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Morbark BLIZZARD 12 Operators Safety Manual

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MODEL-12
BLIZZARD
OPERATORS
SAFETY
MANUAL
MANUFACTURED BY:
MORBARK, INC.
1
S/N: 59999
76347-170A
02/02
02/02

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Summary of Contents for Morbark BLIZZARD 12

  • Page 1 MODEL-12 BLIZZARD OPERATORS SAFETY MANUAL MANUFACTURED BY: 76347-170A MORBARK, INC. 02/02 02/02 S/N: 59999...
  • 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: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ...................... 4 LOCKOUT PROCEDURES ..................5 LOCATION OF CHIPPER COMPONENTS ............6 DESCRIPTION OF CHIPPER COMPONENTS ..........7 SAFETY ........................8 CRIME PREVENTION................... 12 SAFETY OPERATION .................... 15 IMPORTANT SAFETY INFORMATION! ..................15 SAFETY HINTS ..........................21 NEW ENGINE BREAK-IN ........................

  • Page 4: Introduction

    INTRODUCTION Congratulations on your purchase of a new Morbark brush chipper. The brush chipper, designed and introduced by the world's leading manufacturer of portable chippers, is produced with the finest com- ponents and workmanship available. If you show proper care and maintenance, your brush chipper will prove to be a safe and reliable unit.

  • Page 5: Lockout Procedures

    LOCKOUT PROCEDURES 02/02...

  • Page 6: Location Of Chipper Components

    LOCATION OF CHIPPER COMPONENTS A. Frame F. Discharge Flipper K. Axle B. Hitch G. Fuel Tank L. Hood / Hinged C. Infeed H. Belt Shield M. Hood / Bolted on D. Jack Stand I. Hydraulic Oil Tank N. Feed Control Arm E.

  • Page 7: Description Of Chipper Components

    DESCRIPTION OF CHIPPER COMPONENTS Chipper Drum This is the component in which the knives are mounted. The chipper drum is dynamically balanced and should not be welded on or modified. Chipper Shaft This shaft is connected to the drum by means of two bushings, then rests on a pair of pillow block bearings for support.

  • Page 8: Safety

    SAFETY OBSERVE SAFETY SIGNS AND MESSAGES THINK SAFETY: Safety is a combination of operator common sense and alertness at all times when the machine is being operated or serviced. CAUTION: This message is used for general reminders of good safety practices or to direct attention to unsafe prac- tices.
  • Page 9 SAFETY WEAR PROTECTIVE CLOTHING Wear close-fitting clothing and safety equipment appro- priate to the job. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Prolonged exposure to loud noise can cause impaired or loss of hearing.

  • Page 10: Safety Stickers

    SAFETY SAFETY STICKERS READ SAFETY SIGNS CAREFULLY Carefully read and follow all safety signs. Danger signs identify the most serious hazards. Keep safety signs in good condition. Replace any missing or damaged safety signs. Signs are attached to machine near specific hazard areas.
  • Page 11 SAFETY SAFETY STICKERS CON’T 02/02...

  • Page 12: 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 check sheet supplied with your machine and on the various components.
  • Page 13 CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE 1. Remove ignition key and the main power switch box key when applicable. 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 14: 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 tongue near the front) to the investigating officer and insurance carrier.

  • Page 15: Safety Operation

    All personnel must observe these guidelines when working with the equipment. This special safety manual has been prepared for all owners and operators of Morbark hand-fed brush and tree chippers. SAFETY IS NO ACCIDENT.
  • Page 16 SAFETY OPERATION Before anyone starts up a brush chipper, they should know this: ANY MACHINE THAT CAN PULL IN A WHOLE TREE AND CHIP IT IN LESS THAN A MINUTE IS DANGEROUS IF THE OPERATOR DOES NOT FOLLOW PROPER SAFETY PROCEDURES.
  • Page 17 SAFETY OPERATION If the chipper is attached to a truck or van, make certain the hitch is secure and the safety chains are properly attached. If the chipper is not attached to a vehicle, the tongue should be blocked and wheel chocks should be placed under both wheels to keep the chipper from moving.
  • Page 18 SAFETY OPERATION Again, the single most important chipper safety rule is NEVER BREAK THE PLANE OF THE INFEED CHUTE WITH YOUR HANDS, AND NEVER, FOR ANY REASON, ATTEMPT TO KICK BRUSH IN WITH YOUR FEET! To safely feed short material into your chipper, place the feed system in the neutral position, lay the short material on top of longer material, and engage the feed system.
  • Page 19 SAFETY OPERATION At least two people should be on the job site at all times. No one should ever operate the chipper alone. It is the operator's responsibility to ensure that other workers or bystanders are kept away from the path of discharged chips. Be prepared in case of an accident.
  • Page 20 SAFETY OPERATION When refueling the chipper, always be certain there is no open flame or source of a spark in the vicinity of the machine. Always remove the ignition key when the machine is left unattended for any reason. No one should ever operate the chipper when under the influence of drugs, alcohol or pre- scription medications which could in any way affect the operator's performance and concen-...

