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FORST XR8P, User Manual

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FORST XR8P User Manual Download Page 5

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Purpose of Machinery

 

The Forst XR8p is designed to reduce wood material up to 203mm diameter and 
254mm wide to woodchip. This machine is capable of processing up to 5.5 tonnes of 
wood per hour. 

 

 

 

 

 

 

 

Engine 

Kubota 4 cyl Petrol     Roller feed 

Twin series hydraulic motors 

Maximum power 

45.5 Kw (61.2hp) 

 

Maximum material diameter 

203mm 

Cooling method 

Water cooled 

 

Fuel capacity 

35 litres 

Overall weight 

2075 Kg 

 

Hydraulic oil capacity 

55 litres 

Starting method 

Electric 

 

Material processing capacity 

5.5 tonnes/Hr 

  

      Fuel type 

Petrol 

 

 

 

Summary of Contents for XR8P

Page 1: ...Redwood Global Ltd Unit 86 Livingstone Road Walworth Business Park Andover Hampshire SP10 5NS United Kingdom XR8p Woodchipper USER MANUAL ENGLISH 11 07 2019 Revision 0 ...

Page 2: ...ogram 16 Feed jam blockages 17 Track control and driving 18 Transportation 19 Care of rubber tracks 20 Routine maintenance 22 Debris screen 24 Engine maintenance 24 Fastener tightening torques 24 Service schedule 25 Covers engine chipping chamber side panels 27 Engine bay 28 Blade changing 30 Blade sharpening 31 Hydraulic oil filter 32 Battery 35 Battery safety information 35 Storage and transport...

Page 3: ...assembly Flywheel drive 44 Chipping chamber assembly Bottom feed roller cover 45 Chute assembly 46 Top feed roller assembly 47 Flywheel assembly 48 Flywheel belt tensioner assembly 49 Fuel tank assembly 50 Traxion Track Base Cradle 52 Hydraulics circuit diagram 53 Electrical circuit diagram Mechanical touch sensor hopper 54 Decals 55 Manufacturer s Statutory Plate 56 Warranty 57 CE Certificate 58 ...

Page 4: ...d machine operation sections covered on pages 4 to 21 must be read and understood Failure to do so could result in serious injury or loss of life to the operator and others nearby Also damage to property and this machine may occur Please observe and obey all warning signs decals located on the machine Their meaning is covered in this manual under decals All personnel working with this machine must...

Page 5: ...essing up to 5 5 tonnes of wood per hour Engine Kubota 4 cyl Petrol Roller feed Twin series hydraulic motors Maximum power 45 5 Kw 61 2hp Maximum material diameter 203mm Cooling method Water cooled Fuel capacity 35 litres Overall weight 2075 Kg Hydraulic oil capacity 55 litres Starting method Electric Material processing capacity 5 5 tonnes Hr Fuel type Petrol ...

Page 6: ...UTORY PLATE ON CHIPPING CHAMBER COVER UNDER ENGINE COVER 10 SERIAL NUMBER ON CHIPPING CHAMBER UNDER ENGINE COVER 11 TRACK CONTROL LEVERS 12 THROTTLE 13 ENGINE COVER 14 FOOT PLATE 15 CHASSIS 16 FRONT TRANSIT LASHING EYE 17 TRACK BASE 18 ENGINE COVER LATCH 19 TRACK BASE INTERFACE JACK LIFTING POINTS 20 CHIPPING CHAMBER 21 GREASE POINT 22 IGNITION SWITCH 23 FUEL TANK 24 CONTROL PANEL 25 FEED START ST...

Page 7: ...P a g e 6 Figure 2 Track Fully Extended Track Retracted 1 CHUTE HANDLE 2 CHUTE HOOD LOCK HANDLE 3 CHUTE ROTATION LOCK HANDLE 4 SAFETY CURTAIN 5 REAR TRANSIT LASHING EYE 6 BATTERY ...

Page 8: ...rects woodchip to a safe location so that no one can be harmed or property damaged Do not allow discharge to be directed onto roads or public rights of way 4 Maintain a 10m exclusion zone around the machine and clearly mark if in a public area Keep this area free of material build up 5 Make sure the machine is on even level and stable ground and cannot move or topple when in use Use wheel chocks i...

