material balled up on flywheel Clean flywheel with putty knife or orther tool Broken or loose part Access flywheel and repair what is required Chipper RPM slows but tractor Excessive belt wear Pulleys damaged or worn Replace pulley or pulleys in question Rotor will not turn Plugged rotor Clear rotor then feed material more evenly Obstructed discharge Clean discharge chute Drive belts loose or broken Replace belts and or spring 19 PARTS BREAKDOWN DESCRIPTION Belt BX 57 Tapered Locking Unit VK 700 35 60 Drive Pulley BX 100 x 2 Stop Nut M14 x 2 DIN 982 6 Washer UNI 6592 M14 Bearing UCFL 208 Tensioner Belt Support Screw UNI 5739 M14 x 50 8 8 Tapered Locking Unit VK 700 1 40 65 D rive Pulley Shaft Elastic Pin UNI 6873 6 x 55 Stop Nut M12 x 1 75 DIN 6927 8 Flywheel Blade Blade Disk Screw UNI 5739 M8 x 30 8 Chipper Blade Washer UNI 6592 M8 Washer UNI 1751 M8 Screw UNI 5739 M8 x 16 8 Upper Transmission Cover Stop Nut M8 DIN 985 6 PTO Shield Wing Screw M8 x 20 UNI 5449 Circlip External D20 DIN 471 Bearing 6204 2RS Tensioning Roller Belt Tensioner Lower Transmission Cover Screw UNI 5739 M8 x 20 8 8 Tapered Locking Unit VK 156 35 80 D rive Pulley BX 315 x 2 D rive Pulley Shaft Bearing UCEL 207 Screw UNI 5739 M12 x 40 8 8 Release Pin D 10 Pin srd Lower Point Washer UNI 6592 M22 Stop Nut M22 DIN 982 6 Pin Upper 3rd Point Cotter Pin DA 3 Point Hitch
17. ll safety shields are not installed Stop machine if anybody comes within 100 feet SAFETY LABELS Attention Read carefully all instructions and safety rules before using the machine Hooking point for the ma chine s lifting ENTANGLEMENT HAZARD To prevent serious injury or death Do not unbolt or remove safety shields while engine is running Operate only with 540 rpm PTO to avoid injury or machine damage Thrown objects Keep a safety distance from the machine Danger of hands injuries Keep safety guards in position while operating THROWN OF FLYNG OBJECTS To preven serious injury or death DO MOT operate H ali safety shields are mot inglalled STOP machine if anybody comes within 190 lagt gt ENTANGLEMENT HAZARD To prewent genous mjury or death DO NOT unbolt or remove safety shields vile engine ls running Operate only with 540 rpm PTO To avoid Injury or Machine Damage Other Labels SERIES 420 TECHNICAL FEATURES ae FEATURES MAIN PARTS TERMINOLOGY Main PARTS TERMINOLOGY Hopper Extension Cover Optional Hopper Chipper Housing Chipper Base Lower 3rd Point Hitches PTO at 540 rpm Upper 3rd Point Hitch Transmission Cover Knives Housing Blower Discharge Tube Exit Deflector Deflector Adjustment gt ae 2 e IDENTIFICATION PLATE An identification plate is placed on every chipper F MADE IN ITAL
18. ment pins of Category e Make sure you fix the pins with the corresponding klik pins Lock the arms of the lift with proper chains turnbuckle or tensioners After executing the above mentioned activities it IS always good to check that all bolts and nuts of your _ 4 chipper are tightened strongly refer to the torque specifications in this manual Pay attention to the tractor s front wheels grip when the o d equipment is set up and lifted from the ground if the wheels appear to be too lightened ballast the tractor front part 11 SET UP DRIVELINE ATTACHMENT Before assembling the PTO shaft it is very important to check out that its number of revolutions and direction of rotation match those of the tractor Also read carefully the instruction manuals of the PTO shaft and the tractor s manufacturers Before starting work check the presence of the safety guards on the power takeoffs of the machine of the PTO shaft and of the tractor Check in particular that the safety guards cover the PTO shaft throughout its extension When at their maximum extension the safety guards plastic tubing shall overlap at least 1 3 of their length When in their e maximum closing position the minimum clearance allowed shall be 3 4 Fig 1 Dm ll Check out that the PTO shaft minimum and maximum length are the ones required by the machine tractor coupling Should problems la UT arise contact your Gearmore
