Caravaggi Bio 80 User guide

USE AND MAINTENANCE INSTRUCTION
MANUAL
Bio 80
BEFORE USING THE MACHINE, READ THE
INSTRUCTION MANUAL

1. HOW TO USE AND KEEP THE INSTRUCTION MANUAL
This instruction manual is aimed at the user of the machine ,
the owner , the maintenance cleaning operator and the repair
technician and must always be avaiable for consultation . The
instruction manual shows the user for which the machine was
designed and the machine’s technical characteristics . It also
supplies instructions for transport , cleaning adjustment , use ,
personnel informations , maintenance , spare parts ordering and
residual risk , and warnings with regard to operations that must
be carried out with particular care .
The machine is for professional use , so the instruction manual
can never be a substitute for suitable user experience. The
manual should be considered a part of the machine and must
by kept for future reference until the machine is demolished .
The instruction manual must always be avaiable for
consultation and must be kept in a dry , protected place . In
the case of loss or damage the user may request a
replacement from the manufacturer , quoting the series
reference , type and year of construction which are shown on
the plate fixed to the bio-chopper ( section 5 ) . The
manufacturer reserves the right to update production and
manual without the obligation to update earlier production and
manuals . The manufacturer is relieved from all responsability in
cases of:
improper use of the bio-chopper ;
uses not conforming with what is expressly specified in this
documentation ;
serious deficientes in prescribed and recommended
maintenance ;
unauthorised modifications or interferences ;
use of spare parts that are not original or model specific ;
total or partial failure to follow the instructions ;
force majeure ;

2. IDENTIFICATION OF MAIN PARTS
1. Hopper with guards
2. Chaff cutter hopper
3. Petrol engine-electric motor
4. Wheels / axle
5. Chassis
6. Sieve lever
7. Power take-off for MTC
8. Machine support
3
4
5
6
7
8
1
1
2
2
5
6

3. CORRECT USE OF THE MACHINE
The machine must be run by one operator only .
The operator must be have read and fully understood the instructions in this
manual in order to use the machine correctly .
The operator must be ensure that person or animals do not come whithin
the field of action while the machine is running .
The Caravaggi company’s Bio 80 bio-chopper has been built to chop
vegetables , foliage and natural wood of the dimensions indicated in the
relevant section .
It may be used for cutting peat and similar .
It is not suitable for chopping products other than those listed above .
To work with other products , contact the machine manufactures or
authorised dealers .
The operator must be aware of all the instructions given in the instruction
manual .
4. UNPACKING AND PREPARATION
The Bio 80 bio-shredder is delivered partially dismantled. It ca be arranged on
pallets to facilitate handling and transport before installation, depending on the
versions.
To transport the machine in these conditions it is indispensable to use a
transpallet or similar with a load capacity of around 100 kilos .
Avoid :
hoisting the bio-chopper with ropes or unsuitable hoists ;
dragging the bio-chopper ;
bumps or shocks ;
exposing the machine to rain , frost or any bad weather .
On taking delivery check that the contents correspond with the delivery note .
Should damage or deformity due to transport be noted , make an immediate
compliant to the carrier and advise the authorised dealer or the manufaturer .
In particular , check that :
there are no dents , signs of bumps or deformations ;
there are no damp areas or signs tha may lead to suppose that the
pack has been exposed to foul weather ;
there are no signs of tampering ;
After checking that transport has been carried out correctly , proceed to
assembling the machine as shown in figures 4 - 5 .

Fig. 4
Remove all the bio-shredder components from the packing.
Remove the snap catches from the axle and position the axle in its seat
in line with the central pin.
Mount the castors and the stop washers.
Remount the snap catches.
Position the hopper and tighten the screws using number 17 spanners.
Mount the chipper hopper and insert the pin.

5. TECHNICAL CHARACTERISTICS
The EC identification plate is clearly visible on the Bio 80 bio-
chopper ( fig. 5 ) .
In all communications with the manufacturer state the serial
number on the identification plate .
MACCHINE INDUSTRIALI
89/392
EN 292
EN 294
SERIAL No.
25037 PONTOGLIO (BS) - VIA M. ADAMELLO, 20
TELEF. 030 7470464 - FAX [phone] - ITALY
Fig. 5
Version
Power HP / kw
Supply
Prod. m3 /
h
BIO 80 B
59 / 812
Petrol
10*
BIO 80 MTC
610 / 5.98.9
MTC
10*
* data depending on quality of material to be chopped and feeding
speed
5.1 Overall dimensions
Breadth ( mm ) : 1100
Lenght ( mm ) : 500
High ( mm ) : 1200
Weight ( kg. ) : 100
LWA MAX ( dB ) : 104

