K-State Chipper/Shredder Installation and operating manual

Chipper/
Shredder
Safety
For the Landscaping and
Horticultural Services Industry

2 – Chipper/Shredder Safety
Chipper/
Shredder
Safety
Contents
Introduction
What’s Inside? ......................................................... 3
Lesson 1
Take Control of Your Own Safety ............................. 4
Lesson 2
Prepare for Safe Operation ..................................... 9
Lesson 3
Avoid Being Caught in the Chipper ........................ 14
Lesson 4
Avoid Being Struck by Equipment’s Hood ............... 18
Lesson 5
Environmental Hazards ......................................... 21
Conclusion ........................................................... 28
Quiz Yourself Solutions ......................................... 31
Written by:
Sara Lind, Information specialist
Mitch Ricketts, Coordinator, Health, Safety and Environmental
Quality, K-State Research and Extension
Disclaimer
is material was produced under grant number 46G3-HT04 and
revised and updated under grant number SH-19503-09-60-F-20
from the Occupational Safety and Health Administration, U.S. De-
partment of Labor. It does not necessarily reect the views or policies
of the U.S. D It does not necessarily reect the views or policies of
the U.S. Department of Labor, nor does mention of trade names,
commercial products, or organizations imply endorsement by the
U.S. government.
is booklet was produced by K-State Research and Extension, Kan-
sas State University, Manhattan, Kansas.
e information in this publication has been compiled from a
variety of sources believed to be reliable and to represent the best
current opinion on the subject. However, neither K-State Research
and Extension nor its authors guarantee accuracy or completeness of
any information contained in this publication, and neither K-State
Research and Extension or its authors shall be responsible for any
errors, omissions, or damages arising out of the use of this informa-
tion. Additional safety measures may be required under particular
circumstances.

Chipper/Shredder Safety – 3
is booklet teaches important safety practices to be followed when
operating a chipper/shredder.
Safety tips, along with real accident reports, have been combined in
order to give you a better understanding of the risks of incorrectly
operating equipment as well as working in unsafe environments.
Use this booklet in conjunction with hands-on safety training and
the equipment operator’s manual.
What’s Inside?

4 – Chipper/Shredder Safety
Take Control of
Your Own Safety
Greatest Dangers
You can be seriously injured or killed if you incorrectly operate a
chipper/shredder. e most commonly reported causes of serious
accidents are:
1. Being Caught in Moving Parts
You can be seriously injured or killed if you are caught in the
equipment’s moving parts.
2. Struck by Chipper/Shredder’s Hood
You can be seriously injured or killed if you open or close the
hood on a running chipper/shredder.
Lesson 1
Objectives
1. Name the most common types
of accidents involving wood
chipper/shredders.
2. Interpret the meaning of common
warning signs and labels.
3. Identify appropriate protective
equipment.
Summary of OSHA Accident Inspection 300492832
An employee was chipping branches when the chipper became
jammed. He tried to unjam the machine and was caught in the
infeed roller and chopped to death by the blades.
Never reach in to a running chipper/shredder.
Accident Report
Employee Killed in Chipper
Summary of OSHA Accident Inspection 124829318
An employee attempted to close the hood on a running chipper.
The hood struck some moving parts and hit the employee in the
chin, inging him backward. His head hit the pavement and he
was killed.
Never open or close the hood of a running
chipper/shredder.
Accident Report
Employee Struck by Chipper Hood

Chipper/Shredder Safety – 5
Help Yourself
Safe work habits are important. Here are three important actions
you can take to be safe on the job site.
1. Learn all you can.
To prevent accidents with wood chippers/shredders, read and
follow directions in the equipment operator’s manual. Pay atten-
tion to safety instructions in the manual and to warning labels
you see on the equipment. If you have questions, stop and ask
your supervisor before you continue.
2. Concentrate on working safely.
Sometimes you may be tempted to take risky shortcuts. Remem-
ber that an accident can leave you permanently injured or cut
your life short. For your safety and the safety of those around
you, do not take unnecessary risks. No deadline is so pressing
you can’t take the time to do your work safely.
3. Additional Precautions
Do not operate machinery if you are tired or have taken drugs
or alcohol. If you are on medication, discuss with your doctor or
pharmacist if you are capable of safely operating machinery.
Choose Safety

