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Morbark WOODHOG 2600 Operators Safety Manual

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MODEL
WOODHOG
OPERATOR
MANUAL
MANUFACTURED BY:
MORBARK, INC.
2600
SAFETY
1
76347-374
03/05
03/05

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Summary of Contents for Morbark WOODHOG 2600

  • Page 1 MODEL 2600 WOODHOG OPERATOR SAFETY MANUAL MANUFACTURED BY: 76347-374 MORBARK, INC. 03/05 03/05...
  • Page 2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 Thank you for purchasing a Morbark, Inc. product. Before we begin this manual, the people at Morbark, Inc. want you, the owner-operator, to know this piece of equipment can be very dangerous if safety procedures and warnings are ignored. Read &...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS LOCKOUT PROCEDURES ..................6 SPECIFICATIONS ....................7 MAIN COMPONENTS ..................... 8 SAFETY ........................10 OBSERVE "CAUTION" MESSAGES ....................10 DO NOT MODIFY MACHINE ......................10 BEFORE OPERATING ........................10 OBSERVE SAFETY SIGNS AND MESSAGES ................. 10 OPERATE SAFELY ..........................11 PROTECT AGAINST NOISE ......................
  • Page 5 TABLE OF CONTENTS BELT CLEANING INSTRUCTIONS ....................35 BELT TIGHTENING PROCEDURES ....................36 OPERATION OF THE BRUNEL TORQUE LIMITER ............... 37 GENERAL MAINTENANCE ......................37 REMOVING SAFETY ELEMENT FROM TORQUE ASSEMBLY ........... 38 DISASSEMBLY OF SAFETY ELEMENTS ..................39 METHOD OF ASSEMBLING SAFETY ELEMENTS ................ 39 MOUNTING INSTRUCTION FOR SAFETY ELEMENTS ..............

  • Page 6: Lockout Procedures

    Failure to lock out while performing maintenance could result in serious personal injury or death! Morbark equipment is designed to be quickly and easily locked out whenever maintenance or repairs are performed. Train your crew to lock out every time!

  • Page 7: Specifications

    SPECIFICATIONS General Length ........................34 ft (10.3 m) Width ........................... 7.8 ft (2.3 m) Height ........................... 11 ft (3.3 m) Gross Weight ....................24,500 lb (11,113 kg) Electrical System ........................12 Volts Axle ........................19,800 lb (8,891 kg) Power Options Cummins .........................

  • Page 8: Main Components

    MAIN COMPONENTS RIGHT SIDE MAGNETIC HYDRAULIC PULLEY CLEANER TANK DEBRIS FUEL BELT SHEILD PINTLE- CHUTE TANK FIFTH WHEEL HITCH 03/05...

  • Page 9: Left Side

    MAIN COMPONENTS LEFT SIDE BATTERY MUFFLER INFEED BED CONTROL POWER DISCHARGE STABILIZERS PANEL UNIT CONVEROR SERIAL NUMBER PLATE 03/05...

  • Page 10: Safety

    DO NOT MODIFY MACHINE Any modification to the machine must be approved by Morbark. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life or cause serious personal injury or death.

  • Page 11: Operate Safely

    SAFETY OPERATE SAFELY CAUTION: Do not allow familiarity (gained from frequent use of your ma- chine) to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict serious injury. Be sure everyone is clear of the machine. Sound horn 2 or 3 times to alert all personnel and anyone else close by that you are ready to start up the power unit.

  • Page 12: Do Not Modify Machine

    SAFETY AVOID CONTACT WITH MOVING PARTS There are hazards associated with conveyor belts, V- belts and chains. Objects or body parts can become crushed between conveyor belts and rollers, between V-belts and pulleys and between chains and sprockets. Stay away from these areas when the machine is running and follow Lockout/Tagout procedures before adjusting or performing any maintenance on any of these systems.

  • Page 13: Avoid High Pressure Fluids

    SAFETY AVOID HIGH PRESSURE FLUIDS High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured, seek emergency medical help. Immediate surgery is required to remove oil. Do not use finger or skin to check for leaks. Lower load or relieve hydraulic pressure before loosening fittings.