  • Page 21: Safety Hints

    Safety is just too important to be taken lightly. With proper information and commit- ment to safety every day, your Morbark hand- fed chipper will give you years of reliable, safe service. SAFETY HINTS 1.

  • Page 22: New Engine Break-In

    SAFETY OPERATION NEW ENGINE BREAK-IN Proper break-in will lead to trouble free operation and increased engine life. The factory test given to a new engine is not sufficient to establish the polished bearing surfaces which are so necessary for good performance and long life.

  • Page 23: Brush Preparation

    SAFETY OPERATION BRUSH PREPARATION Inspecting and organizing the brush prior to chipping will allow the job to be performed more efficiently and provide added safety in performing the job by minimizing the danger of foreign material, vines, etc from entering the chipper. Pre-trimming and proper de-limbing will allow the brush to be drawn easily through the chipper.
  • Page 24 SAFETY OPERATION BRUSH PREPARATION CON’T Know the limitations of your chipper. Never attempt to feed material too large for your chipper. Always pre-cut large crotches to ensure adequate clearance through the transition area. When preparing large material for feeding, properly trimming the crotches will greatly reduce the amount of downtime from clearing jammed materials.

  • Page 25: Inspecting Chipper Knives

    SAFETY OPERATION INSPECTING CHIPPER KNIVES CAUTION: BEFORE INSPECTING KNIVES, REMOVE IGNITION KEY AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. Remove chipper hood lock pin and open the hood. Turn drum by hand until first knife is accessible.

  • Page 26: Machine Warm-Up

    SAFETY OPERATION MACHINE WARM-UP NOTE: Most engines include a safety shutdown system. This system will shut down if coolant tem- perature is too high or oil pressure is too low. If service is required, please contact your nearest authorized dealer. 1.

  • Page 27: Disengaging Cutter Drum

    SAFETY OPERATION DISENGAGING CUTTER DRUM Disengage the hydraulic feed sys- tem by moving the feed control bar to the NEUTRAL or center position. Push the throttle control in to reduce engine speed to idle. When the engine and cutter drum reach idle speed, disengage clutch.

  • Page 28: Feeding Brush To The Chipper

    SAFETY OPERATION FEEDING BRUSH TO THE CHIPPER Keep the working area clear of limbs and debris. Tripping or entanglement hazards CAN cause the operator to be dragged into the chipper, causing serious injury or death. Do not throw clean up sweepings into the cutter mechanism. Foreign material such as stones, wire or metal CAN cause blade failure, resulting in serious personal injury.

  • Page 29: Engine Controls

    ENGINE CONTROLS 1. PERMISSIVE START BUTTON - Used 6. TACHOMETER\SPEED SWITCH - in conjunction with the key switch to start The tachometer measures the revolutions per minute of the power unit. engine. 2. KEY SWITCH - Used in conjunction with Refer to LOR for speed switch setting proce- the permissive start button to start engine.

  • Page 30: Dust Suppression Controls

    DUST SUPPRESSION CONTROLS 1. ON/OFF SWITCH - Powers up the system. 2. DIAGNOSTICS - When low water level light comes on, 5 seconds later pump will shut off. 02/02...

  • Page 31: Feed Controls

    FEED CONTROLS The feed rollers are controlled by pushing or pulling the feed control bar, which is located on the top and both sides of the feed chute. The 3 (Three) control positions are: FEED - Pulls material into the chipper cutting zone. NEUTRAL - Stops movement of the feed rollers.

  • Page 32: Routine Maintenance Schedule

    ROUTINE MAINTENANCE SCHEDULE GENERAL EVERY 8 HRS WEEKLY Check engine oil level Check radiator fluid level (if applicable) Check hydraulic fluid Check clutch engagement torque Check tightness of engine bolts* Check tire pressure before moving machine Replace engine air, fuel and oil filters refer to engine manual CHIPPER Check sharpness of knives...

  • Page 33: Routine Maintenance

    ROUTINE MAINTENANCE Safety and daily maintenance are the two most important things to remember when operating machin- ery. A small amount of daily maintenance will make the weekly or monthly maintenance much easier and less expensive. While maintaining your brush chipper, please follow the safety guidelines which are written in bold print.

  • Page 34: Changing Chipper Knives

    ROUTINE MAINTENANCE CHANGING CHIPPER KNIVES CAUTION: BEFORE CHANGING KNIVES, ALWAYS REMOVE IGNTION KEYS AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. 1. Remove chipper hood lock pin and open the hood. 2.