6 – Chipper/Shredder Safety
Safety Messages and Signs
Manufacturers put important safety messages on each piece of equip-
ment and in the operator’s manual. It is critical to read, understand
and follow all safety messages.
e triangle shape is the symbol for caution. e exclamation
mark in the center means Pay Attention. In some instances,
the triangle-shaped sign will show a picture. Other times, words
explain why the sign is used.
Many safety messages use the words Caution, Warning and Danger to
get your attention. Following are safety messages and their meanings.
Each of these signs will have a written message, and perhaps a
picture, about an unsafe condition.
CAUTION means you need to be careful. Follow the directions on
the sign or you could get hurt.
WARNING is more serious and means you need to follow the
directions on the sign or you could be badly hurt or killed.
DANGER is the most serious safety message. If you don’t follow the
directions, you will be seriously injured or killed.
DANGER
!
ENTANGLEMENT IN
PTO SHAFT CAN
SERIOUSLY INJURE
OR KILL YOU.
WARNING
!
YOU CAN BECOME
CAUGHT IN THE
EQUIPMENT’S
MOVING PARTS.
CAUTION
!
HEARING
PROTECTION
REQUIRED
Images displayed in the caution, warning and danger boxes have been recre-
ated from images taken with permission from ASAE S441.3, FEB1999 (R2005),
Safety Signs.

Chipper/Shredder Safety – 7
When to Wear Hearing Protection
OSHA Standard 1910.95 (i) (l) requires hearing
protection to be worn when sound levels
exceed certain limits (generally, a daily average
of 85 or 90 decibels, depending on the
circumstances). These levels can be measured
with a sound level meter. A hearing conservation
program requiring hearing tests and other
precautions may also be necessary. Check with
the equipment operator’s manual, as well as
your supervisor, for suggestions on hearing
protection for each piece of equipment as well
as instructions on how to wear it properly.
Hearing Protection Rules of Thumb
Hearing protection may be needed if:
4 You have to raise your voice signicantly to
be heard by someone three feet away.
4 After leaving a noisy area, your ears feel
plugged or you hear a mild ringing or
whooshing noise that goes away after an
hour or two.
4 When you start your car in the morning, the
radio is so loud from the evening before that
you have to turn it down.
Protective Equipment
Certain equipment is necessary to protect your body from materials
thrown from the chipper/shredder and to avoid being caught in the
equipment’s moving parts.
When operating a chipper/shredder, you should wear:
Close-tting clothes and no jewelry
Loose shirt sleeves, pant legs or jewelry can catch in the equip-
ment’s moving parts, resulting in injury. Do not wear gloves with
loose cus. Pull back long hair.
Long pants and sturdy, non-slip boots
Wear long pants, without cus, to protect your legs from objects
that could be thrown from the chipper. Sturdy, non-slip boots
will help you keep a rm footing on the ground and reduce the
risk of slipping and falling into the chipper/shredder.
Safety glasses
Wear safety glasses to protect your vision.
Hard hat
Wear a hard hat to protect your head from material that may be
kicked out of the machine.
Hearing protection
Over time, you will lose your hearing if you are exposed to loud
noises without protection.
Two common types of hearing protection are mus and plugs.
Ear mus should seal around your ears to properly mue loud
noises. Wash reusable ear plugs with warm, soapy water after
each use in order to prevent infection. Discard disposable ear
plugs after each use.
This logger’s style safety helmet can also be used while operating a chipper/
shredder. It contains a hard hat, hearing and face protection in one piece.

8 – Chipper/Shredder Safety
Quiz Yourself
Answers can be found on page 31.
Circle the correct answer.
1. What are the two most commonly reported causes of serious
injury and death from operating wood chippers?
a. Being caught in moving parts and being struck by the hood
b. Being struck by lightning and heat stroke
c. Being struck by debris and burns
Select the correct answer for the following sentences from the list
below.
a. Danger
b. Hard hat
c. Alcohol
d. Triangle
2. Do not operate machinery if you are under the inuence
of drugs or _________.
3. e __________ shape is the symbol for caution.
4. A __________ should be worn at all times when operating
a chipper/shredder.
5. _________ is the most serious safety message.