19. r and lower Remove the two covers e Adjust on the nuts A of rod B which is threaded to stretch or extend the spring C with a power of 20 lb 9kg e If the spring is slackened it 5 necessary to replace it first it is necessary to disassemble the threaded rod Block the rod washers Reassemble the two transmission covers and tighten the relevant screw SPARE PARTS ORDERING To order spare parts please see parts section in this catalog Request of spare parts must be made to a Gearmore dealer and must always be complete with the following information Type and width of the implement Part number of the needed spare part If not in possession of this number you can replace it with the number of the table where the part is represented and the correspondent reference Denomination of the needed part and desired quantity 18 MAINTENANCE TORQUE SPECIFICATIONS Bolt Grade For correct hardware tightening on the Chipper we suggest the use of a suitable torque wrench and the applicable torque as listed in the table TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Not chipping cleanly or flywheel Dull knives Sharpen or replace knives plugging Bed knife dull or rounded Sharpen or reverse bed knife Bed knife not adjusted properly Adjust to clearance of 063 to 126 Unit will not feed Limb forks too wide Remove from hopper and trim off forks power or Stalls more evenly Ch
20. the right to make any necessary changes without giving prior notice in order to optimize the quality and safety features and does not commit itself to updating this manual every time a change 1s made This booklet provides a thorough and accurate description of the instruction and maintenance activities to be carried out on the chipper you purchased We congratulate you on your choice and urge you to thoroughly familiarize yourself with and follow the instructions contained in this manual This will assure you a long safe and trouble free working life for your chipper Gearmore shall not assume any responsibility should problems arise as a result of lack of compliance with the instructions and or operator s negligence The manual is divided in chapters and paragraphs and the pages are numbered thus offering accurate and precise information The requested information can be easily found by searching the key words or referring to the table of contents GENERAL INFORMATION INTRODUCTION The Model 420 Chipper was designed to chip branches up to 4 inches in diameter The chippers are assembled for operation with 540 PTO R P M tractors only rated PTO up to 45 H P and supplied with Cat 1 lift pins for tractor attachment The chippers can fit Cat 1 quick attach hitch by using suitable bushings to adapt diameters of lift pins SYMBOLS This booklet contains three safety graphic symbols which highlight the relevant danger levels or
21. uded Repeat operation for the remaining blades 16 MAINTENANCE If the blades are worn you should Fig 5 then proceed with their So sharpening In case blades are particularly worn or damaged replace them with genuine Gearmore blades 1 4 Blade sharpening must be done with suitable machines that can guarantee a correst sharpening to insure the angle indicated Fig 5 Every time blades are removed disassembling reassembling before starting the machine again it 5 advisable to check and adjust the distance between blade and bed knife To adjust bed knife position proceed as follows e Loosen locking screws 4 Rotate the rotor 1 bringing the blades 2 near the bed knife 3 e Adjust the position of the bed knife 3 by means of adjusting nuts 5 making sure that distance between blade and bed knife is included between 063 and 126 e Make sure that this distance is the same for all blades Block adjusting nuts 5 and tighten locking screws 4 with a torque wrench per the torque specification chart 17 MAINTENANCE BELT TENSION CHECK Belts have an automatic spring tensioner and need a check on the condition of springs To increase or decrease tension of belts proceed as follows 0 e Stop the machine 50 FORCE Disengage the PTO shaft and SAG 0 a 20 Ib 9kg remove tractor ignition key e Take off screws of the two transmission covers uppe
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