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Rears Mfg Engine Drive Shredder Operator's Manual (2005 Model Year)

Rears Engine Drive Shredder Manual

(Click to view pdf file for 2005 Model Year Engine Drive Shredder by Rears Mfg)

The following operators manual is only for the year 2005 EDS05 Model Engine Drive Shredder, there may be parts differences between years. We are not responsible for ordering incorrect parts based on this information. The information provided is intended to help provide safe operations for the end user.

The Rears Mfg EDS05 Manual has been converted to plain text for your convenience below:

R E A R S Engine Drive Shredder



10.17.05 Engine Drive Shredder Flail Safety: Operator Training

Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by a single careless act of an operator. In addition to the design and con.guration of equipment, hazard control and ac­cident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of equipment. It has been said, the best safety device is an informed, careful operator. We ask you to be that kind of an operator. It is the operator’s responsibility to read and understand all safety and operating instructions in the manual and to follow these. Accidents can be avoided. Working with unfamiliar equipment can lead to careless injuries. Read this manual and the manual for your tractor before assembly or operation, to acquaint yourself with the machines. If this machine is used by any person other than the owner or is loaned or rented, it is the owner’s responsibility to make certain that the operator has instruction for the safe and proper use of the machinery and that the operator reads and understands the operator’s manuals. Know your controls and how to stop the tractor, engine, and implement quickly in an emergency. Read this manual and the one provided with the tractor. Train all new personnel and review instructions frequently with existing workers. A person who has not read and understood all operating and safety instructions is not quali.ed to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. Do not allow children to operate this machine.




Flail Safety: Preparation

Never operate the tractor and implement until you read and completely understand this manual, the tractor operator’s manual, and each of the safety messages found on the safety decals on the tractor and the implement. Personal protection equipment, including a hard hat, safety glasses, safety shoes, and gloves are recommended during assembly, installation, operation, adjustment, maintenance, repair, removal, or transport of this implement. Do not allow long hair, loose .tting clothing or jewellery to be around moving parts. Tractors, with or without implements, can often be noisy enough to cause per­manent, partial hearing loss. We recommend that you wear hearing protection on a full-time basis if the noise in the operator’s position exceeds 80db. Long-term exposure to noise over 85db can cause severe hearing loss. Long-term exposure to noise over 90db may cause permanent, total hearing loss. NOTE: Hearing loss from loud noise (from tractors, chain saws, radio earphones) is cumulative over a lifetime without hope of natural recovery. Operate the implement only with a tractor equipped with an approved Roll-Over­Protection-System (ROPS). Always wear your seat belt. Serious injury or even death could result from falling off a tractor– particularly during a turnover, when the operator could be pinned under the tractor. Operate only in daylight or good arti.cial light. Ensure the implement is properly mounted and in good operating condition. Safety shielding and safety decals must be properly installed and in good condition. iii

Flail Safety: Operation

The use of this equipment is subject to certain hazards which cannot be protected against by mechanical means or product design. All operators of this equipment must read and understand this entire manual, paying particular attention to safety and operating instructions, prior to use. If there is something in this manual you do not understand, ask your supervisor, dealer, or call the manufacturer. Most accidents occur because of neglect or carelessness. Keep all helpers and bystanders at least several hundred feet away from the operating implement. Only properly trained people should operate this machine. Keep children away at all times. When the machine is operated in populated areas or in other areas where thrown objects could injure persons or property, standard equipment safety chain shielding (which is designed to reduce the possibility of thrown objects) must be installed. If the machine is not equipped with full chain shielding, operation must be stopped when anyone comes within several hundred feet. The majority of accidents invlolve entanglement on a driveline, injury of bystanders by objects thrown by rotating blades, and operators being knocked off the tractor by low hanging limbs and run over by the mower. Accidents are most likely to occur with untrained operators or machines that are loaned or rented to someone who has not read the owner’s manual and is not familiar with the mower. Always stop the tractor, set the brake, shut off the engine, remove the ignition key, lower the implement to the ground and allow cutter blades to come to a complete stop before dismounting the tractor. Never leave equipment unattended with the tractor running. Never place hands or feet under the mower with tractor engine running or before you are sure all motion has stopped. Stay clear of all moving parts. Do not reach or place yourself under equipment until it is blocked securely. Take all possible precautions when leaving unit unattended: set parking brake, stop engine, and remove key from ignition.

