Morbark Wood Hog 3800 Operators Safety Manual

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MORBARK

MODEL 3800

WOOD HOG

OPERATOR

SAFETY MANUAL

76347-359

06/07

•

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Summary of Contents for Morbark Wood Hog 3800

Page 1 MORBARK MODEL 3800 WOOD HOG OPERATOR SAFETY MANUAL 76347-359 06/07 06/07 •...
Page 2 2 3800 Wood Hog...
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 & understand this manual carefully, page by page before operating machine.
Page 4: Table Of Contents
LOCKOUT PROCEDURES ........................... 6 SPECIFICATIONS ............................7 MAIN COMPONENTS ............................ 8 SAFETY ............................... 10 SAFETY SIGNS ............................14 CRIME PREVENTION ..........................16 REMOTE CONTROLS ..........................19 TETHER CONTROLS ..........................24 ENGINE CONTROLS ........................... 26 CENTER SECTION CONTROLS ......................... 28 VALVE BANK CONTROLS ......................... 29 SAFETY OPERATION ..........................
Page 5 HAMMERMILL MAINTENANCE .............................. 61 ROTOR MAINTENANCE ................................. 61 HAMMER PATTERNS ................................63 REPLACING GRATES WITH SUPPLIED CHAIN HOIST ......................64 HOOD RAISING PROCEDURE ............................... 64 MILL BEARING GREASING INSTRUCTIONS ........................67 ADJUSTING THE BELLY CONVEYOR............................ 68 CENTERING THE BELLY CONVEYOR ........................... 68 ADJUSTING THE DISCHARGE CONVEYOR .........................
Page 6: Lockout Procedures
Failure to lock out while performing mainte- no unintended motion will occur, or test the equipment and nance could result in serious personal injury or death! Morbark machine by use of appropriate test equipment to determine that equipment is designed to be quickly and easily locked out the energy isolation has been effective.
Page 7: Specifications
SPECIFICATIONS General Length..................................35 ft (10.6 m) Width ................................10 ft 8 in (3.2 m) Height .................................. 13 ft 2 in (4 m) Gross Weight .............................53,140 lb (24,103 kg) Axle................................39,600 lb (17,962 kg) Tongue Weight ............................13,540 lb (6,141 kg) Electrical System ................................
Page 8: Main Components
MAIN COMPONENTS LEFT SIDE MAGNETIC DRUM RADIATOR SCREEN DEBRIS SLIDE CONVEYOR SERIAL NUMBER PLATE TAKE AWAY CONVEYOR FUEL TANK AXLE 8 3800 Wood Hog...
Page 9: Right Side
MAIN COMPONENTS RIGHT SIDE CONVEYOR FOLD CYLINDER RECEIVING HOPPER CONVEYOR LIFT CYLINDER HYDRAULIC TANK BELT SHIELD FRONT STABILIZER 06/07 •...
Page 10: Safety
If these instructions are not followed, it could result in damage to the machine. DO NOT MODIFY MACHINE Any modiﬁ cation to the machine must be approved by Morbark. Unauthorized modiﬁ cations to the machine may impair the function and/or safety and affect machine life or cause serious injury or death.
Page 11: Operate Safely
SAFETY OPERATE SAFELY CAUTION: Do not allow familiarity (gained from frequent use of your machine) to become commonplace. Always remember that a careless fraction of a second is sufﬁ cient to inﬂ ict severe 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 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, rollers, V-belts ,pulleys, chains, and sprockets. Stay away from these areas when the machine is running and follow Lockout/Tagout procedures before adjusting or performing any mainte- nance 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 • Do not use ﬁ nger or skin to check for leaks • Lower load or relieve hydraulic pressure before loosening ﬁ ttings BATTERY SAFETY Batteries generate explosive gases.
Page 14: Safety Signs
SAFETY SIGNS 14 3800 Wood Hog...
Page 15 SAFETY SIGNS 06/07 •...
Page 16: Crime Prevention
CRIME PREVENTION GOOD ADVICE • Keep your machine damage-free • Reduce vandalism, discourage theft and help recover your machine if it is stolen RECORD IDENTIFICATION NUMBERS • Record Serial Number (S/N) of machine and identiﬁ cation numbers of en- gine, clutch, hydraulic components etc. EXACTLY numbers as they appear on the plates •...
