DMC 1300-830-250

DRUM CHIPPER
 I N D E X
CHAPTER CONTENTS PAGE
1 GENERAL COMMENTS 1
1.1 Introduction/preface 1
1.2 Application 3
1.3 Copyright 3
1.4 Safety instructions 4
2 DESIGN AND FUNCTIONING 6
2.1 Constructional design 6
2.1.1 Rotor bearings 7
2.1.2 Upper grip rollers carrier (Cradle) pivot 7
bearings
2.1.3 Bottom feed grip rollers and bearings 7
2.1.4 Upper feed grip rollers and bearings 8
2.1.5 Dead knife 9
2.1.6 Rotor 9
2.1.7 Rotor hood 10
2.1.8 Rotor locking pin 10
2.1.9 Screen 10
2.1.10 In-feed conveyor head pulley and drive 11
2.1.11 Upper feed roll carrier (Cradle) 11
2.1.12 Cradle guide liner plate 11
2.1.13 Machine frame 11
2.1.14 Pulley 11
2.1.15 Hydraulic power pack 11
2.2 Function 12
3 TRANSPORTATION AND STORAGE 12
3.1 Transport regulation 12
3.2 Storage at site 13
3.3 Scope of supply 13
4 ERECTION / INSTALLATION 14
4.1 General comments 14
4.2 Set-up and pre-alignment of Drum Chipper 14
4.3 Final alignment 15
4.4 Installation of main motor 15
4.5 Installation of drive belts and guard 15
4.6 Electrical installation 15
5 START UP 16
5.1 Previous controls 16
5.2 Starting 16
5.3 Subsequent controls 17
6 OPERATING INSTRUCTIONS 17
6.1 General comments 17
6.2 Operation of the machine 17
6.3 Operation of the hydraulic unit 18
6.3.1 Lifting the hood 19
6.3.2 Lifting the cradle 20
6.3.3 Setting the cradle level 20
6.4 Dead knife change 21
6.5 Fly knife change 22
7 INSPECTION AND MAINTENANCE 23
7.1 General comments 23
7.2 Inspection and maintenance 23
7.3 Instructions for inspection and maintenance 24
7.3.1 Re-grinding of knives 24
7.3.2 Maintenance of hydraulic system 25
7.3.2.1 Adjusting oil pressure P3 25
7.3.2.2 Oil pressure 25
7.3.3 Maintenance of V-belts 25
7.3.3.1 V-belts 25
7.3.4 Lubrication of chain drives 26
7.3.5 Lubrication of bearings 27
7.3.6 Gear motors 27
7.3.7 Electric motor 27
8 TROUBLESHOOTING 28
8.1 Problems with the chip quantity 28
8.2 Problems with the machine 28
8.3 Problems with V-belt drive 29
8.4 Problems with the hydraulic system 29
9 KEEPING OF SPARE PARTS 30
10 SPARE PART LAYOUT AND QUANTITY 31
1 GENERAL COMMENTS
1.1 Introduction/Preface
This manual narrates the complete information pertaining to
the operation and maintenance of the ‘CIBI’ brand “DMC 1300-
830-250” model wood chipping machine and will give you a clear
understanding of the operation of the machine.
We advise you to always keep the working manual near the
machine.
With the help of this manual, one can acquire a deep
knowledge of the complete operation of this machine and will be
beneficial for its smooth operation. Any damage caused to the
machine due to improper handling will not be covered under
warranty. Hence, we strongly advise the operator to go through
the manual thoroughly before installation and subsequent
operation.
In case of any clarification, feel free to contact us at any
time.
We reserve the right to change the features and specification
of this machine, if necessary, to further its efficiency and
productivity.

DMC 1300-830-250 DRUM CHIPPER

Figure 1.1

1
Drum Chipper with input conveyor
Figure 1.2

Drum Chipper with output conveyor

Figure 1.3

2
1.2 Application
DMC1300-830-250 is used for the production of fine quality
wood chips for varied applications.
The described drum chipper is designed and built for a
specific purpose. Any attempt to use the chipper for a different
purpose or use of an input material other than mentioned must be
done only after prior consultation with us.
1.3 Copyright
This operation manual and its content is copyright of
Subhasurya Energy and Engineering Services Pvt. Ltd.
It can be used for those persons who are connected with
installation, start up, maintenance and repair of the CIBI Brand
drum chipper.
This manual contains technical information, instructions and
drawings which shall not be copied fully or partially or shared with
other persons.

Subhasurya Energy and Engineering Services Pvt. Ltd.,

No 14/127 C, Major Sandeep Unnikrishnan Road,
Cheruvannur, P.O Feroke,
Calicut-673631(Kerala State) India.