Do not allow riders on the implement or tractor at any time. There is no safe place for any riders.

Do not operate unless all personnel, livestock, and pets are several hundred feet away to prevent injury by thrown objects. Never direct discharge toward anyone. Keep children away at all times. Install and secure all guards and shields before starting or operating. Keep hands, feet, hair, and clothing away from all moving parts. Take care when operating tractor and implement under trees with low hanging limbs: the operator can be knocked off the tractor and run-over. The rotating parts of this machine have been designed and tested for rugged use. However, they could fail upon impact with heavy, solid objects, such as steel guard rails and concrete abutments. Such impact could cause the broken object to be thrown outward at a very high velocity. To reduce the possibility of property dam­age, serious injury, or even death, never allow the cutting blades to contact such obstacles. Frequently check blades. They should be free of nicks and cracks and securely fas­tened. Pick up rocks and other debris before operating. Enter new areas carefully. Never assume an area is clear. Always check. Stop mower and tractor immediately upon striking an obstruction. Turn off the trac­tor, remove the key, allow all moving parts to stop before leaving the tractor seat. Inspect and repair any damage before resuming operation. Keep wood dust and debris cleared from engine compartment to minimize .re dan­ger. The operator should always have a .re extinguisher immediately available. The chain guards, bands, .aps, driveline shields, and gearbox shields should be used and maintained in good working condition. They should be inspected carefully, at least daily, for missing or broken cable, chain links, shields, or guards. Missing, broken or worn items must be replaced at once to reduce the possibility of injury from thrown objects or entanglement. Stay alert for holes, rocks and roots in the terrain and other hidden hazards. Keep away from drop-offs. Use extreme care and maintain minimum ground speed when transporting on hill­side, over rough ground and when operating close to ditches or fences. Be careful when turning sharp corners. Reduce speed on slopes and sharp turns to minimize tipping or loss of control. Be careful when changing directions on slopes. Do not start or stop suddenly on slopes. Avoid operation on steep slopes. When using an implement, 20% of the combined tractor and implement weight (at a minimum!) must be on the tractor’s front wheels. Without this weight, the tractor could tip over, causing personal injury or death. The weight may be attained with a front end loader, front wheel weights, ballast in the tires or front tractor weights. When attaining this minimum 20% front wheel weight, you must not exceed the ROPS weight rating. Weigh the tractor and the implement. Do not guess or esti­mate! Inspect the entire machine periodically as indicated in the maintenance section of this manual. Look for loose fasteners, worn or broken parts, pinched hydraulic hoses, and leaky or loose .ttings. Make sure all pins have cotter pins and washers. Serious injury may occur from not maintaining this machine in good working order. Be careful when operating the tractor and implement on uneven ground to avoid upsetting. In extremely uneven terrain, front wheel weights, front tractor weights, and/or tire ballast should be used to improve stability. Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up the tractor and implement. Practice improves skills in maneuvering rough terrain.

Avoid sudden starts and stops while travelling up or downhill.

Always travel down slopes, never across the face. Avoid operation on steep slopes. Slow down on sharp turns and slopes to prevent tipping and/or loss of control.

Flail Safety: Maintenance

Good maintenance is your responsibility. Poor maintenance is an invitation to trouble.