Page 17 CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE Remove ignition key and lock the main power switchbox. Place hard-to-move equipment in front of exits. If machine is being stored, remove the battery or any essential component in the electrical system. Lower hitch or ﬁ...
Page 18: Fire Protection
CRIME PREVENTION REPORT THEFT If a theft occurs, notify the law enforcement agency having jurisdiction and the insurance carrier immediately. Give a full description and a complete set of serial and identiﬁ cation numbers (found on the road side of the infeed bed near the front) to the investigating of- ﬁ...
Page 19: Remote Controls
REMOTE CONTROLS RADIO CONTROL The remote control transmitter and receiver provided with this machine have matched radio signals that prevents uninten- tional 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 erratically.
Page 20 REMOTE CONTROLS THE LIST READS FROM LEFT TO RIGHT 20 3800 Wood Hog...
Page 21 REMOTE CONTROLS DANGER/CRUSH, ENTANGLEMENT HAZARD: Keep everyone clear of feedworks during operation. THROTTLE - Push the toggle up to increase, push the toggle down to decrease engine RPM. ENGINE STOP - Push up and hold the toggle for three seconds to shut down engine. CAUTION: This button should only be used for emergency shut down.
Page 22: Tether Controls
TETHER CONTROLS THE LIST READS FROM LEFT TO RIGHT 22 3800 Wood Hog...
Page 23 TETHER CONTROLS DANGER/CRUSH, ENTANGLEMENT HAZARD: Keep everyone clear of feedworks during operation. THROTTLE - Push the toggle up to increase engine RPM. Push the toggle down to decrease engine. ENGINE STOP - Push in and engine will shut down. CAUTION: This button should only be used for emergency shut down. CONVEYOR SWING (OPTIONAL) - Turn left to swing the conveyor left and turn right to swing the conveyor right.
Page 24: Engine Controls
ENGINE CONTROLS 24 3800 Wood Hog...
Page 25 ENGINE CONTROLS MASTER BATTERY DISCONNECT - Disconnects the batteries from the electrical system. DATA LINK HOOKUP - Provides access for the Iqan system. IQAN DISPLAY - Refer to Iqan manual for operating information. ENGAGE/DISENGAGE SWITCH - This switch will either engage the hydraulic pto or disengage the hydraulic pto. DATA LINK HOOKUP - Provides access for the engine computer.
Page 26: Center Section Controls
CENTER SECTION CONTROLS ENGINE STOP - Push up and hold the toggle for three seconds. The power unit will throttle to an idle, then shut down. CAUTION: This button should only be used for emergency shut down. 26 3800 Wood Hog...
Page 27: Valve Bank Controls
VALVE BANK CONTROLS DISCHARGE CONVEYOR TOP SECTION FOLD - This lever will raise and lower the top conveyor section. DISCHARGE CONVEYOR BOTTOM SECTION FOLD - This lever will raise and lower the bottom conveyor section. DISCHARGE CONVEYOR - This lever will engage and disengage the discharge conveyor. BELLY CONVEYOR - This lever will engage and disengage the belly conveyor.
Page 28: Safety Operation
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 op- eration of this machine and dangerous areas to avoid. CAUTION: Remember, this is a dangerous piece of equipment if not maintained and operated properly.
Page 29: Pre-Operational Checklist
SAFETY OPERATION PRE-OPERATIONAL CHECKLIST It is the operator’s responsibility to inspect the machine before the start of each workday by completing a preoperation inspection. It is recommended that each operator inspect the machine before operating, even if another operator has already put the machine into service. Check for foreign objects in the receiving hopper or lying on the discharge con- veyor and engine area.
Page 30: Starting Machine
SAFETY OPERATION STARTING MACHINE/HYDRAULIC CLUTCH NOTE: On electric drive models refer to O.E.M starter manual Review the condition of the machine. Place all hydraulics in the neutral position. Make sure hydraulic clutch is disengaged. Turn main power switch to the ON position. Give several blasts of the warning horn to clear area with remote or tether.
Page 31 SAFETY OPERATION STARTING MACHINE CON'T 10,13 Engage the feedworks system to forward feed. Note: The feedworks will not engage until the engine RPM reach the HI speed switch settings. Engage the belly conveyor to the forward position. DANGER/CRUSH HAZARD: Never allow anyone to stand under discharge conveyor.