Telephone : +91-495-2481273,2483317,
+91-9349113576,9349792266,9346331332
E-mail :suryaenergy@gmail.com
Website :www.suryaenergy.com

3
1.4 Safety Instructions
• The drum chipper is technically easy and safe to operate.
However, it can cause damage if operated in an unsafe
manner or without personnel supervision.
• Any person concerned with the installation, start-up,
operation and maintenance of the drum chipper must read
and understand the complete operation manual, in
particular, ‘Safety Instructions’. The user is advised to have
this confirmed by signature of the appropriate personnel.
• The user is responsible to protect the machine from foreign
materials like metals or mineral bodies with appropriate
devices such as metal detectors, magnets, cleaning rolls etc.
• The user must also ensure that the area surrounding the
chipper is within the allowable limits for dust concentrations.
• The in-feed and cradle area must be guarded by fencing or
suitable barriers.
• Depending on the regulation at site, noise control measures
should be taken.
• Emergency stop buttons must be located in the immediate
vicinity of the machine.
• In the vicinity of the drum chipper, earplugs must be worn.
• Unauthorized changes and modifications to the machine
must not be done for reasons of safety.
• The user must make sure that the machine is operated in
good condition.
• The operating personnel must inspect the drum chipper at
least once per shift and report any defects or changes in its
operation immediately.
• Any control and maintenance work must only be performed
with the machine at a standstill condition.
• If it is necessary to remove guards for maintenance work, or
to open protective or safety devices, the drum chipper has
to be secured by locking out the main switch against
accidental starting. Any repair work must only be performed
with the machine at a standstill condition.
• No protective or safety devices may be removed or set out
of operation. If it is necessary to remove guards or safety
devices for maintenance or repair (e.g. belt guard or chain
guard), they must be re-installed immediately upon
completion of the work.

4
• When working underneath the hood, it must be secured by
placing a wooden block in between the hood and the side
frame walls.
• When performing work that requires raising the top feed roll
carrier, it must be secured against accidental lowering by
placing a steel rod or wooden block in the cutouts on the
sidewalls.
• When working on the rotor, it must be secured with the rotor
locking pin.
• Besides these safety instructions, all appropriate local rules
and regulations must be followed.

5
2 DESIGN AND FUNCTIONING (MACHINE DESCRIPTION)

2.1 Constructional Design (Components)

Machine side view

Figure 2.1

Machine pulley side view

Figure 2.2

6
 1. MAIN FRAME (BODY) 16. HYDRAULIC OIL PRESSURE
2. FOUNDATION HOLE GAUGE
3. CRADLE HOUSING 17. NITROGEN
ACCUMULATOR
4. 10HP GEARED MOTOR FOR
CRADLE GRIP ROLLERS 18. HOOD LOCKING BOLT
5. 10HP GEARED MOTOR FOR 19. HOOD LIFTING PISTON
IN-FEED CONVEYOR 20. 10HP GEARED MOTOR
6. CHAIN & SPROCKET COVER FOR BOTTOM GRIP
ROLLERS
7. CRADLE ADJUSTING PISTON
8. CRADLE 21. BACK DOOR
9. ROTOR HOOD 22. LIFTING HOOK
10. MACHINE PULLEY 23. ROTOR LOCKING HOLE
11. RE-CHIPPING DEAD KNIFE 24. HYDRAULIC POWER PACK
MOTOR
12. DEAD KNIFE LOCK PLATE
25. DEAD KNIFE HOLDER
13. SCREEN SUPPORT PIN SUPPORTING RAIL
14. MAIN BEARING HOUSING 26. DEAD KNIFE PULL OUT
15. HYDRAULIC OIL TANK HANDLE

2.1.1 Rotor (drum) bearings

The rotor runs on two numbers of oversized FKL make spherical
roller bearings (Bearing no. 22238 K). The steel housings are flanged
into the chipper frame side plates.
2.1.2 Upper grip rollers carrier (cradle) pivot bearings
The upper feed rollers carrier pivot is supported by two numbers
of self-aligning ball bearings (Bearing no. 2216K) in steel housings.
2.1.3 Bottom feed grip rollers and bearings
The horizontal grip rollers with special teeth profile run on self-
aligning ball bearings (Bearing no. 2218 K) in steel housings fitted to
the main frame sidewalls.
The feed rollers are driven by a geared motor, driving the first
feed roll behind the rotor with roller chain drives from roll to roll.
These chain drives are protected by chain guards, completely
enclosed, ensuring proper lubrication while keeping out dust or dirt.

7
 2.1.4 Upper feed grip rollers and bearings
Drive is by gear motor to the first feed roll at the machine inlet.
These feed rolls are similar to the lower feed rolls, running on self-
aligning ball bearings with the exception that they are mounted in a
carrier (cradle) which pivots up and down to adjust for different sizes
of input material to be chipped.