Follow good shop practice. Keep service area clean and dry. Be sure electrical out­lets and tools are properly grounded. Use adequate light for the job at hand. Make sure there is plenty of ventilation. Never operate gas/diesel engines in a closed building. The exhaust fumes may cause asphyxiation. Before working on this machine shut off the engine, set the brakes and remove the key from the ignition. Be certain all moving parts on tractor and implement have come to a complete stop before attempting to perform maintenance. Never work under equipment unless it is blocked securely. When performing any service or maintenance, always use personal protection de­vices such as eye, hand and hearing protection. Frequently check mower blades. They should be free of nicks or cracks and securely fastened. Periodically tighten all bolts, nuts and screws and check that all cotter pins are properly installed to insure unit is in a safe condition. When completing a maintenance or service function, make sure all safety shields and devices are installed before placing the unit back in service. Remove hydraulic pressure prior to doing any maintenance. Block the implement securely and turn off the engine. Never use your hands or any part of your body to locate a hydraulic leak. Use a piece of cardboard or wood to pass along the hydraulic line and determine the loca­tion of any leak. Wear protective gloves and glasses. Hydraulic .uid escaping under pressure can penetrate the skin. Openings in the skin and minor cuts are suscep­tible to infection from hydraulic .uid. If injured by escaping hydraulic .uid, see a doctor at once. Gangrene and death can result. Without immediate medical treat­ment, serious infection and reactions can occur. When disconnecting hydraulic lines, shut off supply: relieve all hydraulic pressure. Before pressurizing system, inspect all components. Make sure .ttings are tight and lines are not worn, kinked or damaged.

After servicing, be sure all tools, parts and service equipment are removed. Do not allow grease or oil build up on any deck or platform. Keep engine compartment clear of wood dust and debris to minimize .re danger. Never replace hex bolts with less than grade 5 bolts unless otherwise speci.ed, i.e. shear bolts. Refer to bolt torque chart for head identi.cation markings. Where replacement parts are necessary for periodic maintenance and servicing, gen­uine factory replacement parts must be used to restore your equipment to original speci.cations. The manufacturer will not claim responsibility for use of unapproved parts and/or accessories and other damages as a result of their use. If equipment has been altered in any way from the original design, the manufac­turer does not accept any liability for injury or warranty. A .re extinguisher and .rst aid kit should be kept readily accessible while perform­ing maintenance on this or any equipment.

Flail Safety: Tires

Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experi­ence to do the job. In.ating or servicing tires can be dangerous. Whenever possible, trained personnel should be called to service and/or mount tires. Always order and install tires and wheels with appropriate capacity to meet or exceed the anticipated weight to be placed on them. ix

Flail Safety: Transport

Comply with state and local laws governing highway safety and movement of farm machinery on public roads. re.ective red border

The use of .ashing amber lights is acceptable in most localities. However, some localities prohibit their use. Local laws should be checked for all highway lighting and marking requirements. When driving the tractor and equipment on the road or highway under 20mph (32kph) at night or during the day, use .ashing amber warning lights and a slow moving vehicle identi.cation emblem (SMV). Plan your route to avoid heavy traf.c. slow moving vehicle emblem Always install transport locks, pins or brackets before transporting. Do not drink and drive. Watch out for traf.c when operating near or crossing roadways. When driving hills or curves, slow down and make gentle turns. Make certain that at least 20% of the total weight of tractor and implement is on the front wheels to maintain safe steerage. Slow down on rough or uneven surfaces. Use extreme care and maintain minimum ground speed when transporting on hill­sides, rough ground, or when travelling close to ditches and fences. Be careful when steering around sharp corners. Never allow riders on either the tractor or implement. Falling off can kill. Be a safe and courteous driver. Always yield to oncoming traf.c in all situations, including narrow bridges, intersections, etc. Do not exceed 20mph (32kph). Reduce speed on rough roads and surfaces. Use hardened hitch pins with retainers when attaching to pull-type machines. Use a safety chain to prevent unexpected separation with pull-type models.

