Caravaggi Bio 150 User guide

USE AND MAINTENANCE INSTRUCTION
MANUAL
Bio 150
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. Handles for transport
5. Outlet
6. Chassis 3rd point
7. Power take-off for MTC
8. Power take-off for a tractor
Fig. 1
Fig. 2
Fig. 3
3
2
1
4
5
6
7
8

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 150 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 150 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 300 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 that 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 5-6-7.

Kg. 150
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

5. TECHNICAL CHARACTERISTICS
The EC identification plate is clearly visible on the Bio 150 bio-
chopper ( fig. 8 ) .
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. 8
Version
Power HP / kw
Supply
Prod. m3 / h
BIO 150 B
11÷13 / 8.2÷9.7
Petrol
10*
BIO 150 B
10 / 7.5
Electric
10*
BIO 150 MTC
1014 / 7.510.4
MTC
10*
BIO 150 T
1025 / 7.518.6
P.T.O.
10*
* data depending on quality of material to be chopped and feeding
speed
5.1 Overall dimensions
SAFETY ZONE
R=2.00 m
Breadth ( mm ) : 1500
Lenght ( mm ) : 1100
High ( mm ) : 1580
Weight ( kg. ) : 150
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 discherger 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. 9 ) . Grasp the
starting knob ( fig. 10 ) 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. 9
Fig. 10
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 conected then press the
start / stop button .
Version with tractor coupling
Make sure the cardan shaft connecting the bio-shredder and tractor is
in proper working order.
Before each use, make sure the cardan shaft is in proper working
order.
Check that the bio-chopper is correctly hooked up to the PTO
then 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.
11 ) .
Ø MAX
3 cm
Ø MAX
9 cm
Fig. 11
Fig. 12
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 3 cm diameter .
The sieve control lever (fig. 12) is located on the left side of the Bio-
chopper; when the introduction of too much material causes blockage of
the machine, open the lever completely to release all the material, then
return it to its initial position and resume normal working.
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 (fig. 7) is well fixed.
Use the side hopper (fig. 11) for working large size material ( branches of
up to 7 cm diameter).

8. MAINTENANCE
Caution ! Before proceeding with any maintenance operation swith 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 150 bio-chopper its overall size
can be reduced by folding the side hopper inwards as follow :
Unhook the closure hook shown in fig. 7 .
Fold the chaff cutter hopper ( fig. 13 ) immobilising it with wing
nut 1 .
1
Fig. 13
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 yhe power supply cable is in perfect
condition . Never repair a damaged cable with insulating tape or
termal 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 .

8.1 Blade replacement
Unscrew the retaining screws and remove the upper hopper .
Insert the keys in the two apertures ( fig. 14 ) 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. 14
8.2 Counter-blade replacement
Remove the side hopper by unscrewing the 3 nuts as shown in fig.
15.
Unscrew the two security nuts of the counter blade to remove the counter
blade.
Fig. 15
Fig. 16
Caution ! For this operation the blade must be removed as indicated at
point 8.1 .
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 .

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. 5 ) .
Remove the transmission belt casing as shown in fig. 17 .
Remove the galvanised hole plate .
Manuallty turn the rotor to align the cutter shaft with the
aperture.
Insert the seeger pliers and remove the ring as shown in fig. 19
( chaff cutter side ) .
Remove the shaft , taking care to note the position of the
spacers separating the breaker bars ( fig. 20 ) .
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. 17
Fig. 18
Fig. 19
Fig. 20

8.4 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 .