Conveyor head pulley, Grip rollers & Stipper plate

Figure 2.3

27. LOWER GRIP ROLLERS

28. UPPER GRIP ROLLERS
29. IDLE ROLLER
30. IN-FEED CONVEYOR HEAD
PULLEY
31. STIPPER PLATE
32. DEAD KNIFE HOLDER
33. DEAD KNIFE
34. CRADLE GUIDE LINER
PLATES
Grip rollers& Conveyor head pulley
Figure 2.4

8
2.1.5 Dead knife

Dead knives
Figure 2.5

The dead knife is held by plates and pressure bolts on each

side of the machine frame, on top of the dead knife holder
welded on the machine. There are two dead knives- one on front
side of rotor and other on back side; main dead knife and re-
chipping dead knife respectively. Both main and re-chipping
dead knives are identical.

2.1.6 Rotor (Drum)

(for description of rotor bearing see
2.1.1)
35. BLADE LINER
36. FLYKNIFE
37. CENTRIFUGAL WEDGE
38. MAIN SHAFT
39. LEAD SCREW
40. LEAD SCREW SUPPORT BLOCK
41. TAPER BLOCK MALE
42. TAPER BLOCK FEMALE

Rotor
Figure 2.6

9
 The rotor consists of the rotating
steel drum. The three fly knives are
mounted on the rotor by using
centrifugal wedge clamping
assembly. Rotor is the ‘heart’ of
chipper machine, rotating at 380
rpm. The rotating assembly is
mounted on main shaft with a
locking assembly. The power
required for the cutting operation
is supplied from an electric motor
of capacity 250HP and 1440 rpm. Wedge clamping assembly parts
Figure 2.7

2.1.7 Rotor hood

The hood covers the machine housing over the rotor. The
hood is fixed on to the machine by means of a hinge.
2.1.8 Rotor locking pin
Rotor locking pin locks the rotation of rotor during
maintenance and transportation of the machine.
2.1.9 Screen
The screen is made of gas cut steel on 16mm thick MS plate,
heavily reinforced and mounted in the guides of the main frame
side plates. It helps in screening the wood chips to the required
chip size.

43. SCREEN LOCKING BOLT

44. SCREEN (MESH)
45. SCREEN HOLDER
46. SCREEN HOLDER LIFTING
HOOK

Screen and screen holding system

Figure 2.8

10
2.1.10 In-feed conveyor head pulley and drive
This group includes the conveyor head pulley and the belt
drive. The belt drive roll is driven by a 10HP geared motor. Bearing
number is 22216K.
2.1.11 Upper feed roll carrier (cradle)
The feed roll carrier (cradle) is made of solid welded steel,
and carries the upper feed rolls. The carrier is pivoting from the
inlet of the machine and is connected to the machine housing
(See 2.1.2)
2.1.12 Cradle guide liner plate
It works as a separation barrier between in-feed material flow
and cradle up & down motion.
2.1.13 Machine frame
The machine frame is a heavy welded steel construction and
carries all components.
2.1.14 Pulley
Machine pulley and motor pulley made of cast iron is used to
transmit power from main motor to the chipper, having eleven
number V grooves of SPC section. V-Belt used is SPC6000.

2.1.15 Hydraulic Power Pack

Hydraulic power pack includes the hydraulic pump drive
motor, hydraulic oil tank, cylinders, accumulator, high pressure
valves, pressure gauge, high pressure hoses, and piping on the
machine. The connection from the piping to the cylinders is by
high pressure hoses. Oil used is 68 grade.
This type of oil is used only during initial top-up. When changing oil,
any other oils with similar properties can be used.

11
2.2 Function
The material to be chipped is fed to the chipper by a belt
conveyor feeder. The upper and lower grip rollers positively grab
the material and push it towards the rotor at a controlled rate. The
upper grip roller adjusts itself for the height of the material to be
chipped.
The pressure of the upper grip roller on the material is
generated by the weight of the grip roller carrier(cradle).
Chipping is done by the rotor. The radially aligned chipping
knives separate the chips from the material. The wedge effect of
the cutters ensures a nearly constant ratio between the length
and thickness of the chips. The chips are then collected in the
pocket below the knife. The cutting process of a knife is finished
when the last chips between the knife and the dead knife are cut.
The chips are now thrown out of the pockets by centrifugal force
on to the screen. Oversize pieces or splints are held back by the
screen basket and chipped again by the Re-chipping dead knife.

3. TRANSPORTATION AND STORAGE

3.1 Transport regulation
Transportation can be done
either by a crane or by appropriate
floor conveyors.
During transport, the drum
chipper must be carefully handled to
prevent damage caused by force or
carelessness. During transportation,
shocks shall be avoided.
When using wire rope or chains,
wooden blocks are used to prevent
damage to the paintjob. The drum
chipper is to be handled with utmost
care.
Lifting
Figure 3.1

12
3.2 Storage at site
If the chipper is not assembled immediately after delivery, it
needs to be stored in a safe area free of vibrations. The chipper
must be covered to avoid dust and moisture. If stored outside, the
chipper must not be placed directly over the ground.
During storage, huge fluctuations of temperature are to be
avoided (water condensation).
Bare metal parts are provided with a protective coating
which ensures protection for about 1 year. If parts are stored for
more than 1 year, additional protective coating needs to be
applied.