Flail Safety: Storage

Do not work under an implement supported by a jack. Do not put any part of body under a raised implement unless it is blocked securely. Store the implement away from activity. Do not park equipment where it will be exposed to livestock. Damage to equipment or injury to livestock could result. Do not permit children to play on or around the implement. Make sure the parked unit is on a hard, level surface with all safety devices in place and in good working condition. xi

Flail Safety: Safety Decals

This is the SAFETY-ALERT symbol. This symbol is used to visibly mark operating hazards. YOU MUST FOLLOW THE DIRECTIONS POSTED BESIDE THE SAFETY-ALERT SYMBOL TO AVOID BODILY INJURY OR DEATH. Before you operate any machinery, read the operator’s manual. A copy of every SAFETY-ALERT decal on your implement is included in your operator’s manual with a map of each decal on your implement. With your operator’s manual in hand, walk around the implement: .nd, read, and UNDERSTAND every SAFETY-ALERT decal. EVERY OPERATOR OF THIS IMPLEMENT MUST DO THIS FOR THEIR OWN SAFETY. On Safety Decals, there is often a signal word: DANGER, WARNING, CAUTION. These signal words indicate the level of hazard or degree of seriousness for the described hazard on the decal. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. Indicates a potentially hazardous situation that, if not avoided, may result in death or serious injury. Indicates an area of extreme danger- machine components and hazardous opera­tions that, for functional purposes, cannot be guarded and, if not avoided, could result in death or serious injury. Warns the operator of potential machine damage if indicated procedure is not fol­lowed. Keep safety decals clean and legible at all times and replace safety decals that are missing or have become illegible. When parts that bear safety decals are replaced, the replacement parts must have a current safety decal. Safety decals are available from your dealer or direct from the manufacturer. When applying a safety decal, be sure the application surface is clean (free of dirt and grease) and dry. The surface you are applying the decal to should be above 50°F (10°C).

decals won’t help if you can’t read them

install the decal properly and they’ll stick around




Engine Drive Shredder

Engine Drive Shredder Safety Decal Locations

For the safety of operators, maintenance workers, and bystanders, familiarize yourself with the safety decals on the chopper. Decals indicated on the illustration, below, are reproduced on the previous page. Decal 93 can only be seen if a guard is removed. Item numbers with a * can be found on both the left and right side of the machine. Make certain all decals listed here are present on the shredder and in good condition. Replacement decals are available from your dealer or direct from Rears.

(inside) 1. Top off the gearbox oil if needed. You will .nd instruc­tion for how to check the oil level and a list of recom­mended lubricants included on the parts page for your gearbox model in this manual.

2. Check your drive belt tension. New belts will stretch and become slack much more quickly than belts that have been broken in. Check new belts frequently.

3. Properly lubricate all grease points.

4. Check all fasteners - tighten as required.

5. In.ate tires to 36psi. Check tire pressure frequently.

Tractor Setup 1. Tractor size: 85hp 4x4 tractor recommended.

2. Tire pressure: in.ate tractor tires as recommended in your tractor’s operator manual.

3. Front weights: the tractor must have a full rack of front weights to keep adequate front wheel traction-when pulling the shredder up a hill or onto a trailer. When the 3-point is raised above the center of the axle at the end of a row or when loading onto a trailer, the pull from the shredder will tend to lift the tractor front end. In operating conditions with the 3-point lowered, the pull from the shredder will have little effect on front end loading (see table, right)

4. Shielding: to minimize brush dragging under the tractor, full tractor belly plates are strongly recom­mended. The tractor belly plate needs to extend beyond the tractor rear axle to overlap the shielding on the shredder arch. Any gaps in the shielding are potential catch points for brush and may keep brush from feeding properly.

5. Wheel tread: increase wheel tread to maintain tractor stability when working on inclines or rough ground. Refer to your tractor’s operator manual for instruction.