10. GUARANTEE
1. The Manufacturer hereby guarantees its BIO - SHREDDERS against
breakage caused by faulty materials or workmanship .
2. This warranty is valid for the first owner only for 12 months as from the
date of purchase and / or delivery .
3. The Manufacturer is entitled to inspect the Bio - Shredder and any
components for which a claim has been made under the guarantee , in
order to determine the validity of the claim .
4. This warranty covers replacements free of charge only of components
found to be defective due to faulty materials or workmanship under the
guarantee period.
5. This warranty does not cover reimbursement for labour , consumables or
transport charges for repairs under guarantee .
THIS WARRANTY DOES NOT APPLY IN THE FOLLOWING CASES
1. The Manufacturer may in no way held liable for general damage ,
including damage or injury , loss due to halts in production , loss of
earnings , leasing costs or any moral or commercial damage .
2. All claims concerning motors or engines mounted on Bio - Shredder will
be handled by the relevant Manufacturers’ after - sales service .
3. This warranty does not cover damage caused by misuse , abuse ,
insufficient maintenance , accident or damage caused during transport .
4. Parts which are subject to war , such as hammers , blades , anvil blades ,
etc . are not covered under this guarantee .
5. All expenses for setting the machine to work will be charged to the
distributor or dealer .
6. This warranty is not valid if the repairs , maintenance or modifications are
performed by an unauthorised persons or dealers .
7. The owner is responsible for routine maintenance and settings , which are
thus excluded herefrom .
8. The use or fitting or components and accessories that are not original
will immediately invalidate this warranty .
PROCEDURE FOR MAKING CLAIMS UNDER THIS WARRANTY
If the Bio - Shredder is found to be defective due to faults material or
workmanship , you are required to send the Manufacturer a written claim and
proceed as follows :
1. The machine must be returned to the Seller or the authorised
CARAVAGGI importer .
2. You are required to present the guarantee duly filled in or the bill , if this
is not avaiable.
3. The claim will be completed by the Dealer , who will forward it to the
Manufacturer .
4. The Manufacturer alone reserves the right to determine whether to accept
the claim or otherwise .
Any disputes will be put before the Court of Brescia , Italy .

11. DECLARATION OF CONFORMITY
The company Caravaggi , hereby declares under its own
responsability , that the machine: BIOSHREDDER Type BIO
150 electric ( E ) , with petrol engine ( B ) , and with P.T.O.
( MTC , PTO ) ,
complies with the Basic Safety and Health Requirements
prescribed in EC Directive 98/37 , 89/336 and 89/392 94/626
and subsequent modifications thereto 89/686 , 91/368 , 93/44 ,
93/68 , and 2000/14.
EN 292
EN 294
The Manufacturer
( CARAVAGGI S.R.L.)
Pontoglio , 01 / JAN / 1995

SPARES BIO 150

SPARES BIO 150
Pos.
Description
Q.ty
Code
1
Rivet ø 4,9x16 Al
12
530002000
2
Upper rubber
1
010302000
3
Pin
1
010610000
4
Washer ø5x15x2
8
510003005
5
Angle
1
010310000
6
Lower rubber
1
010410000
7
Knob M8 F
1
013710000
8
Upper hopper
1
010304100
9
Chaff cutter hopper
1
011810000
10
Washer ø11x22x2
4
530001800
11
Self-lock nut M10
4
520007010
12
Chaff cutter support
1
011601000
13
Washer ø9x18x2
31
510005009
14
Self-lock nut M8
43
520002008
15
Knob ø25
2
012310000
16
Sieve lever
1
013410000
17
Lever spacer
1
013411000
18
Washer
2
511000100
19
Belleville washer
2
511100100
20
Knob M12
1
012311000
21
Washer ø12x24x2
19
511100120
22
Self-lock nut M12
11
520003012
23
Chaff cutter side panel
1
012510000
24
Counterblade
1
013100001
25
Bottom
1
012000001
26
Bottom pin
4
012100000
27
Screw TSPEI M8x20
2
500011008
28
Screw TE M8x20
19
500008008
29
Discharge casing
1
012210001
30
Left side panel
1
010140001
31
Discharge rubber
1
012910001
32
Nut M12
1
520000001
33
Sieve pin L
1
012110001
34
Sieve guides
2
012710001
35
Sieve ø40 STD
1
012810003
36
Screw TSPEI M8x30
3
500012008
37
Blade
1
013300000
38
Bearing SBPF 206
2
550002030

SPARES BIO 150