Page 32: Safety Procedures
SAFETY OPERATION SAFETY PROCEDURES Always make sure all ﬁ ller plugs, caps and guards are in place. DANGER/THROWN DEBRIS HAZARD Never under any circumstances, open the hood without ﬁ rst making sure the mill has completely stopped. CAUTION: Do not use your hand to check for mill movement. Always wear appropriate safety equipment such as a hard hat and safety glasses.
Page 33: Yoke Lock Procedure
SAFETY OPERATION YOKE LOCK PROCEDURE Throttle engine down to an idle and disengage the clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has come to a complete stop before attempting any maintenance. CAUTION: Do not use your hand to check for mill movement. Raise yoke with remote and hold in the up position.
Page 34: Regrind Lock Procedure
SAFETY OPERATION REGRIND LOCK PROCEDURE For more production when doing regrind, this lock when used will keep the yoke wheel up off of material to allow for faster processing of materials. Throttle engine down to an idle and disengage the clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has come to a complete stop before attempting any maintenance.
Page 35: Hood Lock Procedure
SAFETY OPERATION HOOD LOCK PROCEDURE Throttle engine down to an idle and disengage the clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has come to a complete stop before attempting any maintenance. CAUTION: Do not use your hand to check for mill movement. Raise yoke with remote and hold in the up position.
Page 36 SAFETY OPERATION HOOD LOCK PROCEDURES CON'T Lift hood lock bar to yoke and install pin. DANGER/CRUSH HAZARD: Clear the hood area before raising hood. Raise yoke, disengage yoke locks and lower yoke. Lower hood, this will raise the hood completely. Push in and lock hood pin in place.
Page 37: Machine Shut Down
SAFETY OPERATION MACHINE SHUT DOWN Place all hydraulics in neutral. Throttle engine down to an idle and disengage clutch. Allow engine to idle 3-5 minutes and then shut off. Turn off key switch and remove ignition key. Turn off main battery disconnect switch and lock box. Clean around the machine.
Page 38: Transporting
SAFETY OPERATION TRANSPORTING Check to make sure the clutch is disengaged. Make sure the mill has completely stopped, fold the conveyor up and over the receiving hopper. Then install the safety chains. Secure the conveyor with chains and binders for transport. Raise machine using the stabilizers to the height needed to hook the machine to the tractor.
Page 39 06/07 •...
Page 40: Routine Maintenance Schedule
ROUTINE MAINTENANCE SCHEDULE Please note that the following maintenance intervals apply for normal operating conditions start 1000 only. Intervals are hours of operations based on 8 hours per day, 5 days per week. If your hours hours hours hours hours hours operating conditions are difﬁ...
Page 41 ROUTINE MAINTENANCE SCHEDULE Please note that the following maintenance intervals apply for normal operating conditions start 1000 only. Intervals are hours of operations based on 8 hours per day, 5 days per week. If your hours hours hours hours hours hours operating conditions are difﬁ...
Page 42: Routine Lubrication Schedule
ROUTINE LUBRICATION SCHEDULE 9,10,11 42 3800 Wood Hog...
Page 43 ROUTINE LUBRICATION SCHEDULE Please note that the following maintenance intervals apply for normal operating conditions only. Intervals are hours of operations based on 8 hours per day, 5 days per week. If your operating conditions are 1000 difﬁ cult, adjust the speciﬁ ed intervals accordingly. hours hours hours...
Page 44: Routine Maintenance
ROUTINE MAINTENANCE TIGHTENING TORQUE GUIDE Making sure that all the bolts are regularly checked and tightened to the proper torque is critical. The chart shows the proper torque rela- tive to the bolt size and type. When using this chart, keep the following guidelines in mind.
Page 45: How To Use A Belt Tension Guage
ROUTINE MAINTENANCE HOW TO USE A BELT TENSION GUAGE Before adjusting the belt tension: Throttle the engine down and disengage the clutch. Shut off the engine, remove the key, and conduct machine lockout. Remove the belt guard. If maintenance is required, loosen the engine bolts, remove the belt, and ﬁ x before setting belt tension. Inspect and/or repair the following: •...