Page 9: ...f wood if necessary 11 Material can be forcibly ejected from the hopper towards the operator Ensure full head and face protection is worn 12 Very twisted material should be trimmed into manageable pieces Failure to do this can result in material extending outside the hopper moving aggressively side to side creating a hazard to the operator 13 Do not try to force material over 203mm in diameter or ...

Page 10: ...ne in poor visibility or insufficient light to see clearly DO NOT use or attempt to start the machine without the discharge chute or guards correctly and securely fitted DO NOT stand directly in front of the in feed hopper when using the chipper Stand to one side DO NOT allow the following to enter the machine as damage is likely BRICKS METAL STRING GLASS CLOTH RUBBER PLASTIC ROOTS STONES BEDDING ...

Page 11: ... must wear appropriate ear protection at all times while machine is in operation to prevent the risk of hearing damage A weighted emission sound pressure beside operator s ear LpA 106 2dB A Peak C weighted instantaneous sound pressure beside operator s ear LCpeak 128 8dB C Results at 10 metre radius are calculated Guaranteed sound power 117dB A As required by Machinery Directive 2006 42 EC Noise E...

Page 12: ...ebris from hopper 15 Close hopper tray by lifting fully up against stops and engage latch ORANGE BUTTON PROGRAMME MACHINE USE TOUCH SENSOR HOPPER STAGE 1 Fold down hopper tray Start engine Turn ignition key to pre heat 2 Wait for display to indicate Start Engine Turn key to start engine and let go once engine has fired 3 Allow engine to run for 30 seconds then open throttle to full 4 For forward f...

Page 13: ...gs shown below will be displayed at certain intervals The engine will not start until OK is pressed First 20 Hour Warning Change Hydraulic Oil Filter Every 20 Hour Warning Blade and Machine check required see manual 50 Hour Service Warning 1st Full Service recommended Every 200 Hour Service Warning Full Service recommended Using the control panel Ignition switch Figure 4 Turn ignition key clockwis...

Page 14: ...ng Hours and charging indicator text at the screen bottom centre P2 shows I O tests Tests all functions and safety controls Pin screen P3 shows No Stress Settings Actual RPM Upper Band 1450 RPM Mid Band 1125 RPM Lower Band 925 RPM Pin screen automatically displays if any setting changes are attempted ...

Page 15: ...ed see Figure 5 Turn dial to align number with pip Set feed speed so that the No Stress operates as little as possible this will give the highest throughput When feeding Leylandii or leafy material set feed roller speed to 4 5 To stop engine turn off with ignition key by turning fully anti clockwise 1 CONTROL VALVE FEED SPEED ADJUSTMENT POSITION INDICATED BY PIP 0 MINIMUM 10 MAXIMUM ...

Page 16: ...nel With the engine running at full speed tap the green button 3 once and the rollers will go into reverse Tap the green button again and rollers will go into forward chipping mode To stop the feed rollers either tap the red stop button 2 or push the red stop bar 1 and the rollers will stop instantly If any of these functions fail turn off the machine and remove the key from the ignition switch an...

Page 17: ...full speed tap the green button 3 and the rollers will go into forward chipping mode Tap the orange button and the rollers will go into a short reverse tap it again and the rollers will continue in reverse To stop the feed rollers push the red stop bar 1 and the rollers will stop instantly and or push the e stop button and whole machine will shut down If any of these functions fail turn off the ma...

Page 18: ...ammed see Figure 6 1 Stop the engine and remove ignition key 2 Open engine and chipping chamber covers 3 Release feed roller spring tension on both sides by slackening off the eye bolt nuts and remove if necessary 4 Insert feed lift tool and lift top feed roller to fully open 5 Insert M12 screw into side of feed chamber and screw completely in If possible lower top feed roller onto the screw to se...

Page 19: ... Track control and driving Figure 7 1 SLACKEN OR REMOVE SPRING TENSIONER NUTS BOTH SIDES BEFORE LIFTING FEED ROLLER 2 INSERT TOP FEED ROLLER LIFTING TOOL INTO SLOT AND LIFT 3 INSERT M12 SCREW TO HOLD FEED IN OPEN POSITION ...