  • Page 14: Safety Signs

    SAFETY SIGNS 03/05...
  • Page 15 SAFETY SIGNS 03/05...

  • Page 16: Crime Prevention

    Record serial number (S/N) of machine and identification numbers of engine, clutch hydraulic components etc. EXACTLY as they appear on the plates. These numbers can be found in your Morbark Parts Manual supplied with your machine and on the various components.
  • Page 17 CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE 1. Remove ignition key and lock the main power switchbox. Place hard-to-move equipment in front of exits. 2. If machine is being stored, remove the battery or any essential component in the electrical system.

  • Page 18: Fire Protection

    CRIME PREVENTION REPORT THEFT 1. If a theft occurs, notify the law enforcement agency having jurisdiction and the insurance carrier immediately. 2. Give a full description and a complete set of serial and identification numbers (found on the side of the infeed bed near the front) to the investigating officer and insurance carrier.

  • Page 19: Engine Controls

    ENGINE CONTROLS IQAN DISPLAY - Refer to Iqan manual for operating information. DATA LINK HOOKUP - Provides access for the Iqan system. DATA LINK HOOKUP - Provides access for cat diagnostics. DATA LINK HOOKUP - Provides access for cummins and john deere diagnostics. SETUP MODE - Push switch up for machine set up or maintenance (run stabilizers,raise yoke) and push down when grinding.

  • Page 20: Radio Control

    REMOTE CONTROLS RADIO CONTROL The remote control transmitter and receiver provided with this machine have matched radio signals that prevents unintentional operation by stray signals. However stray radio signals, high voltage power lines and other forms of interference can cause the remote control system to stop working or work errati- cally.
  • Page 21 REMOTE CONTROLS REMOTE AND TETHER CONTROL YOKE - Push toggle up to operate the DANGER/CRUSH, ENTANGLEMENT yoke foward. Push toggle down to reverse HAZARD: Keep everyone clear of the yoke. feedworks during operation. YOKE UP - Push and hold the toggle up to raise the infeed yoke.

  • Page 22: Safety Controls

    SAFETY CONTROLS YOKE STOP BAR This bar is used to stop the yoke wheel from raising to high. CAUTION: Yoke stop bar must be installed during operation or damage to your machine can result. INFEED DEBRIS DEFLECT Used for containment of flying debris when in position.

  • Page 23: New Power Unit Break-In

    SAFETY OPERATION For a safe and productive operation, read the safety section thoroughly along with the controls section before start up. All personnel (not just the operator) shall read this section and understand the operation of this machine and dangerous areas to avoid.

  • Page 24: Pre-Operational Checklist

    SAFETY OPERATION PRE-OPERATIONAL CHECKLIST 1. It is the operator’s responsibility to inspect the machine before the start of each workday by completing a pre- operation inspection. 2. It is recommended that each operator inspect the machine before operating, even if another operator has already put the machine into service.

  • Page 25: Starting Machine

    SAFETY OPERATION STARTING MACHINE 1. Review the condition of the machine. 2. Place all hydraulics in the neutral position. 3. Make sure clutch is in disengaged and locked position. 4. Turn main key switch to the ON position. 5. Give several blasts of the warning horn to clear area with remote or tether.

  • Page 26: Yoke Lock Procedure

    SAFETY OPERATION YOKE LOCK PROCEDURE DANGER/THROWN DEBRIS HAZ- ARD: Never have the Hammermill engaged when installing the yoke locks. DANGER/THROWN DEBRIS HAZ- ARD: Always use the Center Section controls to raise and lock yoke. Unpin yoke stop bar and remove. Raise yoke with remote and hold in the up position.
  • Page 27 SAFETY OPERATION REGRIND LOCK PROCEDURE DANGER/THROWN DEBRIS HAZ- ARD: Never have the Hammermill engaged when installing the yoke locks. DANGER/THROWN DEBRIS HAZ- ARD: Always use the Center Section controls to raise and lock yoke. Unpin yoke stop bar and remove. Raise yoke with remote and hold in the up position.