6. SAFETY NORMS
Training
The machine must not be used by under 16’s and persons who
have not learnt the user instructions .
The operator is responsible for third parties present in the work
area . Keep children and domestic animals at distance when the
bio-chopper is in operation .
This machine may be used only for cutting up natural wood and
foliage . It must not be used for other purposes ( e.g. for
breaking up bottles and boxes in other materials ) .
Work only in adequate light .
When you start up engine check that machine is equipped with
the prescribed guards .
Wear protective gloves and goggles while working .
Preparation / Operation
Before begenning work check that the blades and the cutters are
perfectly fixed. If the blades show signs of damage they should
be sharpened or replaced .
Do not use the bio-chopper when it is raining .
The bio-chopper must be positioned on a flat , solid surface
where there is no danger of overturning .
Switch off the motor, remove the keys from the start panel and remove
the sparkplug cap ( the power supply cable for electric motor bio-
choppers , or check that the machine is disconnected from the
tractor PTO ) in order to :
-remove foreign bodies from the hoppers ;
-transport the machine or move it from the workplace ;
-carry out maintenance or cleaning ;
-leave the machine unattended .
The blades continue to turn for a few seconds even after the
ignition has been switched off .
Assemble the blades following the appropriate instructions and
use only original spare parts supplied by the manufacturer .
Never use the chopper with defective guards and protection or
without the safety devices correctly fitted .
Start up the engine with care and following the user instructions .
When the engine is functioning it is imperative to prevent anyone
from approaching the loading hopper , the discharger and the
side hopper .

If the blades undergo heavy shock and function in an anomalous
manner , stop the engine , remove the spark plug hood and
request expert advice .
Caution ! The fuel is highly flammable :
Keep fuel only in the containers made avaiable for this purpose ;
Refuel only in the open air . Do not smoke or in any way cause
naked flames during refuelling .
Fill the tank before starting the engine . Never open the fuel cap
or add petrol while the engine is running or when it is still hot .
If petrol should be split , never try to start the engine . Move the
machine away from the area involved area and avoid any
sources of ignition until the fuel vapours have despersed ;
Tighten up the fuel tank cap .

7. START - UP
Caution ! Before starting up the engine / motor check that the bio-
chopper is on a stable surface and that there are no animals or
unauthorised persons in the work zone .
Read the engine / motor manufacturer’s instruction book carefully .
Check that there is oil and fuel in the tank . Fill if necessary .
Petrol engine version
Put the selector at position “I” ( Start ) ( fig. 7 ) . Grasp the
starting knob ( fig. 8 ) and pull the cord without force until you
feel the resistance caused by compression , release the knob and
then give a sharp tug to start the engine .
Before beginning work let the engine idle for about 1 minute
then take it to maximum revs ( using accelerator lever ) and
proceed with normal use .
0
1
Fig. 7
Fig. 8
Electric motor version
Make sure the mains voltage corresponds to the motor rated voltage
(check the rating plate on the motor) .
Check that the power supply cable is connected then press the
start / stop button .
Version with tractor or motor cultivator coupling
Check that the bio-chopper is correctly hooked up to the PTO the
proceed with starting .
Functioning
Having correctly prepared the bio-chopper you can now proceed to
working the material to be chopped .

Upper hopper
Load trimming and foliage into the upper loading hopper , taking
account of avaiable power in function of the model you possess ( fig.
9 ) .
2
1
0
Ø 2,5 Ø 7
Fig. 9
Caution ! Take the material to the hopper mouth and let it fall in .
Never put hands and arms in to push material into the hopper !
The material that can be worked and chopped in this hopper must
not exceed 2,5 cm diameter .
To avoid the danger of intoxication from fumes , machines with
internal combustion engines should never be used in closed
environments .
Side hopper ( chaff cutter )
Assemble this hopper ( as shown in section 3 ) ensuring that the
closure hook is well fixed .
Use the side hopper ( fig. 9 ) for working large size material (
branches of up to 7 cm diameter ) .
0 Closed
1 Half-open
2 Open

8. MAINTENANCE
Caution ! Before proceeding with any maintenance operation swich
off the engine / motor and in any case ensure that there is no
possibility of the machine functioning . Suitable gloves are obligatory
for all maintenance operations .
To facilitate transportation of the Bio 80 bio-chopper its overall size
can be reduced by folding the side hopper inwards as follow :
Unhook the closure hook .
Fold the chaff cutter hopper immobilising it with wing nut 1 .
Fig. 10