Page 20: ...r down slopes of more than 25 Caution Dependant on ground conditions this machine can traverse gradients up to 35 Do not traverse gradients in excess of 35 and take care when traversing any gradient especially when ground conditions are slippery or loose Make sure the engine and hydraulic oil are warm before working on inclined ground If the machine has to be stopped on an incline make sure that t...

Page 21: ...ring on asphalt and concrete as this will cause excessive track wear Also avoid driving on asphalt that is hot and above 60 C it will damage the tracks and asphalt Loose tracks can be detached and damaged when manoeuvring on very uneven ground Tracks are for use on soft ground They will rapidly deteriorate if used on hard or abrasive surfaces such as sand stone or minerals Do not let synthetic oil...

Page 22: ... side on which the track has come off and fit hydraulic jack bracket as shown below and retain with screw clamp as show below Fit hydraulic jack assembly as shown below adjusting the height and securing with the two pins as shown and fit the lynch pins to stop the pins falling out ...

Page 23: ... side cover and lower the jack and remove Routine maintenance The following must be checked at least on a daily basis during use also see Service schedule Check engine oil See Figure 12 Check water level in radiator reservoir bottle See Figure 12 Check debris screen on front of radiator and remove any debris Check hydraulic oil level When the machine is new the oil level may drop during initial us...

Page 24: ...ropriate torque Check after 1 hours work then weekly Anvil and side anvil are replaceable and double sided Make sure that the anvil seat is clean and free of damage before reassembly Exercise extreme care to avoid injury when removing and replacing blades and anvils The flywheel can turn creating crush and cutting points in and around the chipping chamber Check all hydraulic hoses and fittings aft...

Page 25: ...ue Size M6 10 9 5 10 4 14 5 14 15 3 M8 25 23 1 25 3 35 34 37 2 M10 49 46 51 72 68 75 M12 86 80 87 125 117 128 M16 210 194 214 310 285 314 M20 410 392 431 610 558 615 M24 710 675 743 1050 961 1059 Class 8 8 Class 10 9 Tightening torques for class 8 8 and 10 9 fasteners All machine fastener torques should be regularly checked to the above table In particular those for the flywheel blades flywheel be...

Page 26: ... via central point on control panel Change hydraulic filter cartridge Check brake adjustment wheeled only Check flywheel shaft bearings Check cutting blade anvil condition change if required Change oil filter Check fuel hoses and clamp bands Check feed roller tension springs replace if required Check wear mark on towing hitch wheeled only Clean air filter element Clean fuel filter Check battery el...

Page 27: ...adiator Replace engine fan belt Check recharge battery Change hydraulic filter cartridge Check valve clearances Change hydraulic oil Check fuel injector pressure Check fuel injection pump Check fuel injection timer Get the machine overhauled by a service specialist Change air filter element Check wiring for damage loose connections Change radiator coolant Replace battery Replace radiator hoses cla...

Page 28: ...T SIDE PANEL REMOVAL FOR OIL FILTER AND FEED SPRING ANCHOR ACCESS 2 6x FASTENERS 3 HYDRAULIC OIL FILTER HOUSING 4 2 FEED SPRING TENSION ANCHORS LEFT SIDE VISIBLE 1 MANUFACTURER S STATUTORY PLATE 2 2x M12 SCREWS SECURE COVER IN CLOSED POSITION 3 SERIAL NUMBER 4 ENGINE COVER LATCH ...

Page 29: ...FILLER CAP 3 RADIATOR FILLER CAP 4 DEBRIS SCREEN 5 RADIATOR RESERVOIR BOTTLE 6 AIR FILTER 7 CHIPPING CHAMBER COVER FIXING 8 ANVIL CLAMP BOLT 1 TOP FEED ROLLER M12 SECURING SCREW HOLE 2 CHIPPING CHAMBER COVER FIXING SCREWS 3 SIDE PANELS 4 TOP FEED ROLLER LIFTING TOOL SOCKET ...

Page 30: ...14 1 FLYWHEEL BELT TENSIONER IDLER PULLEY 2 FLYWHEEL TAPER LOCK RETAINER 3 FLYWHEEL DRIVE BELT TENSION ADJUSTMENT 4 FUEL FILTER 5 FLYWHEEL DRIVE BELT TENSION ADJUSTMENT 1 HYDRAULIC OIL FILLER CAP 2 HYDRAULIC OIL LEVEL SIGHT GLASS ...