Page 46 ROUTINE MAINTENANCE HOW TO USE A BELT TENSION GUAGE CON'T Turn the engine belt drive adjustment bolts until the belt is fairly taut. Measure the belt span length of the drive, and lay a straight edge across the drive (see Figure 7.) Set the rubber O-ring on the body of the tension gauge at the dimension equal to 1/64 inch for every inch of span length.
Page 47: General Maintenance
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 48 ROUTINE MAINTENANCE REMOVING SAFETY ELEMENT FROM TORQUE ASSEMBLY Remove the safety elements (1-1) from the housing carrier (1-2) by removing the four 3/8-24 x 2 long socket head cap screws (2-2) from each unit. Remove the element (1-1) complete with shims (1-10) detent ball (2-14) and ﬂ anged bush- ing (2-13.) Remove the 5/16-18 socket head cap screws (2-2) from the detent pocket and extract the detent pocket with simple tools shown in page 4.
Page 49 ﬁ nally remove the O-Ring (2-6) from the housing. Clean all parts and inspect for wear. METHOD OF ASSEMBLING SAFETY ELEMENTS Clean all components and coat all working surfaces with a suitable grease “MOBIL XTC” grease (Morbark P/N 18683- 082) or equivalent.
Page 50 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. 50 3800 Wood Hog...
Page 51: Changing Mill Hammers
ROUTINE MAINTENANCE CHANGING MILL HAMMERS CAUTION: Read maintenance safety procedures carefully before begin- ning. This procedure should be followed whether you are changing one hammer, all ham- mers or changing to a different hammer pattern. Personnel performing this proce- dure should always wear proper safety clothing, including gloves. CAUTION: Do not install the inserts on the hammers until after the hammers are installed.
Page 52 ﬁ rst hammer. Thread the rod driver into the end of the rod. The rod driver was furnished by Morbark with your machine. As each hammer or raker is guided into position, drive the rod into place until all hammers and rakers are installed and the rod is driven ﬂ...
Page 53 ROUTINE MAINTENANCE CHANGING MILL HAMMERS CON'T Insert the second rod in the 12 o’clock hole and attach the rod driver. Position the second row of hammers, one at a time and drive the rod into po- sition engaging the back of the ﬁ rst row of hammers and the front row of the second row of hammers.
Page 54: Hammer Rod Puller Instructions
ROUTINE MAINTENANCE HAMMER ROD PULLER INSTRUCTIONS CAUTION: Read maintenance safety procedures carefully before begin- ning. This procedure should be followed whether you are changing one rod or all rods. Personnel performing this procedure should always wear proper safety clothing, including gloves. CAUTION: Do not install the inserts on the hammers until after the hammers are installed.
Page 55 ROUTINE MAINTENANCE HAMMER ROD PULLER INSTRUCTIONS CON'T Removing rods is a two (2) man job. One man should be positioned on the infeed bed with the rods. The second man should be positioned on the side of the machine opposite the drive sheave. Remove pin, rotate rod puller out so it is parallel to hammer rods and insert in back side hole (A) to lock rod puller in place.
Page 56: Changing Mill Inserts
ROUTINE MAINTENANCE CHANGING MILL INSERTS WARNING: Read maintenance safety procedures carefully before begin- ning. Place all hydraulics in neutral. 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. CAUTION: Do not use your hand to check for mill movement.
Page 57: Raker Maintenance
ROUTINE MAINTENANCE RAKER MAINTENANCE CAUTION: Some mill hammer patterns are designed to run with rakers. To prevent damage to the mill and surrounding components, make sure that rakers are in place and are properly maintained. Damage resulting from poor raker maintenance is not warrantable.
Page 58 ROUTINE MAINTENANCE RAKER MAINTENANCE CON'T Locate the raker gauge on top of the mill plate, next to the raker you are check- ing. With the gauge in a vertical position, note the top of the raker in relation to the raker gauge. Acceptable raker height is between the top of the gauge and the notch in the front of the gauge.
Page 59: Hammermill Maintenance