Chipper/Shredder Safety – 9
Lesson 2
Objectives
1. Indicate features to be inspected
before operation.
2. Recognize safe operating
procedures.
3. Identify safe transportation and
trac guidelines.
Pre-Start Inspection
Safety starts before the engine. oroughly inspect the chipper
before beginning work each shift. Use the checklist on the following
page as a guide. Alert your supervisor if you nd anything wrong
during your pre-start inspection.
Machine Placement
Place the machine on a level surface that is not concrete, paved or
gravel. Operating on these surfaces can cause thrown material to
ricochet and injure or kill the operator or bystanders. Also keep
other workers from falling into the chipper/shredder by ensuring the
location of the machine is not directly in front of or below where
other employees are working.
Safety Decals
Ensure that all safety decals on the machine are legible. Replace
any that cannot be read. Contact the chipper’s manufacturer
to order new decals. Contact information can be found in the
operator’s manual.
Missing or Damaged Guards
Guards and shields protect you from moving parts. Check the
operator’s manual for the location of guards and safety shields.
Prepare for
Safe Operation
Summary of OSHA Accident Inspection 112887237
An employee was removing a tree when the tail section of the
rope to which he was attached became entangled in the chipper
located on the ground below. The employee fell approximately
fty feet and died.
Position equipment away from other workers.
Accident Report
Employee Falls When Rope Becomes Caught in Chipper
Summary of OSHA Accident Inspection 110902368
An employee was operating a wood chipper without all guards
in place. He became caught in the rollers and was pulled through
the chipper and killed.
Never operate equipment without all guards in place.
Accident Report
Operator Pulled Into Chipper

10 – Chipper/Shredder Safety
Hood
Ensure the hood, enclosing the chipper/shredder’s knives, is
closed and latched before operating. Also, check for loose or
missing pins in the hood latch as well as cracked or worn hinges.
If the hood is not properly secured, it could y o and seriously
injure or kill you. e chipper/shredder should never be oper-
ated with the hood open.
Cutting Chamber
Ensure the cutting chamber is free of foreign objects or other
debris such as accumulated wood. Wood and foreign objects can
be thrown from the chipper at high rates of speed.
Fluid Leaks
Fluid leaks can cause res and breakdowns. Report signs of leak-
ing uid to your supervisor immediately.
Power Take-O (PTO)
Check to make sure the PTO shaft is tted correctly with a suit-
able guard. Also, check the operator’s manual to ensure the PTO
speed is suitable for the machine.
Pre-Start Checklist
Machine Placement
o On level surface?
o Not on paved, concrete or gravel surface?
Safety Decals
o Legible?
Guards
o All guards in place?
o No sign of damaged guards?
Hood
o Closed?
o Latched?
o Pins in place?
o Hinges not damaged?
Cutting Chamber
o Free of foreign objects?
o Free of wood and other debris?
Fluid Leaks
o No sign of uid leaks?
PTO
o Shaft tted with suitable guard?
o Speed suitable for machine?
Protective Clothing and Equipment
(as needed)
o No loose clothing or jewelry
o Long pants
o Sturdy, non-slip boots
o Eye protection
o Hard hat
o Hearing protection
Buddy System
o Work in groups of two or more
o Make sure someone knows your plans
Summary of OSHA Accident Inspection 114119498
An employee was trying to open or close the chipper hood when
it was struck by the disc. As the disc hit the hood, the hood was
ung o its hinge, striking the employee in the head and killing
him. Two latch pins and three mounting bolts were found after
the accident had occurred. They had been removed prior to the
accident.
Always inspect equipment for broken
or missing parts, before operating.
Accident Report
Hood Strikes Employee in Head