Page 31: ...the flywheel 10 Clean blade seat on the flywheel thoroughly before fitting new or re sharpened blades WARNING the blades must not have any debris underneath them when tightened the smallest amount of debris behind the blade could result in the blade coming loose causing damage to the machine 11 Re fit blades with new bolts washers and nuts in the order shown in pic 3 12 Shims may be required to ke...

Page 32: ... must be set from the inner blade tip to anvil after sharpening by placing an appropriate shim under the blade also see flywheel assembly The outer blade tip is automatically set due to the anvil being set at an angle to the blade With 3mm at the inner blade tip the outer blade tip should be 5mm from the anvil as shown below The complete blade fastener set must be replaced every time blades are ch...

Page 33: ...ntally responsible manner 1 SIDE ANVIL 2 ANVIL 3 OUTSIDE BLADE GAP 4 FLYWHEEL BLADE 5 INSIDE BLADE GAP Item Description Quantity 1 Complete filter 1 2 Filter element 1 3 Seal kits 1 3a O ring for filter element 1 3b O ring for housing 1 3c Anti extrusion ring 1 3d Gasket 1 3e O ring 1 3f Protection seal 1 4 Indicator plug 1 ...

Page 34: ...ubota engine operator s manual for oil quantities relating to your engine type Hydraulic Oil ISO VG 46 It is advised that the oil is checked and topped up to the RED LINE on the sight glass when the machine is cold and on a flat surface Anti Freeze Mono ethylene Glycol at a 59 mix ratio Please consult your supplied Kubota engine operator s manual for coolant quantities relating to your engine type...

Page 35: ...under the engine cover as shown in Figure 13 and Figure 14 and tension checked at arrows shown in Figure 17 Check and set tension as follows 1 Slacken clamp screw s or nut 2 Turn adjuster nut or screw to tension belt until 4 5Kg force at the belt longest centre span deflects by 6mm see Figure 17 Can be approximated by firmly gripping belt between finger and thumb and twisting The belt should not b...

Page 36: ...in a frost free area 6 Dispose of old batteries at an authorised collection point Never dispose of in household waste Storage and transport 1 As batteries are acid filled always store and transport them upright and prevent from tilting to avoid acid escape 2 Store in a cool dry frost free place 3 Do not remove the protective positive terminal cap 4 Run a First in First Out FIFO warehouse managemen...

Page 37: ...ort circuits and sparks Figure 18 Charging 1 Remove battery from machine disconnect negative terminal first 2 Ensure good ventilation 3 Use suitable direct current mains chargers only 4 Connect battery positive terminal to charger output positive Connect the negative terminal accordingly 5 After connection switch on charger When charging is complete switch off charger then disconnect battery 6 Cha...

Page 38: ...ne end of the black jump lead to the support vehicle battery negative terminal 7 Connect other end of the black jump lead to a machine metal part away from the battery eg onto the engine from under the chassis 8 Make sure that the jump leads will not come into contact with moving parts 9 Start the support vehicle engine and run at a medium idle speed for 15 seconds 10 Start machine and run for 15 ...

Page 39: ...P a g e 38 Parts lists Hopper tray touch sensor ...

Page 40: ... curtain Item No Part No Description Quantity 1 14 05 008 Safety curtain 1 2 14 05 007 Curtain clamp 1 3 12 14 013 M8 washer ISO 7089 4 4 12 14 014 M8 Spring washer DIN 128 4 5 12 12 401 M8 x 25 Lg 8 8 Hex Head screw 4 ...

Page 41: ...P a g e 40 Chipping chamber assembly ...

Page 42: ...P a g e 41 Chipping chamber assembly Bottom feed ...

Page 43: ...P a g e 42 Chipping chamber assembly Bottom feed anvil ...

Page 44: ...P a g e 43 Chipping chamber assembly Drive Note Hydraulic oil filler extension kits available on request ...

Page 45: ...P a g e 44 Chipping chamber assembly Flywheel drive ItemNo PartNo Description Quantity 1 12 10 193 V beltOptibelt 3 ...

Page 46: ...er assembly Bottom feed roller cover TOP Item No Part No Description Quantity 1 12 12 504 M10 x 20Lg 8 8 Hex Head screw 2 2 12 14 010 M10 Spring Washer DIN 128 2 3 12 14 009 M10 Washer ISO 7089 2 4 14 03 024 Feed roller cover 1 ...

