Forest-Master FM6DD User manual

Model: FM6DD/FM4DDE
IMPORTANT: Read this manual fully before assembly and
use and observe all safety rules and operating instruc-
tions
Forest Master Direct
Drive Wood Chipper
FM6DD
FM4DDE

Forest Master Model: FM6DD/FM4DDE2
Your Product
Thank you for purchasing the Forest Master Direct Drive Wood Chipper. We hope
you are 100% satised with your product but if you have any questions or queries,
please don’t hesitate to contact us:
Forest Master Ltd Sales Tel: [phone]
Industry Road Email: [email protected]
Heaton Website: www.forest-master.com
Newcastle Upon Tyne Technical Enquiries Tel: [phone]
NE6 5XB
About Your Product
This manual is for models:
FM6DD - 6hp Petrol Engine
FM4DDE - 4hp Electric Motor
The FM6DD and FM4DDE are wood chippers specically designed to chip all kinds
of wood that has been freshly cut up to 50mm (2”) diameter. NOTE: Do not insert
wood over the diameter specied, roots or trunks, stones, plastic, metal or any
other objects that are not specically wood branches. Do not insert seasoned wood
as the chippers are designed for freshly cut soft and hard wood.
Please thoroughly read the safety instructions and guidelines and make sure you
are familiar with them before use.
CE Regulation Parts
To comply with CE regulation (countries with the EU), the Hopper Safety Plate (9)
and M3 Discharge Chute Safety Bolts (39) must be installed for your own safety
(Check exploded diagram for parts).
For non-CE regulation (e.g. use in the United States or outside of Europe) these
parts can be removed to make the chipper easier to use, but at the risk of your own
safety. Forest Master Ltd will accept no responsibility for injuries caused by using
the chipper without these parts installed.

Forest Master Model: FM6DD/FM4DDE 3
Contents
Contents
Title Page No.
Specications 4
Safety Instructions 5
Assembly 8
Operation 12
Maintenance 15
Troubleshooting 17
Warranty 19
Exploded Diagram (FM6DD) 20
Parts List (FM6DD) 21
Exploded Diagram (FM4DDE) 22
Parts List (FM4DDE) 23

Forest Master Model: FM6DD/FM4DDE4
Specications
Specication FM6DD FM4DDE
Engine/Motor LCT Maxx 6hp 208cc 4
Stroke
Forest Master 4hp
2800W Electric Motor
Fuel/Input Petrol 230V
Chipper Blade Twin Reversible Blades Twin Reversible Blades
Overall Height 780mm 780mm
Overall Length 910mm 910mm
Overall Width 480mm 390mm
Weight 38kg 35kg
Max Drum RPM 3600rpm 3000rpm
Max Wood Diameter 50mm (2 inch) 50mm (2 inch)

Forest Master Model: FM6DD/FM4DDE 5
Safety
General Safety
• The person using the machine must have adequate knowledge of the functioning
and operation of the machine and must have read the manual.
• Operators must be over the age of 18 and must not be under the inuence of
alcohol, drugs or any other substance that has an adverse eect on reaction
speed.
• The material to be fed into the machine should only be wood that is free from
nails, screws etc.
• The machine should be positioned on dry, level ground in the proper upright
position and there must be no tripping or slipping hazards in the vicinity that
could cause harm to the operator.
• Make sure the blades are in good condition and secure.
• Check that all bolts are tight and secure, especially on the hopper and discharge
chute.
• Only use the chipper in adequate lighting (i.e. sunlight or sucient articial
light).
Operation Safety
• When operating the chipper, always wear gloves, ear protection, safety glasses
and appropriate clothing. Do not wear loose clothing or jewellery.
• The chipper should be operated by one person only. Any other bystanders must
always be at least 50 feet from the work area.
• Do not chip wood over the specied maximum diameter (50mm/2”).
• Do not chip seasoned wood, the chippers are designed for freshly cut soft and
hard wood.
• Do not operate the FM6DD inside or in a conned space; the exhaust from the
engine contains carbon monoxide which is poisonous.
• Never overload or attempt to chip woods beyond the manufacturer’s
recommendation. It could result in personal injury or damage to the machine.
• Never place any part of your body inside the feed hopper or the discharge chute.
Fragments of wood that have not self-fed into the machine should only be
pushed with other pieces of wood that you are feeding into the chipper.
• If the chipper gets jammed you must immediately stop the engine or motor.
• Obstructed fragments inside the hopper should only be removed when the motor
is turned o and the drum has stopped rotating.
• Never leave the chipper unattended while the motor is running.
• Never move in front of the discharge chute.
• Ensure no wood fragments remain inside the chipper when turning it o.
• Always take into account the time delay needed from switching the machine o
for the knife drum to come to a halt.
Safety Instructions

