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Morbark parts and service, the solution to your problems. Buying your parts elsewhere just does not pay. To keep your equipment performing at its peak use GENUINE MORBARK PARTS 800-255-8839 800-832-5618 fax www.morbark.com •...
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SAFETY MANUAL REVISION LOG Revision: Date Issued: Pages Affected: Description of Changes: June 14, 2017 Initial Release April 4, 2018 41-42, 47, 57 41-42: updated lube table: 47: Added Note: 57: Change Torque May 17, 2018 Torque 300 ft. lbs •...
Thank you for purchasing a Morbark, LLC. product. Before we begin this manual, the people at Morbark, LLC. encourages 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.
SPECIFICATIONS General Length................38 ft. 1 1/2 in (Discharge Stowed) 57 ft. 8 1/2 in (Discharge Deployed) Width ......................................8 ft 6 in Height ..................... 12 ft. (Discharge Stowed) 15 ft. 9 in (Discharge Deployed) Weight ......................................64,442 lb Electrical System ..................................24 Volts Power Options Caterpillar ..................................
If these instructions are not followed, it could result in damage to the machine. 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 injury or death.
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 sufficient to inflict 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.
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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 maintenance on any of these systems.
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 finger or skin to check for leaks • Lower load or relieve hydraulic pressure before loosening fittings BATTERY SAFETY Batteries generate explosive gases.
SAFETY SIGNS DANGER! DANGER! STRONG HOOD LOCK MAGNET MUST BE USED WHENEVER THE HOOD IS OPEN FOR ANY REASON. FAILURE TO 39512-493 ENGAGE LOCK MAY RESULT IN SERIOUS INJURY OR DEATH 5” x 3 3/4” 39511-228 5” W x 3 1/2” H CHRUSH HAZARD Chipper disc, drum or rotor, and their drive belts will coast for several minutes after power is shut off.
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SAFETY SIGNS WARNING Crush Hazard. Entanglement Hazard. Stay clear of infeed area. Follow lockout procedure before servicing. Failure to Comply May Result in Death or Serious Injury. WARNING 39511-232 7” x 5 1/2” EXPLOSION HAZARD OPTI-SOLVE EXTREME GRIP VINYLVV Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel fuels with higher Sulfur content.
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Morbark parts and service, the solution to your problems. Buying your parts elsewhere just does not pay. To keep your equipment performing at its peak use GENUINE MORBARK PARTS 800-255-8839 800-832-5618 fax www.morbark.com •...
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 identification numbers of engine, clutch, hydraulic components etc. EXACTLY as they appear on the plates •...
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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. 3�...
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 road side of the infeed bed near the front) to the investigating officer and insurance carrier.
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10� DATA LINK HOOKUP - Provides access for engine diagnostics. 11� TETHER CONTROL - Provides hook up for the tether control. 12� MICS DIAGNOSTIC PORT - USB connection for MORBARK INTERGRATED CONTROL SYSTEM. 13� KEY SWITCH - Spring centered switch used for starting. Turn to the right for start.
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 erratically.
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REMOTE CONTROLS (CON'T) CARE AND HANDLING OF SYSTEM 1� Transmitter should be turned off when not in use. 2� Do not store transmitter in direct sunlight or wet areas. 3� Handle transmitter with care. Do not drop, throw or subject to severe physical shock. 4�...
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WIRELESS REMOTE CONTROLS DANGER: CRUSH, ENTANGLEMENT HAZARD: Keep all personnel clear of infeed during operation� 1� THROTTLE UP/DOWN - Push the toggle up to increase, push the toggle down to decrease engine RPM. 2� DRIVE ON/OFF, DRIVE HIGH\LOW - Push toggle up to enable track drive, down to toggle between high/low. 3�...
CENTER SECTION CONTROLS 1� YOKE LOCK SWITCH - Engages and disengages the yoke lock. WARNING: When the YOKE UP switch is released, the yoke assembly will lower back down to the infeed bed� 2� YOKE UP SWITCH - Raises the yoke. 3�...
VALVE BANK CONTROLS 1� CONVEYOR FOLD (2ND) - This lever will fold and unfold the top conveyor. 2� CONVEYOR FOLD (1ST) - This lever will raise and lower the bottom conveyor. 3� BELLY CONVEYOR - This lever will start and stop the belly conveyor. 4�...
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 the dangerous areas to avoid.
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.
SAFETY OPERATION STARTING MACHINE Review the condition of the machine. 1� Place all hydraulics in the neutral position. 2� Make sure clutch is disengaged. 3� Place the ENGINE BATTERY switch to the ON position. 4� Give several blasts of the warning horn to clear area with remote or tether. 5�...