3.3 Scope of supply

For reasons of transportation, the drum chipper cannot be
shipped completely mounted.
The following parts are shipped separately
• In-feed conveyor with side guards & supporting legs.
• Motor pulley, motor base frame & foundation bolts.
If the drive is supplied by Subhasurya Energy & Engineering
Services Pvt. Ltd., the drive units required are possibly supplied
loose and pre-mounted as far as possible.
The contents of the shipment must be checked on arrival
against the packing list. Any discrepancy, shortage or damage
must be immediately reported to the transportation company.

13
4 ERECTION/INSTALLATION
4.1 General comments
We recommend that the installation of the machine be
performed or supervised by our trained personnel. We shall not be
responsible for any damage caused due to improper installation.
Any person concerned with installation, start-up, operation
and maintenance of the chipper must have read and understood
the complete working manual. The user is advised to have this
confirmed by signature of the appropriate personnel.
A general arrangement drawing containing all necessary
information concerning installation of the drum chipper,
dimensions, weights, load data and connection measurements
will be provided. Installation is to be performed according to this
drawing only.
The drum chipper can be mounted on a steel structure.
Foundation is to be done in accordance with the data in the
given general arrangement drawing. Sufficient space must be
provided in the vicinity of the machine for installation, operation
and maintenance works.
The erection/installation is to be performed as follows-

4.2 Set-up and pre-alignment of drum chipper

Drum chipper is to be placed on a steel platform, fixed with
connecting bolts, and then placed on civil foundation aligned
with the foundation bolts.
Drum chipper has to be leveled horizontally. To level drum
chipper longitudinally, place water level on base of the chipper.
To level drum chipper laterally, use water level across the belt
grooves.
Leveling is done by raising or lowering the base of the
machine. If required, the base has to be shimmed with large
shims.
Do not tighten the machine after this preliminary alignment.

14
4.3 Final alignment
The grip roller motors must be connected electrically and run
for a short time. In the meantime, check for direction of rotation of
the motors (see directing sign/arrow on hood).The top grip roller
carrier is raised and lowered with grip roller motors running.
Unusual noises by metallic contact (‘pinging’) or mutual
contact of feed rolls or if it is noticed that the grip roller carrier
scrapes at the machine side wall, it might be that the machine
frame is twisted. The in-feed area of the frame must then be
realigned and rechecked until movements are satisfactory and
quiet.
4.4 Installation of Main motor
Install main motor on the motor frame. Place the assembly
on foundation and line up so that both the pulley grooves are in
line.
This can be checked with a straight edge or string which
must touch each groove face in two points without being bent.
Before final tightening of foundation bolts, the motor (or
motor base) is to be moved over the whole length of rails, while
checking the alignment of grooves of pulley in different positions.
It is very important that this line up is accurate and without
twist. The motor (or motor base) must rest equally on all rails.
4.5 Installation of drive belts and guard
Prior to installation, the grooves of V-belt pulleys must be
cleaned carefully and any oil, grease or corrosion protection film
must be removed. Reduce center distance by moving the motor
on rails so that the belts can be slipped on to the grooves easily.
Tighten the belts by means of adjusting screws. During this
process, the drive should be turned several times by hand to
equalize tension in the belts. After installation of the belts is
complete, the belt guard must be mounted.
4.6 Electrical installation
Electrical installation must be performed by a qualified
personnel only, observing all local rules and regulations.

15
5 START UP
After completing the installation and all electrical work,
startup procedure is to be executed as follows:
5.1 Previous controls
• During shipment, the rotor would be secured against rotation
by means of a rotor locking pin. This pin can now be
removed.
• Check all bolts for proper tightness. The knife fixing bolts(lead
screw) must be checked.
• Check rotor space, chipper inlet and feed roll area for
foreign objects (such as tools, installation devices etc.) and
remove if found any.
• Check electrical installation in accordance with all local
rules and regulations.
• Check belt drive tension.
• Check direction of rotation of all electric motors.
• Check oil level in oil tank.
5.2 Starting
• In order to deliver a perfect operational sequence, the drum
chipper is to be started first followed by output and in-feed
conveyor in no load condition.
• Check all drives for correct locking and connection.
• Check if all controls are working correctly. Further, all
electrically controlled functions are to be performed several
times.
• Correct functioning of all safety devices (emergency stop
switch, limit switch, electromagnetic switch etc.) is to be
checked thoroughly, as well as the adjustment of grading
margin (locking of rotor covering during rotor deceleration
time).
• If everything is satisfactory, run the chipper without load for
about an hour. Check for abnormal noises and watch the
bearing temperature of rotor (max 70ºC on outside of
bearing housing).
• Now, the chipper can be run on load. It is recommended to
start with small amounts of feeding materials and slowly
increase to full load capacity.