Forest Master Model: FM6DD/FM4DDE6
• If the machine starts to make an unusual noise or vibrate, shut down the engine,
disconnect the spark plug wire (FM6DD) or plug socket (FM4DDE), wait 5 minutes
for the engine or motor to cool down, then inspect for damage. Vibration is
generally a warning of trouble. Check damaged parts and clean, repair and/or
replace as necessary.
• If the machine topples over during operation, immediately turn o the engine or
motor and for the FM4DDE model, disconnect the power cable.
• When using the FM4DDE, always use with a circuit that has an RCD to prevent the
chance of an electric shock.
Safety with Maintenance
• Inspection and maintenance must be done with the motor and driving unit
switched o and the spark plug (FM6DD) or power cable (FM4DDE) disconnected.
Wait 5 minutes for the engine or motor to cool down.
• Any worn or damaged parts must be replaced, to ensure that the chipper
is maintained and in a safe state. Only use Forest Master spare parts for
replacements. Contact us to arrange.
• Never use the wood chipper with damaged or worn cables.
• Never, under any conditions, remove, bend, cut, t, weld or otherwise alter
standard parts on the wood chipper. This includes all shields and guards.
Modications to your machine could cause personal injuries and property
damage and will invalidate your warranty.
• Never use a pressure washer or running water to clean the chipper. This might
lead to water ingress in the engine or the bearings (invalid warranty). Do not use
any aggressive cleaning products.
• Never transport the chipper with the motor still running.
• Prior to transport, use appropriate xing materials to fasten the chipper to the
xing points on the load surface.
• Prior to storing the machine, make sure that it has been restored to a sucient
state (i.e. clean and free from debris). Apply oil to the knives, the knife drum
and the bearings to protect them from corrosion. This is especially the case for
storage during long periods of inactivity of the appliance.
• Store the machine in a dry, closed room, out of children’s reach.
Safety

Forest Master Model: FM6DD/FM4DDE 7
Safety
Safety with Petrol (FM6DD)
Petrol is a highly ammable liquid. Petrol also gives o ammable vapour that can
be easily ignited and cause a re or explosion. Never overlook the hazards of petrol.
Always follow these precautions:
• Never run the engine in an enclosed area or without proper ventilation as the
exhaust from the engine contains carbon monoxide, which is an odourless,
tasteless and a deadly poisonous gas.
• Store all fuel and oil in containers specically designed and approved for this
purpose and keep away from heat, open ame and the reach of children.
• Replace rubber fuel lines and grommets when worn or damaged and after 5
years of use.
• Fill the petrol tank outdoors with the engine o and allow the engine to cool
completely. Don’t handle gasoline if you or anyone nearby is smoking, or if
you’re near anything that could cause it to ignite or explode. Re-install the fuel
tank cap and fuel container cap securely.
• If you spill petrol, do not attempt to start the engine. Move the machine away
from the area of the spill and avoid creating any source of ignition until the gas
vapours have dissipated. Wipe up any fuel to prevent re hazard and properly
dispose of the waste.
• Allow the engine to cool completely before storing in any enclosure. Never store
a machine that has gas in the tank, or a fuel container, near an open ame or
spark such as a water heater, space heater, clothes dryer or furnace.
• Never make adjustments or repairs with the engine running. Shut down the
engine, disconnect the spark plug wire, keeping it away from the spark plug
to prevent accidental starting, wait 5 minutes before making adjustments or
repairs.
• Never tamper with the engine’s governor setting. The governor controls the
safe operation speed and protects the engine. Over-speeding the engine is
dangerous and will cause damage to the engine and to the other moving parts
of the machine. If required, see your authorised dealer for engine governor
adjustments.
• Keep combustible substances away from the engine when it is hot.
• Never cover the machine while the exhaust is still hot.
• Do not operate the engine with the air cleaner or carburettor air intake cover
removed. Removal of such parts could create a re hazard. Do not use ammable
solutions to clean the air lter.
• The exhaust and engine become very hot and can cause a severe burn; do not
touch.
This list of warnings and cautions cannot be all-inclusive. If situations occur
that are not covered by this manual, the operator must apply common sense
and operate the wood chipper in a safe manner. Contact the dealers for
assistance in your area.