  • Page 28: Safety Procedures

    SAFETY OPERATION SAFETY PROCEDURES 1. Always make sure all filler plugs, caps and guards are in place. DANGER/THROWN DEBRIS HAZARD: Never, under any circumstances, open the yoke without first making sure the mill has completely stopped. 2. Always wear appropriate safety equipment such as a hard hat and safety glasses.

  • Page 29: Machine Shut Down

    SAFETY OPERATION MACHINE SHUT DOWN 1. Throttle engine down to an idle. 2. Place all hydraulics in neutral. 3. Disengage clutch. 4. Allow engine to idle 3-5 minutes and then shut off. 5. Turn off main switch and remove ignition key.

  • Page 30: Transporting

    SAFETY OPERATION TRANSPORTING Check to make sure the clutch is Hook up the electrical connections and disengaged. air brake lines. Make sure the mill has completely Check the tire pressure for proper load stopped. range. Raise machine using the stabilizers to Check the brakes, turn signals and tail the height needed to hook the machine lights.

  • Page 31: Routine Maintenance Schedule

    ROUTINE MAINTENANCE SCHEDULE 03/05...

  • Page 32: Routine Lubrication Schedule

    ROUTINE LUBRICATION SCHEDULE YOKE WHEEL DRIVE LUBRICATION Drain all oil out of feed wheel. With feed wheel in position shown fill hose 1 with proper amount of 80/90 gear gear oil. Hose 2 is is for venting while filling. W6 hub (2600) 50 oz. of oil W7 hub (3800) 90 oz.

  • Page 33: Routine Maintenance

    ROUTINE MAINTENANCE TIGHTENING TORQUE GUIDE NOTES: 1. Parts using rivet nuts 25 ft. lbs. maximum. 2. Always use the torque values above when specific torque values are not available. 3. Do not use above values in place of those specified in other sections of this manual; special attention should be observed when using SAE Grade 6, 7 and 8 cap screws.

  • Page 34: How To Use A V-Belt Tension Gauge

    ROUTINE MAINTENANCE HOW TO USE A V-BELT TENSION GAUGE WARNING: Before doing maintenance or tensioning on belt drives, turn equipment off and lock out the power source. Use guards on machinery when running. 1. Place a matched set of belts over the sheave grooves.

  • Page 35: Belt Installation

    ROUTINE MAINTENANCE BELT INSTALLATION Keep the following suggestions in mind when installing drive belts. 1. Clean oil and grease from the sheaves, remove any rust or burrs from the grooves. 2. Loosen adjuster bolts until the belts can be put on the sheaves without forcing or prying.

  • Page 36: Belt Tightening Procedures

    ROUTINE MAINTENANCE BELT TIGHTENING PROCEDURES WARNING: Shut power unit off and follow lockout procedures before any maintenance is performed. 1. Unsnap the two latches that hold shut the belt guard and swing down. 2. Loosen the four (4) bolts that hold the tensioner in place.

  • Page 37: Operation Of The Brunel Torque Limiter

    We recommend that each safety element be given two pumps of “MOBIL XTC” grease (Morbark P/N 18683-082) or equivalent every time the torque disengages or once a week. Note: for proper lubrication of the torque limiter, lubricate with elements disengaged.

  • Page 38: Removing Safety Element From Torque Assembly

    ROUTINE MAINTENANCE FIGURE 2 FIGURE 1 Remove safety elements (1-1) (See "removing safety elements from torque limiter assembly and inspect the detent pocket (2-16) detent ball (2-14) and flanged bushing (2-13) for wear, looseness or distress. While the safety elements are removed check the ball bearings (1-5) for wear by succes- sively lifting and lowering the driven sheave and observing the amount of movement of the outer hub (1-2) with respect to the housing carrier (1-1.) If there appears to be excessive play the torque limiter assembly should be removed from the drive line and disassembled for further inspection.

  • Page 39: Disassembly Of Safety Elements

    METHOD OF ASSEMBLING SAFETY ELEMENTS 1. Clean all components and coat all working surfaces with a suitable grease “MOBIL XTC” grease (Morbark P/N 18683-082) or equivalent. 2. Grease and install o-ring (2-6) into groove in housing (2-1.) 3. Grease inside surfaces of the housing (2-1) and install the outer thrust race (2-3.) 4.

