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Morbark 1300B Safety & Operator Manual

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1300B
TRACK
TUB GRINDER
SAFETY
OPERATORS
MANUAL
76347-387
08/15
1
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  • Page 1 1300B TRACK TUB GRINDER SAFETY OPERATORS MANUAL 76347-387 08/15 • •...
  • Page 2 All rights reserved. This book is protected by copyright. No part of this book may be reproduced in any form or by any means including photocopying, or utilized by any information storage and retrieval system without written permission from Morbark, LLC Printed in the United States of America.
  • Page 3 SAFETY MANUAL REVISION LOG Revision: Date Issued: Pages Affected: Description of Changes: Oct.14, 2021 Initial Release 08/15 • •...
  • Page 4 08/15 • •...

  • Page 5: Table Of Contents Introduction

    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 6: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ......................5 LOCKOUT PROCEDURES ..................8 SPECIFICATIONS ......................9 MAIN COMPONENTS ....................10 SAFETY ........................12 SAFETY SIGNS ......................15 CRIME PREVENTION ....................19 ENGINE CONTROLS ....................22 CENTER SECTION CONTROLS ................23 CENTER SECTION CONTROLS ................24 ROD PUSHER ......................
  • Page 7 BATTERIES ..............................48 HAMMERMILL MAINTENANCE ........................49 ROTOR MAINTENANCE ..........................49 CHANGING HAMMERS ........................... 51 TUB DEFLECTOR ............................. 53 ANVIL REPLACEMENT ........................... 55 CHANGING GRATES ............................57 MILL BEARING GREASING INSTRUCTIONS ....................58 ADJUSTING THE DISCHARGE CONVEYOR....................59 CENTERING THE DISCHARGE CONVEYOR ....................59 TUB CHAIN ADJUSTMENT ..........................

  • Page 8: Lockout Procedures

    LOCKOUT PROCEDURES Lockout procedures shall be used at all times when mainte- Upon completion of the work, each employee must remove nance is being done or the machine is being shut down. This his/her lock, rendering the machine operable when the last will prevent accidents and prevent the machine from acci- lock is removed.

  • Page 9: Specifications

    SPECIFICATIONS General Length....................................38’4” (13 m) Height ....................................12’ (4.1 m) Weight .................................. 86,500 lb (35,924 kg) Electrical .......................................24 volt Power Options Caterpillar & Cummins ..........................750 - 1050 hp (559 - 745 kw) Outside Opening................................13 ft ( 3.9 m) dia Inside Base Opening ...............................

  • Page 10: Main Components

    MAIN COMPONENTS NOTE: Parts (Covers, Doors, etc.) Hidden for Clarity. Debris Deflect Emergency Stop Pushbutton 17 Hydraulic Oil Tank (270 gal) 25 Auger Drive Motors Magnetic Roller 10 Fuel Cooler 18 Radiator 26 Engine Exhaust Discharge Coveyor (Deployed) 11 Air Compressor 19 Torque Limiter 27 Battery Disconnect Switches Conveyor Fold Cylinders...
  • Page 11 NOTE: Parts (Covers, Doors, etc.) Hidden for Clarity. 08/15 • •...

  • Page 12: Safety

    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.

  • Page 13: Operate Safely

    SAFETY OPERATE SAFELY NOTE: Do not allow familiarity, gained from frequent use of your machine to become common place. 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.

  • Page 14: 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 •...

  • Page 15: Safety Signs

    SAFETY SIGNS 08/15 • •...
  • Page 16 SAFETY SIGNS 08/15 • •...
  • Page 17 SAFETY SIGNS 08/15 • •...
  • Page 18 DECAL,NOTICE,WELDING 39511-236 DECAL,DANGER,ROTATING HAZARD 39511-824 TAG,NOTICE,WELDING 39511-399 DECAL,WARNING,OPERATOR'S/PARTS MANUALS 39511-825 DECAL,NOTICE,ENGAGE CLUTCH,LOW IDLE 39511-408 DECAL,WARNING,FLAMMABLE 39511-827 DECAL,USE GENUINE MORBARK PARTS AND SER 39511-410 DECAL,FUEL SHUTOFF VICE 39511-411 DECAL,HYDRAULIC OIL 39511-832 DECAL,WARNING,CRUSH HAZARD,KEEP HANDS 39511-412 DECAL,DIESEL FUEL CLEAR 39511-420 DECAL,WARNING,DO NOT REMOVE THE DECALS...

  • Page 19: Crime Prevention

    CRIME PREVENTION GOOD ADVICE • Keep your machine damage-free • Follow the advice on these pages to 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.
  • Page 20 CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE Remove ignition key, lock cab doors, windows and the main power switch box. 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. Secure all openings to storage buildings PARKING OUTDOORS Remove ignition key and lock cab doors, windows and lock the main power switch box.

  • Page 21: 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 identification numbers (found on the roadside of the tongue near the front) to the investigating officer and insurance carrier.

  • Page 22: Engine Controls

    Access port for tethered remote control Press to operate warning horn. USB access for Morbark Integrated Control System (MICS) system Press to increase engine RPM. Key switch to turn MCP on and start engine Press to decrease engine RPM.

  • Page 23: Center Section Controls

    CENTER SECTION CONTROLS BATTERY DISCONNECT SWITCHES Battery disconnect switches are located on the side of the machine and are accessible from ground level. The ROD PUSHER battery switch (OPTIONAL) allows power to the hydraulic system that operates the rod puller when in the ON position.