Forest Master Model: FM6DD/FM4DDE8
Assembly
Assembly
1. Lay all the parts out at in a suitable assembly area and check to make sure all
parts are there.
2. Slide the axle (46) into the square tubing of the base (42) and place a 16mm at
washer (47) on each end of the axle.
3. Next, place the wheels (43) on each end of the axle (46) and secure with a split
pin (45) through the small holes on the outer of the axle (46).
4. Finally, place each dome cap (48) on the ends of the axle (46) and secure the cap
by tapping it with a mallet or hammer.
Part Name Part
No. Qty.
Engine/Motor with Drum 60 1
Base 42 1
Feed Hopper 1 1
Discharge Chute 34 1
Axle 46 1
Wheels 43 2
Split Pin 45 2
16mm Washer 47 2
Dome Cap 48 2
M8x35 Bolts 56 4
Part Name Part
No. Qty.
M8 Washers 33 8
M8 Spring Washer 30 4
M8 Nut 57 4
M8x110 Bolt 49 2
M8 Serrated Washer 55 2
M6x23 Bolt 51 1
M6 Washer 41 3
M6 Spring Washer 59 3
M6x12 Bolt 50 2
Assembly Parts

Forest Master Model: FM6DD/FM4DDE 9
Assembly
5. Place the engine/motor (60) on top of the base (42), lining the engine/motor
mounting holes with the bolt holes of the base.
Fastening the engine and motor through the following methods:
Engine (FM6DD)
Fasten the engine (60) with the M8 bolts (56), M8 washers (33), M8
spring washers (30) and M8 nuts (57). The order of assembly is:
[Bolt] – [Washer] – [Base] – [Engine] – [Washer] – [Spring Washer] – [Nut].
Motor (FM4DDE)
Fasten the motor (60) with the M8 bolts (56), M8 washers (33) and M8 Lock Nuts
(57). The order of assembly is:
[Bolt] – [Washer] – [Base] – [Motor] – [Washer] – [Lock Nut].
FM6DD FM4DDE

Forest Master Model: FM6DD/FM4DDE10
7. Place the feed hopper (1) on the drum housing (14) so that the tube on the back
of the hopper lines up with the top bolt holes on the drum housing.
8. Slide the M8 bolt (49) through the M8 serrated washer (55), the drum housing
bolt holes and feed hopper tubing; the bolt should nd a thread on the other
side of the housing to fasten together.
9. Fasten the bottom of the feed hopper (1) to the drum housing (14) using the
M6 bolts (51) the M6 washer (41) and the M6 spring washer (59). There is a
thread in the drum housing to fasten the bolt into. The order of assembly is:
[Bolt] – [Spring Washer] – [Washer] – [Feed Hopper] – [Drum Housing].
Assembly

Forest Master Model: FM6DD/FM4DDE 11
Assembly
10. Place the discharge chute (34) on the drum housing (14), lining up the tubing on
the bottom of the chute with the bolt holes on the drum housing.
11. Slide the M8 bolt (49) through the M8 serrated washer (55), the drum housing
bolt holes and discharge chute tubing; the bolt should nd a thread on the other
side of the housing to fasten together.
12. Fasten the other side of the discharge chute (34) to the top of the drum housing
(14) through the bolt holes using the M6 bolts (50), M6 spring washers (59) and
M6 washers (41). The order of assembly is: [Bolt] – [Spring Washer] – [Washer] –
[Discharge Chute] – [Drum Housing].