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SAFETY OPERATION STARTING MACHINE CON'T WARNING: Never engage the clutch with safety guards missing or with the yoke in the raised position� 9� Throttle up power unit all the way. NOTE: The feedworks will not engage until the engine RPM reaches the HI speed switch settings.
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 hood without first making sure the mill has completely stopped� CAUTION: Do not use your hand to check for mill movement� 2�...
SAFETY OPERATION YOKE LOCK PROCEDURE 1� Throttle engine down to an idle and disengage the clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has 2 & 4 come to a complete stop before attempting any maintenance� CAUTION: Do not use your hand to check for mill movement� 2�...
SAFETY OPERATION HOOD LOCK PROCEDURE 1� 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� 2�...
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SAFETY OPERATION HOOD LOCK PROCEDURES CON'T 6� Lift hood lock bar to yoke and install pin. DANGER/CRUSH HAZARD: Clear the hood area before raising hood� 7� Raise yoke, disengage yoke locks and lower yoke, this will raise the hood completely. 8�...
SAFETY OPERATION MACHINE SHUT DOWN 1� Place all hydraulics in neutral. 2� Throttle engine down to an idle and disengage clutch. 3� Allow engine to idle 3-5 minutes and then shut off. 4� Turn off key switch and remove ignition key. 5�...
SAFETY OPERATION TRANSPORTING 1� Check to make sure the clutch is disengaged. 2� Make sure the mill has completely stopped, fold the conveyor up and over the engine. 3� Secure the conveyor with chains and binders for transport. 4� Turn off main ignition key and remove. 5�...
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Morbark parts and service, the solution to your problems. Buying your parts elsewhere just does not pay. To keep your equipment performing at its peak use GENUINE MORBARK PARTS 800-255-8839 800-832-5618 fax www.morbark.com •...
ROUTINE MAINTENANCE 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 different, adjust the specified intervals accordingly. GENERAL Complete machine visual inspection (condition, leaks), clean if necessary...
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ROUTINE MAINTENANCE 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 different, adjust the specified intervals accordingly. HYDRAULICS Hydraulic pump belts tighten to correct tension...
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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 different, adjust the specified intervals accordingly. X = ONE SHOT OF GREASE 1) Infeed Chain drive and driven bearings 2) Yoke &...
ROUTINE MAINTENANCE NOTE: If using an air gun to install nuts/bolts, always check for proper torque using a calibrated torque TIGHTENING TORQUE GUIDE wrench. TORQUE IN POUNDS - FOOT COARSE FINE Socket Socket Socket Socket head head head head Grade screw screw Grade...
ROUTINE MAINTENANCE HOW TO USE A BELT TENSION GAUGE Before adjusting the belt tension: 1� Throttle the engine down and disengage the clutch. 2� Shut off the engine, remove the key. DANGER/CUT and PINCH HAZARD: Shut power unit off and install lockout devices before any maintenance is performed�...
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ROUTINE MAINTENANCE Figure 1 Figure 3 Small 0’ ring Deflection Force Scale Table 1 Small Sheave Deflection force in lbs. for Drive Speed Ratio of; V-belt- Section Speed Range Diameter 4.0+ 1200 - 1800 Figure 2 1200 - 1800 1200 - 1800 1200 - 1800 900 - 1800 900 - 1800...
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Morbark parts and service, the solution to your problems. Buying your parts elsewhere just does not pay. To keep your equipment performing at its peak use GENUINE MORBARK PARTS 800-255-8839 800-832-5618 fax www.morbark.com •...
SAFETY OPERATION HYDRAULIC CLUTCH BRAKE RELEASE This brake release when applied, will allow free movement of the mill for servicing. CAUTION: Read maintenance safety procedures carefully before beginning� NOTE: The hydraulic clutch brake release will not operate while the engine is running. NOTE: The hydraulic clutch brake release will not operate while the mill is turning.
ROUTINE MAINTENANCE CHANGING MILL HAMMERS CAUTION: Read maintenance safety procedures carefully before beginning� This procedure should be followed whether you are changing one hammer, all hammers or changing to a different hammer pattern. Personnel performing this procedure should always wear proper safety clothing, including gloves. NOTE: Do not install the inserts on the hammers until after the hammers are installed.
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9� Thread the rod driver into the end of the rod. The rod driver was furnished by Morbark with your machine. 10� As each hammer or raker is guided into position, drive the rod into place until all hammers and rakers are installed (depending on the desired pattern) and the rod is driven flush.