Chipper/Shredder Safety – 11
Using a Buddy System
1. Always work in groups of two or more. Be aware at all times of
the location of coworkers.
2. Make sure someone knows your plans: where you are going,
what you are doing and when you are going to be back.
3. If you have any severe allergies (such as bee sting), make sure
someone you are working with knows about the allergy and what
to do in the event of an allergic reaction.
Safe Startup Procedures
4 Start the chipper/shredder at the lowest possible speed and listen
for any noise or vibration that could indicate loose or broken
parts. If heard, turn o the machine.
4 Be aware at all times of the location of coworkers. Keep all others
out of the area.
4 Check the operator’s manual for additional procedures.
PTO
Additional precautions for PTO-driven models:
1. Ensure the PTO is hitched securely and level according to
the operator’s manual.
2. Put the tractor in neutral and set the parking brake.
3. Start the tractor engine, engage PTO clutch and then in-
crease speed to recommended RPM.
Safe Shutdown Procedures
4 Disconnect the power supply and remove key. You can tell the
machine has stopped when no noise or vibration is heard.
4 Check the operator’s manual for additional procedures.
Summary of OSHA Accident Inspection 119960789
An employee turned o a chipper’s motor, but did not wait the
recommended (by the manufacturer) ve minutes before open-
ing the hood to allow the parts to come to a stop. When the
employee opened the hood, the ywheel struck the edge of the
hood and ung it into the employee’s stomach. His intestines
were bruised and had to be partially removed.
Wait for all moving parts to come to a
complete stop before opening the hood.
Accident Report
Chipper Hood Strikes Employee in Stomach
Those with severe allergies to insect stings
should consult a physician about carrying
a prescription medical kit. The kit contains
medicine and instructions to be used if the
person is stung. If the kit is used, the victim
still must receive medical attention. Call for
help or take them to the nearest hospital.

12 – Chipper/Shredder Safety
Safe Fueling Procedures
Gasoline and other fuels are ammable. Following safe fueling pro-
cedures will help reduce the risk of fuel ignition.
4Always shut o the engine and wait at least 5 minutes for the
engine to cool before refueling.
4Use only approved fuel containers and store in a well ventilated
area, away from direct sunlight.
4Never smoke or have an open ame near fuel.
4Touch the fuel nozzle to the chipper/shredder before opening the
fuel cap to reduce the chance that a static spark will ignite the
fuel. Keep the nozzle in contact with the ller neck while fuel-
ing. Replace the cap as soon as you are nished.
4Use a funnel or non-spill nozzle when fueling to reduce spillage.
4Wipe up all spills immediately, before starting the engine.
4Never clean your hands or tools with gasoline. Use a nonam-
mable solvent instead.
Transportation & Trac
Never move, load or transport a chipper/shredder while the engine
is running. First, shut o the power supply, wait for all moving
parts to come to a complete stop and then disconnect the spark
plug wire (if applicable).
When towing, be sure to connect safety hitch chains and tighten
and secure trailer hitch bolts. Rotate the chipper/shredder’s discharge
chute in a direction where it will not strike objects along the road-
way. Equipment should only be towed at the manufacturer’s recom-
mended speed.
If the chipper/shredder is operated near a roadway, make sure it is
positioned far enough away to not interfere with the ow of trac or
injure passers by. Use ags and warning signs to alert motorists that
there are employees in the area. ese employees should wear highly
reective vests. Ensure the discharge chute is pointed away from the
roadway as well. is will keep debris from ying toward trac.
Summary of OSHA Accident Inspection 111895140
An employee was sitting on a chipper that was loaded on a trailer.
As the trailer was moving, it hit a hole in the ground and the chip-
per tipped over. The employee’s hand was pinned between the
chipper and the ground. He sustained severe cuts to his left hand.
Never sit on any part of the equipment under
any circumstance.
Accident Report
Chipper Overturns on Employee
To Properly Fill Fuel Containers:
1. Set the container on the ground.
2. Touch the fuel nozzle to the container before
opening the fuel cap so that any static spark
will not ignite vapors.
3. Keep the nozzle in contact with the
container while lling.
4. Don’t ll to the brim. Leave room for
expansion. Portable containers and gas
tanks should be lled ¾ full.