ROUTINE MAINTENANCE HAMMERMILL MAINTENANCE It is a good idea to get into the habit of inspecting the hammermill for wear, cracks, loose fasteners etc.while performing routine hammermill maintenance. Look for cracked welds between the rotor plates. If cracks are found, refer to “ Rotor Maintenance”...
Page 60 ROUTINE MAINTENANCE HAMMERMILL MAINTENANCE CON'T CAUTION: Two (2) people are required at all times when performing mill maintenance. If cracks are found it is highly recommended that you make the repairs before an unnecessary failure occurs. The cracks will need to be ground out. The proper procedure is to grind the crack the full length with a gouge 1/8"...
Page 61: Hammer Patterns
ROUTINE MAINTENANCE HAMMER PATTERNS 06/07 •...
Page 62: Replacing Grates With Supplied Chain Hoist
ROUTINE MAINTENANCE REPLACING GRATES WITH SUPPLIED CHAIN HOIST CAUTION: Read maintenance safety procedures carefully before begin- ning. CAUTION: Two (2) People required at all times when changing grates. HOOD RAISING PROCEDURE Place all hydraulics in neutral. 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 63 ROUTINE MAINTENANCE REPLACING GRATES CON'T Loosen and swing the eye bolts clear on the hood. Attach the link bar to the yoke lug with pin as shown and install lynch pin. Attach other end to lug on hood as shown install pin and install lynch pin. DANGER: CRUSH HAZARD: Clear all personnel from engine platform area.
Page 64 ROUTINE MAINTENANCE Remove grates by lifting out from behind mill. REPLACING GRATES CON'T Replace grates by lowering them back down between supports and guides. Inspect the grates and ensure the grates ﬁ t the contour of the base. Inspect grate clearance by turning the mill by hand. HOOD CLOSING PROCEDURE CON'T Remove all lockouts after insuring all personnel are clear, then start machine.
Page 65: Mill Bearing Greasing Instructions
ROUTINE MAINTENANCE MILL BEARING GREASING INSTRUCTIONS tween the housing and bearing (on the drive side of the bearing). Rotate and push down until the ring meets the bottom of the bearing housing and the ends are equal The mill bearings support the mill drum shaft and should be on the side of the shaft.
Page 66: Adjusting The Belly Conveyor
ROUTINE MAINTENANCE ADJUSTING THE BELLY CONVEYOR DANGER/THROWN DEBRIS, CUT, CRUSH HAZARD: Shut power unit off and follow lockout procedures before any maintenance is performed. If the conveyor belt is slipping but tracking OK, remove the wing pulley guard, loosen the jam nuts (B) turn the adjusting bolts (A) one full turn each clockwise. You must turn the adjusting bolts the same amount or tracking (centering) will be affected.
Page 67: Adjusting The Discharge Conveyor
ROUTINE MAINTENANCE ADJUSTING THE DISCHARGE CONVEYOR DANGER/THROWN DEBRIS, CUT, CRUSH 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 (B) on the bearing (C) and carrier (A.) Turn adjusting bolt (D) one full turn clockwise.
Page 68: 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. If conveyor chain is not properly adjusted it will wear on itself, the drive, and idler sprockets more than normally.
Page 69: Servicing Tires
ROUTINE MAINTENANCE SERVICING TIRES Maintaining proper air pressure in the machine’s tires is critical to safe operation. Correct air pressure provides balance and stability during transportation and opera- tion. Never exceed maximum inﬂ ation pressures when sealing tire beads on rims. To add air to the tires remove the stem cap and place the air pump nozzle securely on the stem.
Page 70: Clean Engine Area
ROUTINE MAINTENANCE CLEAN ENGINE AREA CAUTION: Never clean engine with engine running. A combination of dirt, oil, wood dust and chip material in the engine area presents a risk of fire. Clean engine and mill area daily by blowing debris out from around power unit with compressed air.
Page 71: Fuel Specifications
ROUTINE MAINTENANCE FUEL SPECIFICATIONS No. 2D diesel fuel is recommended for use in all diesel power units. In extreme cold temperatures see engine mfg for recommended fuel options. In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to vaporous state and condensed, thus eliminating all sediment and resi- due.
Page 72: Radiator
ROUTINE MAINTENANCE RADIATOR WARNING: Never open cap on a hot radiator. Check coolant level only, when engine is stopped and ra- diatorcap is cool enough to touch with your hand. Prior to cold weather, be sure cooling system has a proper amount of antifreeze.