6. Brakes: do not transport implements unless tractor brakes are in good condition.

7. Hydraulics: two sets of remotes are required to operate the lift axle and the upper feed roll independently.

The hoses with orange ties are for the upper feed roll. Purple ties mark the axle lift hoses. A free .ow case drain connection is also required to allow the upper feed roll to .oat correctly. The case drain hose on the shredder is supplied with a 1/4” male quick connetor. A mating 1/4” female connector, also supplied, should be attached to the tractor. Operating Conditions Equivalent Tongue Weight @ 24” 3pt lowered, .eld operation 2700 lb 3pt raised, .at .eld 3200 lb 3pt raised, hilly .eld 3900 lb 3pt raised, trailer loading with long ramps- 50% grade 4300 lb 3pt raised, trailer loading with short ramps- 67% grade 4800 lb

8. Electrical: all electric controls for the operation of the shredder run off the electrical system on the shred­der. There is a 7-pin SAE J560 trailer plug for tail light operation. The plug conforms to the SAE J560 wiring standard: Terminal 1 Ground Terminal 3 Left Turn Signal, Brakes Terminal 5 Right Turn Signal, Brakes Terminal 6 Tail Lights

Engine Drive Shredder Tractor Hook-Up

The supplied 3-point arch is a tongue extension which connects to the standard tractor 3point. This extended pivot point allows the shredder to track better when turn­ing at the row head. The added brush shield beneath the arch helps to better feed the machine. 1. Connect 3-point arch to tractor: Wrap lower, hinged brush pan chain around the tractor 3-point arm and attach chain to keyhole pad on pan: .g ii. The chain in the center of the brush pan is for arch storage and should be secured out of the way during operation. To minimize brush dragging under the tractor, full trac­tor belly plates are strongly recommended. The tractor belly plate needs to extend beyond the tractor rear axle to overlap the 3-point arch brush pan. Any gaps in the shielding are potential catch points for brush and may keep brush from feeding properly: .g i. 2. Remove hitch jaw cross bolt on shredder tongue: the lower bolt which pins the hitch jaw shut. Pivot the hitch jaw retainer band up so the jaws are free to move. With the band elevated, slide the bolt back into the band holes to keep the retainer band out of the way when hooking up: .g iii.

3. Align hitch ball with hitch jaw: back the tractor up with the hitch ball level with the hitch jaws. As the ball enters the jaws, the jaws will close around the ball. Back up until the jaws are fully closed.

4. Lower retainer band over jaws and re-insert cross bolt through jaws to keep them together.

5. Loop safety chain from the back of the 3-point arch through the eye on the shredder tongue. Fasten with supplied shackle: .g iv.

6. Connect hydraulic hoses to tractor remotes: hoses marked with orange ties control the upper feed roll lift. Hoses with purple ties actuate the axle pantograph. The line marked yellow is the case drain. The feed roll lift function (orange ties) will be used most frequently and should be easily accessible.

7. Mount the shredder control box on the tractor.

8. Connect the trailer plug to the tractor for the rear tail lights.

There are two basic adjustments on the machine: gauge wheel height and the side roller length. 1. Set gauge wheel height: the gauge wheels are typi­cally set to where the feed rolls just skim the ground. The gauge wheels are intended to be a safety stop, protecting the lower feed roll .ngers in uneven terrain. The gauge wheels in normal operation should .oat over the terrain, suspended from the tractor 3-point.

The wheels are adjusted by loosening all the mount plate bolts, sliding the wheel to the desired height, and tightening all fasteners: .g i.

2. Adjust side roller length: the side rolls are set so the bottom of the lower pipe just clears the ground during operation. Align holes on the inner pipe with those on the outer pipe to select from a range of side roll lengths: .g ii. If necessary, cut the inner pipe to the desired length.

The bottom hole on the outer pipe is to allow the inner pipes to act as jackstands when working on the machine.

7 Engine Drive Shredder Th