Chipper/Shredder Safety – 13
Quiz Yourself
Answers can be found on page 32.
Select the correct answer for the following sentences from the list
below.
a. e manufacturer’s recommended speed
b. Level
c. Five
d. Latched
e. Allergies
f. Signs
1. To set up a chipper/shredder for operation, choose a surface that
is ____________.
2. Before operating the chipper/shredder, check to see that the
hood is closed and _______________.
3. When working outside, it is important to know if your cowork-
ers have any severe ____________.
4. e gas tank should be lled after the engine has cooled for at
least _________ minute(s).
5. When towing a chipper/shredder, your speed should never ex-
ceed _____________________________.
6. When working near trac, use ags and warning _______ to
alert motorists that there are employees in the area

14 – Chipper/Shredder Safety
Safe Feeding Procedures
Materials should be fed into the chipper/shredder safely, to avoid
contact with the equipment’s moving parts. Follow these feeding
procedures to keep you safe.
4 Feed material only when the chipper/shredder is at full operating
speed.
4 Feed branches from the side of the chute, not in front of it. is
will reduce the risk of you being caught and dragged into the
machine. Standing to the side of the equipment will also make it
easier for you to reach the emergency shut-o switch in the event
of an accident.
4 Keep hands and feet outside of the feed chute.
4 Use a push stick to help feed small pieces and brush through the
chipper/shredder to keep you at a distance from the machine’s
moving parts. Do not push materials into the chute with your
hands or feet, pitch forks, shovels, etc.
4 Let go of material as soon as it begins to be pulled into the
machine and walk away to avoid being hit or dragged into the
chipper by limbs you are feeding.
4 Feed the branches butt end rst to keep the chipper from being
jammed and to reduce the kickback of material.
4 Lay shorter pieces of material on top of longer pieces and feed
through the machine.
4 Collect small materials such as leaves and twigs and put them
with the chipped material instead of feeding them through the
chipper/shredder.
Avoid Being Caught
in Moving Parts
Lesson 3
Objectives
1. Develop safe feeding procedures.
2. Recognize how to protect yourself
from moving parts.
Use a push stick to feed
small pieces of brush.
YES NO
Never push brush into the
chipper/shredder with your
arm or leg.

Chipper/Shredder Safety – 15
Moving Parts
Follow these steps to avoid losing body parts or your life in the
equipment’s moving parts.
4 Never leave the chipper/shredder unattended. is helps protect
children and unauthorized persons who may go near the equip-
ment.
4 Never inspect or work on equipment while it is running. is
will protect you from the machine’s moving parts.
4 Never operate the chipper/shredder without all guards in place.
ese guards were put on the machine by the manufacturer to
keep you from being caught in moving parts. Never remove or
redesign these guards.
4 Keep hands and feet away from all moving parts.
4 Before attempting to unclog debris or make adjustments:
1. Shut o engine.
2. Disconnect spark plug wire or battery cables (if equipped).
3. Remove key.
4. Disconnect PTO shaft (if equipped).
5. Wait for all parts to stop moving.
4 Eliminate tripping hazards by clearing all brush and debris from
the front and sides of the machine. is will keep you from fall-
ing into its moving parts.
4 Never climb or sit on the chipper/shredder while it is running.
Summary of OSHA Accident Inspection 100746346
The operator of a chipper was feeding small branches with his
foot. The foot became caught in the infeed rollers and was pulled
into the chipper. His right foot and ankle were amputated.
Never feed material with any part of your body.
Always use a push stick.
Accident Report
Operator’s Foot Amputated in Chipper
Summary of OSHA Accident Inspection 125903088
An employee was operating a chipper that became jammed. He
climbed on top of the chipper and unfastened the hood. His hand
slipped into the rotating blades and was cut o at the wrist.
Shut o the machine and wait for all parts to stop
moving before servicing equipment.
Accident Report
Employee Loses Hand in Chipper

16 – Chipper/Shredder Safety
PTO Safety
A rotating PTO shaft can quickly catch your clothing or hair and
wrap your body around the shaft, killing you before you can react.
However, PTO accidents are preventable. Follow these steps to safely
work around PTO shafts.
4 Never operate equipment without the PTO shields in place.
4 Ensure the shaft is secured to the tractor.
4 Keep all bystanders, especially children away from the shaft.
4 Keep hands, feet, clothing and hair away from the shaft.
4 Walk around a PTO shaft, never step over it.
4 Never inspect, service, lubricate or adjust the PTO unless the
PTO is disengaged, the tractor engine is shut o and the shaft
has stopped rotating.
A PTO shaft rotating at 540 rpm can wrap
about 424 feet of string in one minute. This
means that it would take a person 6 feet tall,
less than 1 second to become entangled.
Becoming entangled in the shaft can cause
suocation or amputation of limbs. It can
also cause clothing to be torn from your
body resulting in second-degree burns and/
or severe cuts in your skin.
A replacement PTO shield is inexpensive
and can be bought from most parts stores
and manufacturers.
Did You Know?
Never Operate Equipment
Without a PTO Guard.