  • Page 40: Detent Pocket Extraction Tool

    ROUTINE MAINTENANCE DETENT POCKET EXTRACTION TOOL FIGURE 7 ITEM DESCRIPTION M12 - 1.75 X 150 LG Grade 8 Socket (or Hex) Head Cap Screw. M12 Heat Treated Nut. 2" X 2" X 3/8" Steel Plate 1/2" Hole In Center. JSE2-3001 Detent Pocket. 03/05 REV.

  • Page 41: Changing Hammermill Hammers

    ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS WARNING: Read maintenance safety proced- ures carefully before beginning. DANGER/THROWN DEBRIS HAZARD: Do not use the clutch for hammer changing for any reason. This procedure should be followed whether you are changing one hammer, all hammers or changing to a different hammer pattern.

  • Page 42: Changing Hammermill Inserts

    ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS CONT. CAUTION: Two (2) people are required at all times when performing maintenance. 6. Remove the mill access panel to install rods and for communication purposes. 7. Loosen but do not remove the four (4) bolts in the rod lock plate, with the inside man turning the mill until each bolt is accessible while the outside man loosens them.
  • Page 43 ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS CONT. 14. Insert the second rod in the 10 o’clock hole and attach the rod driver. 15. Position the second row of hammers, one at a time and drive the rod into position engaging the back of the first row of hammers and the front row of the second row of hammers.
  • Page 44 ROUTINE MAINTENANCE CHANGING HAMMERMILL INSERTS WARNING: Read maintenance safety proce- dures carefully before beginning. DANGER/THROWN DEBRIS HAZARD: Do not use the clutch for insert changing for any reason. 1. Disengage the clutch at 800 RPM. 2. After clutch is disengaged the mill will coast (rotate) for several seconds until it completely stops.

  • Page 45: Raker Maintenance

    ROUTINE MAINTENANCE RAKER MAINTENANCE WARNING: Read maintenance safety procedures carefully before beginning. DANGER/THROWN DEBRIS HAZARD: Do not use the clutch for raker maintenance for any reason. 1. Disengage the clutch at 800 RPM. 2. After clutch is disengaged the mill will coast (rotate) for several seconds before it completely stops.
  • Page 46 ROUTINE MAINTENANCE RAKER MAINTENANCE CON’T 5. Locate the raker gauge on top of the hammermill plate, next to the raker you are checking. With the gauge in a vertical posi- tion, note the top of the raker in relation to the raker gauge.
  • Page 47 ROUTINE MAINTENANCE MILL MAINTENANCE WARNING: Read maintenance safety procedures carefully before beginning. 1. Place all hydraulics in neutral. 2. Throttle engine down to an idle and disengage clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has come to a complete stop before attempting any maintenance.
  • Page 48 ROUTINE MAINTENANCE MILL MAINTENANCE 7. Preheat mill plate to the temperature on the chart (see below.) Check temperatures 4" past each end of the crack. To check temperature of the plate use a temperature gun or a tem- perature paint stick 8.

  • Page 49: Hammer Patterns

    ROUTINE MAINTENANCE HAMMER PATTERNS NOTE: The amount of wear experienced by your rakers is determined by the type of material that you are grinding and the number of hammers in your hammer pattern. The fewer hammers you have, the more wear you will experience with your rakers. CAUTION: The fewer hammers in your hammermill, the more aggressive your grinding capabilities.

  • Page 50: Replacing Grates

    ROUTINE MAINTENANCE REPLACING GRATES WARNING: Read maintenance safety proce- dures carefully before beginning. DANGER/THROWN DEBRIS HAZARD: Do not use the clutch for grate changing for any reason. 1. Disengage the clutch at 800 RPM. 2. After clutch is disengaged the mill will coast (rotate) for several seconds until it completely stops.