16
5.3 Subsequent controls
• After 4-5 hours, check V-belt drive for proper tension and
adjust if necessary.
• After 8-10 hrs. check all bolts for proper tightness and adjust if
necessary

6 OPERATING INSTRUCTIONS

6.1 General comments

Any person concerned with the installation, start-up,
operation and maintenance of the drum chipper must have read
and understood the complete manual, in particular, ‘safety
instructions’. The user is advised to have this confirmed by
signature of the appropriate personnel.
For the following description, it is assumed that the controls
have been supplied by the manufacturer. If the controls are
procured by the user, they must be executed in such a way that
the functions correspond completely with those described in this
manual.

6.2 Operation of the machine

The chipper will give maximum output when operated under
average and normal loads when the material is fed in an even
and continuous manner.
Feed rolls can be stopped and reversed to clear any jams or
wedging in the inlet by operating the control panel.

17
6.3 Operation of the Hydraulic unit

Hydraulic system
Figure6.1

Hydraulic system
Figure6.2

18
 07. CRADLE ADJUSTING PISTON
15. HYDRAULIC OIL TANK
16. HYDRAULIC OIL PRESSURE GAUGE
17. NITROGEN ACCUMULATOR
19. HOOD LIFTING PISTON
24. HYDRAULIC POWER PACK MOTOR
47. HYDRAULIC HOSE
48. SOLENOID VALVE (HOOD UP & DOWN)
49. OIL LEVEL INDICATOR
50. HIGH PRESSURE BALL VALVE
51. ROTARY DIRECTIONAL CONTROL VALVE (FOR CRADLE)
52. UNLOADING SOLENOID
53. PRESSURE CONTROL VALVE
54. BREATHER CAP

The main function of hydraulic power pack unit is to lift the

hood and the cradle. It also provides a cushioning effect to the
upper feed roll carrier during operation of the chipper.
6.3.1 Lifting the hood
Two hydraulic cylinders are provided on both sides of the
hood for its easy lifting during regular inspection of drum and fly
knife, changing of fly knife and dead knife etc. The hood shall be
opened only with the machine at a standstill condition. The steps
for this operation are as follows-
• Open locks on the hood.
• Press ‘Hydraulic Motor Start’ push button on the control panel.
• Turn Momentary switch towards ‘HOOD UP’ on the control
panel. Thus, piston starts to rise along with the hood.
• Release the button when the hood rises to a sufficient level.
The hood must be secured additionally by placing a wooden
block in between the hood and the side frame walls to avoid
accidental lowering.
• After completion of the work, remove the wooden block and
turn Momentary switch towards “HOOD DOWN”, thereby
lowering the hood to its initial position.
• Press “Hydraulic Motor stop” push button on control panel.
• Engage locks on the hood.

19
6.3.2 Lifting the Cradle

The cradle has to be lifted for cleaning of feed rollers & the
space between machine frame and cradle guard liner plate,
regular inspection, setting the cradle level etc. Two hydraulic
cylinders have been provided on both side of cradle. The steps for
this operation are as follows-
• Press ‘Hydraulic Motor Start’ push button on the control
panel.
• Set the pressure of the system to 50bar in pressure gauge by
adjusting the pressure control valve.
• Always keep the valve beneath the accumulator line in
open position.
• Turn the 3 position rotary directional control valve in the
power pack towards left for the cradle to be lifted.
• The middle position of the 3 position rotary directional control
valve holds the cradle in the required height.
• For additional safety, lock the gap between the cradle and
the machine side frame by using a wooden block to avoid
accidental lowering of cradle.
• After completion of the work, operate the 3 position rotary
directional control valve towards right for lowering the
cradle.
• Press “HYDRAULIC MOTOR STOP” push button on the control
panel.

6.3.3 Setting the Cradle level

An adequate clearance gap has to be set between the top
and bottom feed rollers for the easy movement of the in-feed
materials.
Keep a minimum clearance of approximately 25mm
(depending on the in-feed raw materials, clearance can be
altered) between top and bottom feed rollers so that proper press
feeding effect is achieved.
• Press “Hydraulic Motor Start” push button on the
control panel.