  • Page 35: Inspecting And Adjusting The Knife Anvil Clearance

    ROUTINE MAINTENANCE INSPECTING AND ADJUSTING THE KNIFE ANVIL CLEARANCE The anvil should be adjusted to a minimum of .045 and a maximum of .080 from the cutting edge of the highest chipper knife. To inspect and adjust the knife anvil clearance, follow these steps: 1.

  • Page 36: What You Should Know About Chipper Knife Maintenance

    ROUTINE MAINTENANCE WHAT YOU SHOULD KNOW ABOUT CHIPPER KNIFE MAINTENANCE Properly maintained chipper knifes will give you longer service. When knives are badly abused you can usually only expect minimal sharpenings before the knife is worn out. With proper maintenance and frequent knife changes, you can get more knife sharpenings per edge.
  • Page 37 ROUTINE MAINTENANCE Use proper hardware for mounting knife to holder. Torque mounting bolts properly to eliminate wood packing and possible knife breakage. Bevel of knife must exceed mounting bolts for clearance when chipping. Proper anvil clearance, sharp anvils and knives should be maintained for quality chips. A good, efficient cut can eliminate plugging problems and undue stress on the chipper.

  • Page 38: Knife Grinding

    Soil is extremely hard on knives. c. Amount of chipper production. d. The quality of the knife. Knives should be sharp- ened professionally with a coolant type surface grinder (Morbark Inc. knives are recommended.) Knives should be ground at 31°. 02/02...

  • Page 39: Tightening Torque Guide

    ROUTINE MAINTENANCE TIGHTENING TORQUE GUIDE Parts using rivet nuts 25 Ft. Lbs. Maximum. Always use the torque values above when specific torque values are not available. 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 Capscrews.

  • Page 40: B-Loc Hubs

    ROUTINE MAINTENANCE B-LOC HUBS 02/02...

  • Page 41: Air Filter Maintenance

    ROUTINE MAINTENANCE AIR FILTER MAINTENANCE NOTE: It's 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.

  • Page 42: Basic Element Service Precautions

    ROUTINE MAINTENANCE BASIC ELEMENT SERVICE PRECAUTIONS 02/02...

  • Page 43: Lubrication Schedule

    ROUTINE MAINTENANCE LUBRICATION SCHEDULE Lubricate wheel bearings with a good grade EP2 Lithium base grease - every 6 months. Chipper bearings - Lubricate every 50 hrs. until excess grease is present. Follow engine manufacturer's guidelines for lubrication of engine. Grease clutch - monthly - According to specifications. Grease remaining pivot points every 8 hrs.

  • Page 44: Adjusting The Belt Tension

    ROUTINE MAINTENANCE ADJUSTING THE BELT TENSION CAUTION: BEFORE ADJUSTING BELTS, REMOVE IGNITION KEY AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. To check for proper tension of belts, follow the directions in V-Belt tension gauge. To adjust the chipper belt tension, follow these steps: Shut off engine, remove ignition key.

  • Page 45: How To Use A V-Belt Tension Gauge

    ROUTINE MAINTENANCE HOW TO USE A V-BELT TENSION GAUGE CAUTION: Before doing maintenance or tensioning on belt drives, turn equip- ment 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 46: Transporting The Brush Chipper

    ROUTINE MAINTENANCE TRANSPORTING THE BRUSH CHIPPER The standard towing hitch on the brush chipper is a 2" ball. Be sure the towing vehicle hitch is properly equipped for the hitch on your brush chipper. The towing vehicle should be capable of handling a minimum of 600# tongue weight.

  • Page 47: Understanding Hydraulics

    UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY If a motor or a cylinder does not work or works slowly, the fluid must be slipping through Be careful of: it or bypassing the work completely. Trace the 1. Leaks lines to the motor or the cylinder, then place a a.
  • Page 48 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 49: 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 50 SERVICING HYDRAULICS PUMP NOT PUMPING Pump shaft turning in the wrong direction: Shut PROBABLE CAUSES down immediately. Some types of pumps can turn in one direction only. NOISY PUMP Air in the system: Check fittings, cracked hoses Intake clogged: Make sure tank is cleaned periodi- and other parts on the pump intake.

  • Page 51: Trouble Shooting The Chipper

    TROUBLE SHOOTING THE CHIPPER DANGER: Before attempting to do any maintenance on chipper, be sure that the engine is shut off, the chipper drum is completely stopped and all lockout procedures are followed PROBLEM PROBABLE CAUSES AND SOLUTIONS Chipper will not 1.

  • Page 52: Pressure Settings

    PRESSURE SETTINGS 02/02...

  • Page 53: 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 54: Warranty

    WARRANTY 02/02...

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