  • Page 51: Mill Bearing Greasing Instructions

    ROUTINE MAINTENANCE MILL BEARING GREASING INSTRUCTIONS WARNING: To ensure that the drive location of the bearing. Apply light coating of oil does not start unexpectedly, turn off to sleeve O.D. and lockout or tag power source before proceeding. C. Bearing - Make sure the internal clearance has been written down.

  • Page 52: Adjusting The Discharge Conveyor

    ROUTINE MAINTENANCE ADJUSTING THE DISCHARGE CONVEYOR DANGER/THROWN DEBRIS, CRUSH, CUT HAZARD: Shut power unit off and follow lockout procedures before any maintenance is performed. If the conveyor belt slips under a load, adjust as follows. Loosen the three (3) bolts (A) on both bearings (C) and mounts.

  • Page 53: Adjusting The Infeed Bed Chain

    ROUTINE MAINTENANCE ADJUSTING THE INFEED BED CHAIN DANGER/THROWN DEBRIS, CRUSH, CUT HAZARD: Shut power unit off and follow lockout procedures before any maintenance is performed. NOTICE: DO NOT OVER TIGHTEN CHAIN. If conveyor chain is not properly adjusted, the chain, drive and idler sprockets will wear more than normal.

  • Page 54: Servicing Tires

    ROUTINE MAINTENANCE SERVICING TIRES DANGER/EXPLOSION HAZARD: Failure to implement proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Never attempt to mount a tire unless you have the proper equipment and experience to perform the job.

  • Page 55: Fuel Specifications

    ROUTINE MAINTENANCE FUEL SPECIFICATIONS No. 2D diesel fuel is recommended for use in all diesel power units. In extreme cold tem- peratures see engine manufacturer for recom- mended fuel options. In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to vaporous state and condensed, thus elimi- nating all sediment and residue.

  • Page 56: Radiator

    ROUTINE MAINTENANCE RADIATOR DANGER/BURN HAZARD: Never open cap on a hot radiator. Check coolant level only when engine is stopped and radiator cap is cool enough to touch with your hand. Prior to cold weather, be sure cooling system has a proper amount of antifreeze. Use a quality brand of permanent-type ethylene glycol antifreeze which contains a rust inhibitor and lubricant.

  • Page 57: Servicing Suspension

    ROUTINE MAINTENANCE SERVICING SUSPENSION DANGER/LOSS OF VEHICLE CONTROL HAZARD: We strongly emphasize that each of the maintenance procedures that we will discuss have a significant safety purpose. Failure to maintain proper torque values on each of the suspension components can result in a failure of suspension components.
  • Page 58 ROUTINE MAINTENANCE SERVICING SUSPENSION CON'T Loose operation of this bolt can result in wear requiring that new components be installed to avoid structural damage. During your visual inspection, if you observe any visible wear or loosening in the bushing, it is imperative that you immediately replace the radius rod bushing and bolt. Failure to replace these components will result in damage to the hanger, spring seat and/or the radius rod.

  • Page 59: Batteries

    ROUTINE MAINTENANCE BATTERIES The battery is located on the side of the frame. All models are equipped with one 12 volt group 31 low maintenance batteries. SERVICING BATTERIES 1. Keep battery and battery box clean. Keep all connections clean and tight. Remove all corrosion and wash termi- nals with a solution of baking soda and water.

  • Page 60: Hydraulic Safety

    UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY BE CAREFUL OF: 1. Leaks If a motor or a cylinder does not work or a. Puddles of fluid are slippery and hazard- works slowly, the fluid must be slipping through ous. it or bypassing the work completely. Trace the b.
  • Page 61 UNDERSTANDING HYDRAULICS TESTING HYDRAULIC FLUID Test the fluid regularly. A number of formal test kits are available to evaluate the condition of hydraulic fluid or a fluid sample can be sent to a lab for evaluation. However, there are simple signs of fluid degradation such as a color shift, bad aroma or feel of grit in a sample.