Chipper/Shredder Safety – 17
Quiz Yourself
Answers can be found on page 33.
Select the correct answer for the following sentences from the list
below.
a. PTO shaft
b. Let go
c. Side
d. Butt end
e. Inspect
f. Reach
g. All guards
1. When feeding material, feed from the ________ of the chute.
2. Branches should be fed into the chipper/shredder _________
rst.
3. Never operate a chipper/shredder without _________ in place.
4. A rotating __________ can quickly catch your clothing or hair
and wrap your body around it.
5. Never _________ into the infeed hopper.
6. Do not __________ or work on equipment while the engine is
running.
7. ___________ of material as soon as it begins to be pulled into
the chipper/shredder.

18 – Chipper/Shredder Safety
Prevent Injury from the Hood
e hood that covers the chipper/shredder’s rotating blades can y
o and seriously injure or kill you. Take the following steps to pro-
tect you from the equipment’s hood.
4Check to see that the hood latch is secured. Check for any miss-
ing parts or hinges that may allow the hood to become loose.
4When starting the machine, unless the manufacturer recom-
mends otherwise, begin by running it at the lowest possible
speed and then increase to full operating speed while listening
for unusual vibrations indicating loose or broken parts. Stop the
engine immediately if there is any unusual noise.
4Do not attempt to open or close the hood of the chipper while it
is running. Close the hood before starting the engine.
4After turning o the engine, wait for all parts to stop moving
and disconnect the spark plug wire or driveshaft before opening
the hood.
Avoid Being Struck
by the Hood
Summary of OSHA Accident Inspection 102782224
The operator of a chipper removed the hood covering the blade
without shutting the machine o. The rotating blade struck the
hood, ripped it o its hinges and threw it at the operator, striking
him in the chest. The operator died.
Never open or remove the hood of a running
chipper/shredder.
Accident Report
Hood Strikes Operator’s Chest
Summary of OSHA Accident Inspection 106387681
The operator of a running chipper went near the hood and
removed the top pin. The hood ew o and struck him in the face
and chest, killing him.
Shut o the machine and wait for all moving parts
to stop before opening the hood.
Accident Report
Operator Struck by Chipper Hood
Lesson 4
Objectives
1. Recognize how to prevent injury
from the chipper/shredder hood.
2. Identify the location of the hood
on dierent chipper/shredder
models.
3. View dierent warning labels on
chipper/shredder hoods.
NOTE: The following information has
been covered in previous chapters. Due to
the seriousness of this issue, please review
the information.

Chipper/Shredder Safety – 19
DANGER
DO NOT OPEN
OR CLOSE HOOD
WHEN CHIPPER
IS RUNNING
DANGER
DO NOT OPEN WHEN
CHIPPER IS RUNNING
Hood Identication
As dierent models of wood chippers vary, so does the location of
the hood. Below are illustrations of dierent types of chippers with a
reference arrow or bracket pointed at the hood.
WARNING
Knife can cut
off your hand.
Warning Labels
Below are examples of warning labels you might
see on or around chipper/shredder hoods.
Warning label on hood.

20 – Chipper/Shredder Safety
Quiz Yourself
Answers can be found on page 34.
Select the correct answer for the following sentences from the list
below.
a. Stop
b. Open
c. Close
d. Parts
1. Never operate a chipper/shredder with the hood __________.
2. After turning o the engine, wait for all moving parts to come
to a complete ____________ before inspecting the machine or
opening the hood.
3. _______ the chipper/shredder hood before starting the engine.
4. Check for any missing ________ or hinges prior to operation.
5. Draw an arrow pointing to the location of the hood on the
following models.