20
 • Turn the 3 position rotary directional control valve in the
power pack towards left for the cradle to be lifted.
• The middle position of 3 position rotary directional
control valve holds the cradle in required clearance.
• Press “HYDRAULIC MOTOR STOP” push button on the
control panel.
6.4 Dead knife change.
25. DEAD KNIFE HOLDER SUPPORTING RAIL
26. DEAD KNIFE PULL OUT HANDLE
55. RACK AND PINION MECHANISM

• For changing the main dead knife, use

rack and pinion mechanism provided
on the side of the machine.
• Remove the hold-down plates over
the dead knife on both sides of the
machine. Pull out the dead knife
holder unit from the machine by using
rack and pinion mechanism. With the
to and fro movement on the handle,
the dead knife holder assembly comes
out.
• Change the position of the existing
dead knife (2 edges are usable) or fix
a new one. Dead knife remover
• Insert the dead knife holder assembly in Figure6.3

to the machine by using rack and

pinion mechanism.
• Lock the assembly with pressure plates and bolts.
• For changing the Re-chipping dead knife, first open the rotor
hood and back door.
• Loose the screen holder bolts and place the holder down. This
provides easy access the re-chipping dead knife.
• Change the position of the existing re-chipping dead knife (2
edges are usable) or fix a new one.
• Rotate the rotor by hand for one full rotation to ensure that the
fixed and rotating knives do not touch each other.
• Fasten the screen holder and close the hood cover and
backdoor.

21
6.5 Fly knife changing
Extra care needs to be taken while handling new and reground
knives as there are chances of accidental cuts due to the sharp edges.
It is therefore advised to wear cut resistant gloves while changing the fly
knives.

Fly knife fixture

Figure6.4

The fly knives and dead knives shall be changed only with
machine at a standstill condition.
• Open the locks on the hood.
• Open the rotor hood using hydraulic piston.
• Secure the rotor (drum) with the rotor locking pin. This will ensure
that the rotor is in an idle position to change the knife.
• Loosen the screw rod of the centrifugal wedge and release the
fly knife from the rotor.
• For setting a constant gap between fly knife and dead knife, a
fly knife fixture (supplied along with the machine) is used.
• Insert the new or reground knife into the rotor. Ensure that the
clamping surfaces are absolutely clean.
• Tighten the screw rod of the centrifugal wedge by proper
torque.
• Once all fly knives are changed, remove the rotor locking pin
and rotate the rotor by hand to ensure that the fly knives and
dead knives do not touch each other. Ensure a minimum
clearance between dead knives and fly knives.
• Close the hood and secure with locking hook bolts.

22
 7 INSPECTION AND MAINTENANCE
7.1 General Comments
The drum chipper must be secured by activating and
interlocking the main switch or hand tripping.
Any bolted connection that was loosened during
maintenance and repair works must be checked after 8-10 hours
of running time and be replaced if necessary. Any bolts and
locknuts that have become unusable must be replaced with the
same type and grade immediately.
Due to the varying operating conditions, it is impossible to
anticipate the intervals of inspection and maintenance. The onus
is on the user to establish these intervals with due consideration of
the operating conditions existing onsite.
7.2 Inspection and maintenance works

➢ Daily:
Check cutting quality of fly knives, dead knife and re-
chipping knife and regrind if necessary, check oil pressure p3 in
the accumulator and adjust if necessary, visual checking.
➢ Weekly:
Grease all bearings (Main drum bearings, grip roller bearings,
conveyor rollers etc.)
➢ Monthly:
Lubricate the chain drive.
➢ Every 6 months :
Check oil level in gear, check V-belt tension and adjust if
necessary, check all bolted connections for tightness and adjust if
necessary.
➢ Yearly:
Check for signs of wearing in in-feed rolls, stippers and
screen. Worn or defective parts are to be replaced by a new one.
➢ After 2 years:
Change gear oil or at least after 10,000 hrs.
Above intervals are applicable only for single shift operation
and under normal conditions. Unfavorable operating conditions or
multi-shift operations require shorter inspection intervals.

23
7.3 Instructions for inspection and maintenance works
7.3.1 Re-grinding of knives
Always use cut-resistant gloves while handling knives.

The knives are made of high-grade alloy steel and must

always be ground with an adequate coolant. Overheating will
cause localized hardness or cracks and tensions, which can cause
the knife to break.
The knives should be kept in sets for re-grinding. After
grinding, all knives must have the same width. This will prevent
rotor imbalance.
The knives must be ground to the angles shown in the
following drawing.
The knives must be ground only on the shaded surface (see
fig 7.1). The shading also indicates maximum extension of grinding
permitted. Concave grinding of the cutting surface must be
prevented. Use a grinding stone/oil stone to remove any burrs.
When the knives have been reduced to a minimum width,
they must not be used anymore and have to be replaced by new
knives. Replace knives only in sets.