  • Page 62: Servicing Hydraulics

    SERVICING HYDRAULICS THE SEVEN STEPS OF TROUBLE SHOOTING 1. Talk to the operator. 5. Test probable causes. 2. Know the system - schematics. 6. Repair the system. 3. Inspect the machine. 7. Check for root causes. 4. List probable causes. GATHER INFORMATION (Steps 1, 2 and 3) Information is very important.
  • Page 63 SERVICING HYDRAULICS PROBABLE CAUSES can turn in one direction only. NOISY PUMP Intake clogged: Make sure tank is cleaned Air in the system: Check fittings, cracked hoses periodically. Fluid must be kept 3/4 full. and other parts on the pump intake. Check Air leak in intake: If any air is going through hydraulic tank.

  • Page 64: Engine Corrosion

    ENGINE CORROSION CAVITATION CORROSION/EROSION LINER PITTING Modern high speed diesel engines contain cast iron replacement cylinder liners that are subject to accelerated corrosion due to a process commonly known as liner pitting. When plain water is used as a coolant, liners can be penetrated in a matter of 500 hours of operation when conditions are severe. It is important to understand the causes of this liner pitting and how to prevent it.

  • Page 65: Preventative Maintenance

    ENGINE CORROSION THE EFFECT OF ENGINE CONDITIONS ON LINER PITTING The formation of bubbles in coolant during cavitation corrosion/erosion is very similar to the way bubbles are formed when boiling water. Remember how water in a pressure cooker boils at a higher temperature because of the higher pressure? In the same way, anything that affects the local pressure or the local temperature around the liners will impact on the ease with which bubbles are formed and will effect the potential for liner pitting.
  • Page 66 ENGINE CORROSION The problem only gets worse in construction/mining fleets where cooling system capacities can vary from 5 to over 100 gallons. Coolant leakage can really cause a problem when using automotive antifreeze plus SCA. Typically the system is topped off with antifreeze and water and no thought is given to the SCA concentration.

  • Page 67: Air Filter Maintenance

    AIR FILTER MAINTENANCE NOTE: Its the customer's responsibility to follow all steps of air filter maintenance every 200 hours or every engine oil change. Low pre-cleaner efficiency will cause short element life. Low pre-cleaning efficiency can be caused by: 1. Leaking dust cup to air cleaner body joint;...
  • Page 68 AIR FILTER MAINTENANCE BASIC ELEMENT SERVICE PRECAUTIONS 03/05...

  • Page 69: Trouble Shooting

    5. Check all motor fluid levels. Electrical NOTE: Your Morbark equipment may have an electronic engine and electronic controls. These sensitive controls have many electrical grounds throughout the machine. These grounds must be clean for the electronics to work properly. When a problem with the electrical system is suspected, first make sure all grounds are clean, dry and have a good connection before continuing troubleshooting.

  • Page 70: Hydraulic System

    TROUBLE SHOOTING HYDRAULIC SYSTEM PROBLEM PROBABLE CAUSES AND SOLUTIONS Noisy pump 1. Check inlet hose for damage. Replace hose. cavitation 2. Fluid viscosity too high. Replace oil. (pump starving) 3. Operating temperature too low. Allow system to warm up. Overheating of 1.

  • Page 71: Pressure Settings

    PRESSURE SETTINGS MODEL 2600 WOOD HOG MAIN VALVE BANK PUMP 2500 PSI YOKE PUMP 1500 PSI Note: All pressure settings should be checked with hydraulic oil at a minimum of 110°. Note: Due to variances in different manufactures gauges we recommend you confirm the accuracy of your pressure gauge with a second gauge.

  • Page 72: Steps To Follow If You Feel You Have A Warrantable Failure

    Ship the warranty consideration parts to: MORBARK, INC., 8507 S. Winn Road, Winn, MI 48896, ATTENTION: Warranty Returns Use the pink copy of the claim, along with a copy of the Morbark invoice as a packing slip. The customer keeps the golden rod copy for his records and any future inquiries concerning the claim.

  • Page 73: Warranty

    Morbark) without charge to the purchaser, when the equipment is returned to Morbarks factory at 8507 South Winn Road, Winn, Michigan or at such other locations as may be designated in writing by Morbark. Morbark is not responsible for the cost of transport or related charges in connection with return of any equipment to Morbark under this Warranty.

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