Maintenance and storage
Keep all nuts , bolts and screws perfectly tightened in order to
work in safe conditions .
For safety reasons promptly replace worn or damage parts .
To protect hands during dismantling and assembly of the blades ,
wear suitable protective gloves .
Version with electric motor
Regularly check that the power supply cable is in perfect
condition . Never repair a damaged cable with insulating tape or
thermal clamps .
For the power supply conductor use only standardised rubber
cable of the type 05 RN-F in accordance with DIN 57282 / VDE
0282 .
Hook-up plugs must be in rubber or rubber covered .
Fig. 11

8.1 Blade replacement
Remove the side hopper
by unscrewing the 3 nuts
as shown in fig. 12.
Fig. 12
Unscrew the retaining screws and
remove the upper hopper .
Insert the keys in the two
apertures ( fig. 13 ) and remove
the blade .
Proceed with sharpening the
blade or , in the case of
replacement , request an original
spare part from the manufacturer
and reassemble following the
instructions in reverse order .
Fig. 13

8.2 Counter-blade replacement
Remove the side hopper by
unscrewing the 3 nuts as
shown in fig. 14.
Fig. 14
Unscrew the retaining screws and
remove the upper hopper .
Insert the keys in the two
apertures ( fig. 15 ) and remove
the counter-blade .
Proceed with sharpening the
counter-blade or , in the case
of replacement , request an
original spare part from the
manufacturer and reassemble
following the instructions in
reverse order .
Fig. 15
Caution ! For this operation the blade must be removed as indicated
at point 8.1 .

8.3 Breaker bar removal , inversion and replacement
Unscrew the retaining screws and remove the upper hopper
Remove the side hopper by unscrewing the 3 nuts ( fig. 14 ) .
Remove the transmission belt casing as shown in fig. 18 .
Remove the galvanised hole plate .
Manually turn the rotor to align the cutter shaft with the aperture .
Insert the Allen key on one side and number 13 spanner on the other.
Unscrew the locking screw and pull out the rod, collecting the spacers
as you do so.
If necessary replace the breaker bars . Take care to replace the
previously removed spacers in the same position on the cutter
shaft .
Caution ! Partial replacement of the breaker bars must be carried
out respecting the opposite position for balancing .
Fig. 16

8.4 Replacing the sieve
Remove the two nuts and detach the sieve from the lever.
Remove the sieve.
Mount the new sieve and the lever, then tighten the nuts.
The lever can be used partially opened out for shredding green or wet
material (Fig. 9).
Fig. 17
Sieve
Sieve lever
Nuts

8.5 Replacing and tensioning the drive belt
Remove the belt guard.
Remove the belt and mount a new one.
To tension the belt unscrew the 4 screws of the motor and pull it in the
direction shown by the arrow. The tighten the screws but avoid over-
stretching the belt.
Remount the guard.
Fig. 18

8.6 Replacing and tensioning the drive belt
Remove the belt guard .
Remove the belt and mount a new one.
To tension the belt unscrew the 4 screws securing it to the motor-
cultivator plate and pull the plate in the direction shown by the arrow.
Remount the guard.
Fig. 19

8.7 Routine maintenance
Beginning
of season
Before
each job
End of
season
Check engine oil level

Check screws , tightness ,
casing , hopper , etc .


Check belt tension and state
of wear


Check wear on cutters


Check wear on blade


Check wear on counter-blade


Check hopper rubber
protection



Clean machine

Check wear on bearings and
transmission shafts



9. TROUBLESHOOTING - REMEDIES
Troubleshooting
Remedies
The bio-chopper does
not start
Check belt tension and condition , blocked pulleys ,
PTO or gears .
Check cutters , blade , counter-blade and presence
of material in the milling chamber .
Check state of engine / motor ( consult the
instruction manual supplied ) .
Difficult start-up or loss
of power
Check belt tension and condition , blocked pulleys ,
PTO or gears .
Check state of engine / motor ( consult the
instruction manual supplied ) .
The bio-chopper loses
revs and functions
irregularly
Check belt tension and condition , blocked pulleys ,
PTO or gears .
Check cutters , blade , counter-blade and presence
of material in the milling chamber .
Check the sieve which should be free of
blockages.
Check state of engine / motor ( consult the
instruction manual supplied ) .
Examine the material being chopped at the
moment of breakdown .
Excessive vibration
Check cutters , blade , counter-blade and presence
of material in the milling chamber .
Drop in quality of
output material
Check belt tension and condition , blocked pulleys ,
PTO or gears .
Check state of engine / motor ( consult the
instruction manual supplied ) .
The hopper rejects the
material
Check cutters , blade , counter-blade and presence
of material in the milling chamber .
Check state of engine / motor ( consult the
instruction manual supplied ) .
Check state of wear on hopper rubber protection .