Forest Master Model: FM6DD/FM4DDE12
Engine Operation for FM6DD Petrol Chipper
Starting the Engine
• Position your wood chipper on at, dry ground and make sure the machine
cannot be moved.
• Before starting, manually turn the drum to make sure it is not obstructed and
moves smoothly.
• Make sure the fuel shut-o valve is in the “ON” position.
• Move the choke control lever to the “CHOKE” position (should only be needed if
the engine is warm or not starting).
• Move the throttle control lever to the “FAST” position.
• Turn the ignition switch to the “ON” position.
• Grasp the recoil starter handle and slowly pull until you feel resistance. Let the
cord retract a little bit then pull the cord rapidly to start the engine. One or two
pulls usually starts the engine.
• Move the choke lever (if used for warm engine) slowly back to the “RUN” position
when the engine is running well.
• If the wood chipper has not been running (cold engine), warm up the engine by
running the engine at half throttle for 3 to 4 minutes, then advance the engine
throttle control to chipping speed.
Operation
Operation
NOTE: Higher revs does not necessarily mean more
torque to the blade drum. As you can see from
the power map, the highest amount of torque is
achieved around the 2500 rpm mark, and therefore
is the most ecient speed to maintain the engine
for chipping. We advise you do not increase the
revs to the maximum for chipping unless required,
as this works the engine harder for less results and
could shorten the long-term life span of the engine
(and use more petrol).
Stopping the Engine
• Move the throttle lever to “IDLE”
• Turn the ignition switch to the “OFF” position.

Forest Master Model: FM6DD/FM4DDE 13
Operation
Engine Operation for FM4DDE Electric Chipper
Starting the Motor
• Position your wood chipper on at, dry ground and make sure the machine
cannot be moved.
• Before starting, manually turn the drum to make sure it is not obstructed and
moves smoothly.
• Plug the power cable into a 230V mains socket or extension cable that is no
longer than 10m and has a wire size of 2.5mm2. The motor plug should have a
13 amp fuse installed. Do not use any other fuse other than 13amp.
• Press the green “ON” button.
Stopping
• Press the red “OFF” button.
• Disconnect the power cable from the mains socket.
Wood Chipping Operation
• The diameter of wood and branches should be no greater than 50mm (2”).
• Do not place any part of your body into the chute when loading. This is a very
unsafe method and could result in serious injury.
• Do not reach or step across the exit chute whilst the wood chipper is running.
This is very unsafe and could result in serious injury.
• The chipper works best with the discharge chute pointing upwards as it reduces
the chance of the chippings blocking the discharge chute.
• Do not use the chipper in wet conditions or place wood that is wet in the feed
hopper, this can cause the wood to stick to the drum and discharge chute and
clog up the chipper.
• When loading wood, place against the bottom side of the chute and let the
machine take the wood into the blades. Do not push the wood into the blades as
this could damage the machine.
• Do not over load the wood chipper. Let previous wood and branches go through
the blades before adding more.
• Always wear gloves, ear protection, safety glasses and appropriate clothing when
operating the chipper.
• Do not feed the chipper any foreign materials (stones, metal, plastic, string,
textile etc.)
• Do not use implements (i.e. fork or shovel) to feed the machine, especially not to
push the wood through.