Page 73: Batteries
ROUTINE MAINTENANCE BATTERIES All models are equipped with two 12 volt 8D low maintenance batteries. The batteries are located on the side of the frame. Two 12 volt-batteries are con- nected in series to furnish 24 volts. SERVICING BATTERIES Keep battery and battery box clean. Keep all connections clean and tight. Remove all corrosion and wash terminals with a solution of baking soda and water.
Page 74: 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 compo- nents can result in a failure of suspension components. Further use of any visibly worn component can result in a failure. Any of these failures can result in loss of vehicle control and personal injury or death.
Page 75 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. Dur- ing 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.
Page 76: Understanding Hydraulics
UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY CAUTION: Never boost pressure settings on hydraulics. This will void the manufacturer's warranty. BE CAREFUL OF: Leaks A hydraulic pump makes oil ﬂ ow but there must be resistance a. Puddles of ﬂ uid are slippery and hazardous. for the ﬂ...
Page 77 UNDERSTANDING HYDRAULICS TESTING HYDRAULIC FLUID Test the ﬂ uid regularly. A number of formal test kits are available to evalu- ate the condition of hydraulic ﬂ uid or a ﬂ uid sample can be sent to a lab for evaluation. However, there are simple signs of ﬂ uid degradation such as a color shift, bad aroma or feel of grit in a sample.
Page 78: 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 79: Noisy Pump
SERVICING HYDRAULICS NOISY PUMP only. Intake clogged: Make sure tank is cleaned periodically. Fluid Air in the system: Check ﬁ ttings, cracked hoses, and other must be kept 3/4 full. parts on the pump intake. Check hydraulic tank. The tank Air leak in intake: If any air is going through pump, it will must be kept 3/4 full.
Page 80: Air Filter Maintenance
AIR FILTER MAINTENANCE REMOVE THE AIR FILTER GENTLY - Accidentally bumping the air ﬁ lter against the ﬁ lter housing will contaminate the clean side of the housing, before the new ﬁ lter element has a chance to do its job. ALWAYS CLEAN THE INSIDE OF THE FILTER HOUSING AND THE GAS- KET SEALING SUFACES CAREFULLY - Use a clean damp cloth to wipe every surface clean.
Page 81 AIR FILTER MAINTENANCE CAUTION: Its the customer's responsibility to follow all steps of air ﬁ lter mainte- nance every 200 hours or every engine oil change. Low pre-cleaner efﬁ ciency will cause short element life. Low pre-cleaning efﬁ ciency can be caused by: •...
Page 82: Troubleshooting
5. Check all motor ﬂ uid 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 prob- lem with the electrical system is suspected, ﬁ...
Page 83: Hydraulic System
TROUBLESHOOTING HYDRAULIC SYSTEM PROBLEM PROBABLE CAUSES AND SOLUTIONS Noisy pump cavitaiton 1. Check inlet hose for damage. Replace hose. (pump starving.) 2. Fluid viscosity too high. Replace oil. 3. Operating temperature too low. Allow system to warm up. Overheating of system. 1.
Page 84: Pressure Sheet
TROUBLESHOOTING PRESSURE SHEET Serial # Model # Sales Order # Customer Date INFEED BED PUMP 15 GALLON @ 2100 RPM = ACTUAL 14 GALLON 3000psi @ pump comp.________stand by 350 psi REVERSING P.S.I. SWITCH/2800psi @ pressure switch ________ BED CHAIN RPM @ SHAFT/18.7 RPM________ = 56 F.P.M.________ YOKE WHEEL PUMP 15 GALLON @ 2100 RPM = ACTUAL 19.25 GALLON FORWARD/3000psi @ pump________ REVERSE/3000psi @ pump________...
Page 85: Steps To Follow If You Feel You Have A Warrantable Failure
All returned parts must be shipped freight prepaid. 4. The white, yellow and green copies need to be mailed in an envelope to Morbark Warranty, PO Box 1000, Winn, MI 48896. Both the parts and claim need to bereceived for warranty consideration.
Page 86: Warranty
Purchasers Exclusive Remedy. The exclusive remedy for the purchaser in the event the equipment does not conform to thisWarranty, shall be the repair or replacement of the equipment is returned to Morbark’s factory 8507 Winn Road, Winn, Michigan, or at such other location designated in writing by Morbark.
Page 87 06/07 •...

Morbark Wood Hog 3800 Operators Safety Manual

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