Knife profile and maximum grinding allowance

Figure 7.1

24
7.3.2 Maintenance of hydraulic system
7.3.2.1Adjusting Oil pressure
The oil pressure in the accumulator must be checked daily. If
the pressure gauge of the system points to low, then increase it by
adjusting the pressure regulator valve to 70 bars. After setting the
proper pressure, stop the power pack motor.
Accumulator oil pressure must be adjusted only with the top
feed rolls in fully lowered position.
7.3.2.2 Oil pressure
Prior to adding or changing the oil, lower all cylinders and
empty the oil side of the accumulator keeping all the valves open.
Following this procedure, the oil pressure must be set again (see
7.3.2.1). Check the oil level in hydraulic tank daily. If the level
drops, find the leakage and seal it. Then add oil if necessary.
While adding oil, make sure to use the already existing make
and type of the oil in the system. If the oil make or type has to be
changed, the system must be completely emptied and flushed
with the new type of oil prior to filling.
7.3.3 Maintenance of V-belts
7.3.3.1 V-belts
• Proper belt tension is very important to achieve full power
transmission and longer life. Too much or inadequate tension
will result in short life. Too much tension will also lead to
bearing overload.
• The belt tension must be checked regularly, and adjusted if
necessary.
• Once a new set is installed, the tension must be checked
after 4-5hrs of running time and adjusted if necessary.
• Belts must only be changed in sets. The V-Belt used is
SPC6000.
• V-belts must be slipped on easily by hand and without
forcing.
• After completion of the work, the belt guard must be fitted
immediately.
• Any work pertaining to the V-belts must be done only with
the machine at stand still condition and with the motor
locked out.

25
7.3.4 Lubrication of chain drives
The chains must be greased regularly with an oil can or a
brush. For this purpose, remove the chain guard. After completion
of work, the guard must be replaced immediately.
The chains should be cleaned thoroughly at longer intervals.
To clean the chains, use a coarse brush to remove any dirt.
Wash and soak the chain in benzene, kerosene or similar solvents
for 24 hrs.
If cleaned properly, the chains will no longer make any
scratching sound when the links are moved.
In order to re-lubricate the chain, it should be submersed in a
bath of good quality oil and moved around so that all links are in
contact with the oil.
Prior to re-installation, the sprockets of the chains must be
cleaned thoroughly.

Sprockets & Duplex chain

Figure 7.2

56. GRIP ROLLER HOUSING 59. GREASE NIPPLE

57. GRIP ROLLER HOUSING 60. 1 ¼” DUPLEX CHAIN
COVER 61. SPROCKET
58. GRIP ROLLER SHAFT END BOLT 62. SPROCKET LOCKINGWASHER

26
7.3.5 Lubrication of bearings
The machine is equipped with a conveyor belt; cleaning roll
and belt drive rollers that are lifetime lubricated. Re-lubrication is
not required. While dismounting, the bearings have to be flushed
and refilled with new grease. The following rule is to be followed
while filling grease:
• Bearing should be entirely filled
• Housing should be half filled
The rotor bearings and grip roller bearings have to be re-
lubricated through the nipples mounted on the bearing housing.
After repeated lubrication, the housing should be opened and the
old grease must be replaced with fresh grease.
While dismounting the bearing over the course of repair
works or overhauling of the machine, the housing and bearing
must be flushed and refilled with new grease.
7.3.6 Gear motors
Three 10HP geared motors with gearboxes are fitted on the
machine. Two to drive the bottom and top cradle feed rollers
linked with chain & sprockets and one to drive the in-feed
conveyor.
7.3.7 Electric motors
For installation, dismounting, inspection and maintenance of
the motor, refer to the separate operation manual of the
manufacturer.

27
8 TROUBLE SHOOTING
8.1 Problems with the chip quantity
Problem Possible cause Suggested solution
Long slivers Excessive knife Adjusting knife clearance.
clearance between fly
knife and dead knife.
Defective screen Install new screen
Lots of fines Blunt knives Grind knives
Blunt dead knife Reverse dead knife

8.2 Problems with the Machine

Problem Possible causes Suggested solution

Rotor slow down Feed control (cradle) Check feed control

defective (cradle) and repair if
necessary
Blunt knives Grind knives (see 7.3.1.1)
Over feeding more than Decrease the feed rate.
the rated capacity
consequences :
material jamming in the
machine
Blunt knives Grind knives (see. 7.3.1.1)
Frequent Load control defective Check load control and
activation of repair
load control
Power of main motor Increase motor power
Chipping volume too Reduce chipping volume
high
Machine vibrate Imbalance of rotor due Grind all knives in one set
to uneven ground to equal width
knives
Unsatisfactory In- Teeth of grip rolls wornReplace grip rolls with new
feed out ones.
Lowering speed ofClean the side walls of
cradle too low. cradle to remove chip
dust.
Lower gear Grip roller jammed with Remove jammed material
motor cannot material between teeth and clean the rolls.
start rolls sides.

28
8.3 Problems with V-belts drive

Problem Possible causes Suggested solution

Side of belts Pulleys not in Align pulleys
worn alignment

Excessive Belts damaged due to Change all belts and install

stretching of improper installation new set correctly
belts
Foreign materials in Remove foreign materials
belt grooves and clean pulleys.