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ROUTINE MAINTENANCE CHANGING MILL HAMMERS CON'T 12� Insert the second rod in the 12 o’clock hole and attach the rod driver. 13� Position the second row of hammers, one at a time and drive the rod into po- sition engaging the back of the first row of hammers and the front row of the second row of hammers and/or rakers.
ROUTINE MAINTENANCE HAMMER ROD PULLER INSTRUCTIONS CAUTION: Read maintenance safety procedures carefully before beginning� 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. NOTE: Do not install the inserts on the hammers until after the hammers are installed.
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ROUTINE MAINTENANCE HAMMER ROD PULLER INSTRUCTIONS CON'T 4� Shut down the engine. 5� Perform the Lockout/Tagout procedure. 6� Place the ROD PULLER BATTERY switch to the ON position. 7� Removing rods is a two (2) man job. One man should be positioned on the infeed bed.
ROUTINE MAINTENANCE CHANGING MILL INSERTS 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� CAUTION: Do not use your hand to check for mill movement�...
ROUTINE MAINTENANCE RAKER MAINTENANCE NOTE: 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.
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ROUTINE MAINTENANCE RAKER MAINTENANCE CON'T 4� Locate the raker gauge on top of the mill plate, next to the raker you are checking. 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.
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. 1� Look for cracked welds between the rotor plates. If cracks are found, refer to “ Rotor Maintenance”...
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ROUTINE MAINTENANCE HAMMERMILL MAINTENANCE CON'T CAUTION: Two (2) people are required at all times when performing mill maintenance� 3� If cracks are found it is highly recommended that you make the repairs before an unnecessary failure occurs. 4� The cracks will need to be ground out. The proper procedure is to grind the crack the full length with a gouge 1/8"...
ROUTINE MAINTENANCE REPLACING GRATES WITH SUPPLIED CHAIN HOIST CAUTION: Read maintenance safety procedures carefully before beginning� CAUTION: Two (2) People required at all times when changing grates� 1� Place all hydraulics in neutral. 2� Throttle engine down to an idle, disengage clutch. DANGER/THROWN DEBRIS, CUT, PINCH HAZARD: Make sure the mill has come to a complete stop before attempting any maintenance�...
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ROUTINE MAINTENANCE REPLACING GRATES CON'T 4� Remove rod puller from holder and install in holes on bottom side of hood. CAUTION: Refer to hoist instructions supplied with come along for proper use� 5� Position hoist onto rod puller and hook grates according to hoist instructions. 6�...
ROUTINE MAINTENANCE ADJUSTING THE DISCHARGE CONVEYOR DANGER/THROWN DEBRIS, CUT, CRUSH HAZARD: Shut power unit off and follow lockout procedures before any maintenance is per- formed� If the conveyor belt slips under a load, adjust as follows: NOTE: Make equal adjustments to BOTH sides of the conveyor to maintain align- ment when performing these steps.
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.
ROUTINE MAINTENANCE SERVICING TIRES Maintaining proper air pressure is critical to safe operation. Correct air pressure provides balance and stability during transportation and operation. Never exceed maximum inflation 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. Avoid twisting or bending the stem while adding air.
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.
ROUTINE MAINTENANCE FUEL SPECIFICATIONS No. 2D diesel fuel is recommended for use in all diesel power units. In extremely cold temperatures use No. 1D diesel fuel. In se- lecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed thus eliminating all sediment and residue.
ROUTINE MAINTENANCE RADIATOR WARNING: 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.
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 connected in series to furnish 24 volts. SERVICING BATTERIES 1� 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.
UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY NOTE: Never boost pressure settings on hydraulics. This will void the manufacturer's warranty. Be careful of: Leaks A hydraulic pump makes oil flow but there must be resistance a. Puddles of fluid are slippery and hazardous. for the flow to generate pressure.
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One of the most important elements in such a program is changing or Whe n refilling t he system we recommend MORBARK HYDREX XV hydra ulic fluid o r equival e n t. adding to the fluid on schedule.
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.
SERVICING HYDRAULICS NOISY PUMP Intake clogged: Make sure tank is cleaned periodically. Fluid must be kept 3/4 full. Air in the system: Check fittings, cracked hoses, and other parts Air leak in intake: If any air is going through pump, it will cause on the pump intake.
AIR FILTER MAINTENANCE 1� REMOVE THE AIR FILTER GENTLY - Accidentally bumping the air filter against the filter housing will contaminate the clean side of the housing, before the new filter element has a chance to do its job. 2� ALWAYS CLEAN THE INSIDE OF THE FILTER HOUSING AND THE GASKET SEALING SUFACES CAREFULLY - Use a clean damp cloth to wipe every surface clean.
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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: • Leaking dust cup to air cleaner body joint;...
4. 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.
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.
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.
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