Forest Master Model: FM6DD/FM4DDE14
Removing Blockage from the Chipper
• Never attempt to unblock the machine whilst the chipper is running.
• If the drum stops while chipping, stop the engine IMMEDIATELY and remove the
spark plug (FM6DD) or disconnect the power cable (FM4DDE).
• Unhinge either the feed hopper or discharge chute by loosening the bolt on the
bottom of chute and lifting it upward to allow access to the drum. Remove wood
or branches that are blocking the drum and then restart the engine and chip
again.
• If the wood or branches cannot be removed by hand, then it is possible to rotate
the drum in reverse. On the drum side of the chipper, remove the plastic cap
with a athead screwdriver and beneath there is a nut that can be turned (with
the appropriate socket) to rotate the drum in reverse.
Operation

Forest Master Model: FM6DD/FM4DDE 15
Maintenance
Maintenance
Regular maintenance is the way to ensure the best performance and long life of your
machine. Please refer to this manual and the engine manufacturer’s user manual for
maintenance procedures.
Before performing any maintenance procedure or inspection, stop the engine, wait
ve minutes to allow all parts to cool. Disconnect the spark plug wire (FM6DD) or the
power cable (FM4DDE).
Regular Maintenance Checklist
Procedure Before Each
Use
Every 25
Hours
Every 100
Hours
Check Engine Oil Level X
Check General Equipment Condition X
Check Blades for Sharpness and Wear X
Clean Engine Exterior and Cooling X
Change Engine Oil X
Replace Air Filter X
Replace Spark Plug X
Engine Oil (FM6DD)
The FM6DD does not have a dipstick in order to check the oil level. To ensure the oil
level is sucient, remove the oil cap on the side of the engine (next to the discharge
chute) and make sure that the oil is full to the brim of the cap. If not, add oil until it
ows out of the hole, replace the cap and wipe o any excess oil.

Forest Master Model: FM6DD/FM4DDE16
Maintenance
Engine/Motor Servicing
For the service of the petrol engine (FM6DD) refer to the engine manufacturer’s user
manual. If you need help accessing the manual, contact Forest Master.
Replacing and Sharpening the Blades
To remove the blades for sharpening or replacement you will need an appropriate
socket with no leading taper, as the bolt heads are shallow. If a socket with a leading
taper is used, there is a possibility of rounding the bolt head as the socket will slip.
Undo the bolt at the bottom of the feed hopper and lift the hopper upwards on
the hinge to access the drum. Loosen the bolts holding the blade to the drum and
remove the blade. There are two blade positions on the drum and both blades will
need to be maintained equally.
Note: The blades are reversible so they can be turned around to use the second side
before they need to be re-sharpened.
If the blades are re-sharpened, you will need to adjust the base block at the bottom
of the drum to close the gap between the edge of the block and the knives. The
base block will need to be moved inwards so that there is a gap of around 1/4mm
between the knives and the base block. Make sure the drum rotates freely by moving
it by hand or with a socket using the nut on the outside of the drum.
When retting the blades, you should use a small amount of mild thread lock to
secure each bolt.

Forest Master Model: FM6DD/FM4DDE 17
Troubleshooting
Most problems are easy to x. Consult the Troubleshooting Table below for common
problems and their solutions. If you continue to experience problems, or your prob-
lem is not listed, check the forest master website at www.forest-master.com rst as
it is continuously updated. If further help is required, contact our technical line on:
0191 276 6553.
Before performing any maintenance procedure or inspection, stop the engine, wait 5
minutes to allow all parts to cool. Disconnect the spark plug (FM6DD) or the power
cable (FM4DDE).
Troubleshooting
Symptom Possible Cause
The engine won’t
start (Petrol)
• Is the ignition switch in the “ON” position?
• Is the fuel shut-o valve on?
• Are you using fresh, clean fuel? If the fuel is old, change
it. Use a fuel stabilizer if you keep fuel longer than 30
days.
• Is the spark plug clean? If the spark plug is dirty or
cracked, change it. If it’s oily, leave it out, hold a rag over
the plug hole and pull the recoil cord several times to
blow out any oil in the cylinder, then wipe o the plug
and reinsert it.
• Is there sucient oil? Check the engine oil level and if
necessary top up to the correct level.
• Is there dirt in the carburettor? Undo the bolt holding the
oat chamber to the carburettor, empty out any fuel and
clean the inside using fresh, clean petrol. Remove the jet
in the bottom of the carburettor and clean it. Ret the jet
and the oat chamber.
• Is the pull start stuck or has more resistance? Check the
drum for blockages.
The motor won’t
start (Electric)
• Is the plug connected to a power outlet?
• If you’re using an extension cable, only use a wire of
2.5mm2 with a maximum length of 10m. Smaller or large
wires could result in loss of power to the motor.
• Check the fuse in the plug. If it has blown, change it.
• Check the power cable, the plug and the switch for dam-
age (both the supplied power lead and any extension
cable being used). If there is damage, change it.
• Is the motor too hot? The motor is protected with a
thermistor if overheating. Wait for it to cool down and try
again.