Page 47: ... 12 11 007 Plain bearing 12 ID 16 OD 22 flange x 10 Lg 4 6 12 14 003 M12 Washer ISO 7089 6 7 12 13 003 M12 nyloc nut ISO 7040 3 8 12 01 043 Hood hinge stud 1 9 12 19 151 Chute hood fab assy 1 10 12 30 024 Forst small orange decal 2 11 12 15 020 M12 Elastomer washer OD 25 ID 12 x 5 THK 2 12 12 19 055 Chute handle 1 13 12 10 004 M12 female steel handle 1 14 12 14 004 M12 Washer extra large OD 44 x 4...

Page 48: ...P a g e 47 Top feed roller assembly ...

Page 49: ... Flywheel assembly BLADE SHIM THICKNESS AVAILABLE Part No Thickness 14 03 042 05 0 5mm 14 03 042 10 1mm 14 03 042 15 1 5mm 14 03 042 20 2mm 14 03 042 25 2 5mm Note Blade Bolt Set Bolt Washer Nut Part No 99 99 099 ...

Page 50: ...bolt 1 2 12 14 019 M16 Spring washer DIN 128 1 3 12 14 005 M16 Washer ISO 7089 3 4 12 11 011 6304 2RS Deep groove ball bearing 52 OD 20 ID 15 wide 2 5 12 01 036 Flat idler pulley 2x 17 V belt 1 6 12 01 024 Flat idler pulley shaft 2x 17 V belt 1 7 12 13 005 M16 nyloc nut ISO 7040 1 8 19 19 016 Tensioner slide fab assy 1 ...

Page 51: ...nk cap 1 1a 12 10 151 Lockable tank cap optional 1 2 12 10 152 Fuel tank filter 1 3 12 02 001 Fuel tank 35L moulded assy 1 4 12 10 154 Fuel tank 5mm connector 1 5 12 10 153 Fuel tank 5mm grommet 1 6 12 14 008 M12 Bonded washer Dowty 2 7 12 10 027 Banjo M12 1 8 12 10 026 Banjo bolt M12 1 ...

Page 52: ...P a g e 51 Traxion Track Base ...

Page 53: ...P a g e 52 Traxion Track Base Cradle ...

Page 54: ... Feed roller motors 2 Track motors 3 Track width cylinders 4 Test points 5 Control valve 6 Return line filter 10 micron 72 litre minute nominal 7 Oil tank 8 Tandem hydraulic pump 11cc 36 litre minute 9 Engine 10kW per pump at 185 Bar 13 6Hp ...

Page 55: ...P a g e 54 Electrical circuit diagram Mechanical touch sensor hopper ...

Page 56: ...ironment protection legislation 3 Ignition switch stop 4 Hearing and eye protection of an appropriate specification to be worn 5 Finger and toe amputation hazard 6 Refer to user manual 7 Allow machine to stop before touching 8 Danger from flying objects 9 Do not open or remove covers while engine is running 10 Keep away from rotating machine parts 11 Push to stop trip bar operation These decals ar...

Page 57: ...tion on the Manufacturer s Statutory Plate in line order from top to bottom is as follows 1 Manufacturing company 2 Vehicle type approval number and construction date 3 17 digit Vehicle Identification Number VIN construction 4 Gross Vehicle Weight GVW ...

Page 58: ...cordance with the user manual 8 The Redwood Global Ltd guarantee will be invalidated if any of the following points apply Failure to use genuine Forst parts Failure to perform routine servicing and maintenance Failed parts or assembly have been interfered with Machine has been modified without written approval from Redwood Global Ltd Machine has been used to performed tasks contrary to those state...

Page 59: ...ollowing models ST6 Towed TR6 on Tracks ST8 Towed TR8 on Tracks XR8 on Tracks PT6 PT8 are classified within the following EU Directives Machinery Directive 2006 42 EC Electromagnetic Compatibility Directive 2004 108 EC and further conform with the following EU Harmonized Standards EN13525 2005 A2 2009 EN 982 1996 A1 2008 EN ISO 12100 2010 EN ISO 14982 2009 Dated Position of signatory Managing Part...

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