Belt sides crack High temperature due Tighten belts to correct

show burn marks to belt slippage tension ( see chapter “start
–up”)

Twisting of belts Pulleys not in Align pulleys

alignment

Foreign material in Remove foreign material

belt grooves and clean pulleys.

Belts damaged due to Change all belts and install

forced installation new set correctly

Belts Sticky or Effect of oil, grease or Clean belt with alcohol or

swollen chemicals benzene

8.4 Problems with the hydraulic system

Problem Possible causes Suggested solution

Jerky movements Air in hydraulic circuit Bleed hydraulic circuit

Directional valves Spool is jammed by dirt Disassemble + clean

does not move or resin build-up directional valve.
Change hydraulic fluid

29
9 KEEPING OF SPARE PARTS
Keeping stock of the most important spares and wear parts
on site is an important factor for the permanent functioning and
readiness for operation of the Drum Chipper.
The fitting and/or use of any parts not tested and certified by
us, may under certain circumstances have negative effects to the
described and prescribed functions of the CIBI Brand Drum
Chipper, and for that reason may actively and/or passively impair
the safety and smooth functioning of the machine.
We accept responsibility only for original spare parts
provided by us.
We do not provide any guarantee to spare parts and
accessories not purchased from us.

30
10 SPARE PART LAYOUT AND QUANTITY

Machine parts
Figure 10.1

31
Machine parts
Figure 10.2

32
 PIECE LIST QUANTITY
• ROTOR 1 NO
• 1 ROTOR HOUSING 2 NOS
• 2 ROTOR HOUSING COVER 2 NOS
• 3 ROTOR HOUSING BEARING (22238 K) 2 NOS
• 4 ROTOR HOUSING BEARING SLEEVE (H 3138) 2 NOS
• 5 ROTOR LOCKING ASSEMBLY 2 NOS
• 6 ROTOR SHAFT 1 NO
• TAPER BLOCK MALE 6 NOS
• TAPER BLOCK FEMALE 12 NOS
• LEAD SCREW AND NUT 3 SET
• LEAD SCREW SUPPORT BLOCK 3 NOS
• V BELT (SPC 6000) 11 NOS
• 7 MACHINE PULLEY 1 NO
• 8 MAIN DEAD KNIFE 1 NO
• 9 DEAD KNIFE HOLDER 1 NO
• 10 RECHIPPING DEAD KNIFE& DEAD KNIFE 1 NO
HOLDER
• GRIP ROLLER 8NOS
• 11 GRIP ROLLER HOUSING 16 NOS

• 12 GRIP ROLLER HOUSING COVER 16 NOS

• 13 GRIP ROLLER HOUSING BEARING(2218K) 16 NOS

• 14 GRIP ROLLER HOUSING BEARING SLEEVE 16 NOS
(H 318)
• 15 GRIP ROLLER HOUSING OIL SEAL (80-110-10) 32 NOS
• 16 GRIP ROLLER LOCKING ASSEMBLY 16 NOS
• 17 GRIP ROLLER SHAFT 8 NOS
• 18 SPROCKET (1¼” DUPLEX 16 TEETH) 14 NOS
• 19 CHAIN (1 ¼” DUPLEX)
• IDLE ROLLER 1 NO

33
• 20 IDLE ROLLER HOUSING 2 NOS
• 21 IDLE ROLLER HOUSING COVER 2 NOS
• 22 IDLE ROLLER HOUSING BEARING (2216K) 2 NOS
• 23 IDLE ROLLER HOUSING BEARING SLEEVE 2 NOS
(H 316)
• 24 IDLE ROLLER HOUSING OIL SEAL (70-90-13) 2 NOS
• 25 IDLE ROLLER LOCKING ASSEMBLY 2 NOS
• 26 IDLE ROLLER SHAFT 1 NO
• HEADPULLEY ROLLER 1 NO
• 27 HEADPULLEY ROLLER HOUSING 2 NOS
• 28 HEAD PULLEY ROLLER HOUSING COVER 2 NOS
• 29 HEADPULLEY ROLLER HOUSING 2 NOS
BEARING(22216K)
• 30 HEADPULLEY ROLLER HOUSING BEARING 2 NOS
SLEEVE (H316)
• 31 HEADPULLEY ROLLER HOUSING OIL SEAL 2 NOS
(70-90-13)
• 32 HEADPULLEY ROLLER SHAFT 1 NO
• 33 CRADLE GUARD LINER PLATE 2 NOS
• 34 CRADLE HOUSING 2 NOS
• 35 CRADLE HOUSING COVER 2 NOS
• 36 CRADLE HOUSING BEARING (2216 K) 2 NOS
• 37 CRADLE HOUSING BEARING SLEEVE ( H316) 2 NOS
• 38 CRADLE SHAFT 1 NO
• MOTOR PULLEY 1 NO

34