Forest Master Model: FM6DD/FM4DDE18
Symptom Possible Cause
The engine lacks
power or is not
running smoothly
(Petrol).
• Check that the throttle lever is in the “RUN” position.
• Is the air lter clean? If it’s dirty change it following the
procedure in the engine manufacturer’s manual.
• Is the spark plug clean? If it’s dirty or cracked, change it.
If it’s oily, leave it out, hold a rag over the plug hole and
pull your recoil cord several times to blow out any oil in
the cylinder, then wipe o the plug and reinsert it.
• Are you using fresh, clean unleaded fuel? If it’s old,
change it. Use a fuel stabilizer if you keep gas longer
than 30 days.
• Does your engine have the right amount of clean oil? If
it’s dirty, change it following the procedure in the engine
manufacturer’s manual.
• Check the oil level and adjust if needed.
Engine smokes
(Petrol).
• Check the oil level and adjust as needed.
• Check the air lter and clean or replace if needed.
• You may be using the wrong oil – too light for the
temperature. Refer to your engine owner’s manual for
detailed information.
• Clean the cooling ns if they are dirty.
Insucient draw-
ing through of
branches or bad
chipping perfor-
mance.
• Are the knives blunt or worn? Sharpen or replace if
needed
• Are the branches too thick? Maximum diameter is 50mm
• Is there too much or too little space between the knives
and the base plate? Adjust the bolts on the knifes to t
and manual rotate the drum to check if it turns smoothly.
Motor cuts out or
does not start.
• Is the motor too hot or overheating? Wait 10 minutes for
the motor to cool down and try again.
• Is there a blockage in the drum? Inspect the drum and
remove any potential blockages.
• Does the motor need to be reset? Press the reset button
on the motor (next to the on o switches).
Troubleshooting

Forest Master Model: FM6DD/FM4DDE 19
Warranty
This product carries a limited parts warranty for 1 year from the date of purchase.
Please keep your proof of purchase as this will be required for any claim.
Should this product become defective, contact the store where it was purchased and
either replacement parts will be issued, it will be repaired, or it will be replaced if
necessary.
IMPORTANT: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THIS
PRODUCT. MODIFICATION OF THIS PRODUCT (UNLESS SAID MODIFICATION HAS
BEEN AUTHORISED BY FOREST MASTER) WILL VOID THE WARRANTY.
The Warranty Does Not Cover:
1. Any part that has become inoperative due to misuse, abuse, neglect, accident,
improper maintenance or alteration.
2. The unit, if it has not been operated and/or maintained in accordance with the
owner’s manual.
3. Normal wear.
4. Routine maintenance items such as lubricants and blade sharpening.
5. Normal deterioration of the exterior nish due to use or exposure.
Warranty

Forest Master Model: FM6DD/FM4DDE20
Exploded Diagram
FM6DD Exploded Diagram (Petrol)
2
4
67
8
5
3
11
12
10
48 45
47
46
47
45
48
25
24
23
52
44
29
17
16
49
49
27
28
56
33
42
21
19
18
50
36
34
37
38
37
35
39
40
11
12
31
26
32
51
57
30
55
16
17
14
12
29
29
30
30
53
54
9
15
22
43
43
60
32
59
41
4141
4141
38
8
66
7
7
59
41
33
33
13
12
7
28
30
12
13 7 58
1
7 87