  • Page 24: Emergency Shut Off Switch

    CENTER SECTION CONTROLS EMERGENCY SHUT OFF SWITCH CAUTION: This switch should only be used for emergency shut down. An emergency stop (engine shutdown) switch is located at the corner of the machine (as shown below). Pressing this palmbutton will shutdown the engine. The engine may not be restarted until this E-stop has been reset. To reset, twist the palmbutton clockwise until the button pops out.

  • Page 25: Rod Pusher

    ROD PUSHER Turn switch to FOR. (Forward) to push in the Rod Pusher. Turn switch to REV. (Reverse) the left to retract the rod. NOTE: This tether is optional and may not be included on your particular machine. FOR. REV. 08/15 •...

  • Page 26: Tub Tilt

    TUB TILT Turn switch to FOR. (Forward) to push in the Rod Pusher. Turn switch to REV. (Reverse) the left to retract the rod. NOTE: This tether is optional and may not be included on your particular machine. STROBES & HORN RED STROBE LIGHT - This light will start flashing when the engine coolant temperature goes above a set temperature.

  • Page 27: Remote Control

    REMOTE CONTROL 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.

  • Page 28: Wireless Remote

    WIRELESS REMOTE [39253-374] 08/15 • •...

  • Page 29: Remote Controls

    REMOTE CONTROLS TUB FORWARD/ TUB REVERSE - Push the toggle forward to turn the tub in the forward motion and backwards for tub re-verse. LEFT TRACK FORWARD/REVERSE - Push the toggle forward to move the left track forward. Push the toggle back to move the left track in reverse.
  • Page 30 TETHERED REMOTE [39253-335] 08/15 • •...
  • Page 31 REMOTE CONTROLS LEFT TRACK FORWARD/REVERSE - Push the toggle forward to move the left track forward. Push the toggle back to move the left track in reverse. THROTTLE UP/ THROTTLE DOWN - Push the toggle forward to increase engine RPM. Push the toggle back to de- crease engine RPM.
  • Page 32 VALVE BANK CONTROLS CONVEYOR FOLD - This lever extends and retracts the cylinders which raises the conveyor. TUB TILT - This lever extends and retracts the cylinder which raises the tub for service. CONVEYOR- This lever will engage and disengage the discharge conveyor. AUGER- This lever will engage and disengage the discharge augers.

  • Page 33: 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 operation of this machine and dangerous areas to avoid.

  • Page 34: 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.

  • Page 35: Thrown Object Area

    SAFETY OPERATION THROWN OBJECT AREA WARNING: Always wear a hard hat and safety glasses when operating the tub grinder. During the grinding operation thrown or falling objects from a grinder can cause sever injury to bystanders and workers. It is recommended that a “thrown object area”...

  • Page 36: Proper Use Of The Tub Cover

    SAFETY OPERATION PROPER USE OF THE TUB COVER WARNING: Always wear a hard hat when operating the tub grinder. Before engaging the clutch on the power unit, use the loader or an auxillary lifting device and place the tub cover directly on the tub. Once the clutch is engaged, throttle the power unit up to full RPM.

  • Page 37: Starting Machine

    SAFETY OPERATION STARTING MACHINE Place all hydraulic switches in the neutral position. Place the clutch in the disengaged position and. Turn main power switch to the ON position. Turn key to START position. (Note: the warn-ing horn will sound for 5 sec- onds to warn ground crews before the engine starts.

  • Page 38: Safety Procedures

    SAFETY OPERATION SAFETY PROCEDURES Always make sure all filler plugs, caps and guards are in place. DANGER/THROWN DEBRIS, CRUSH, CUT HAZARD:Never under any circumstances, lift the tub without first making sure the mill has completely stopped. Always wear appropriate safety equipment such as a hard hat and safety glasses. 08/15 •...

  • Page 39: Machine Shut Down

    SAFETY OPERATION MACHINE SHUT DOWN Throttle engine down to an idle. Place all hydraulics in neutral. Disengage clutch. Allow engine to idle 3-5 minutes and then shut off. Turn off main switch and remove ignition key. Turn off main battery disconnect switch. CAUTION: Do not turn off main battery disconnect until rotor completely stops.
  • Page 40 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 08/15 • •...

  • Page 41: Routine Maintenance Schedule

    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 Procedures Complete Machine...
  • Page 42 ROUTINE LUBRICATION SCHEDULE 08/15 • •...
  • Page 43 XX = 2 SHOTS OF GREASE USE ONLY EP RATED GREASE 1) REFER TO OEM MANUAL FOR LUBRICATION PROCEDURES 2) SPRAY DOWN WITH GOOD QUALITY SPRAY LUBE GREASE 3) Apply thin coat of Silver Streak lubricant (Morbark part number: 18683-005) 08/15 • •...

  • Page 44: Routine Maintenance

    ROUTINE MAINTENANCE Bolts & Torque Torque Values for Imperial Sized Fasteners lbf-ft Table 4.3 • Torque Guides Grade 5 - Coarse Thread. Lbf-ft Grade 5 - Fine Thread. Lbf-ft Bolt Diameter Hex Head Cap Screw, Zinc Plated / Lubricated Bolt Diameter Hex Head Cap Screw, Zinc Plated / Lubricated...
  • Page 45 The specifications prescribed within this document were provided by the Fastenal Bolt Company. Terms M12 x 1.75 for the use of this standard are at the discretion of Morbark, LLC in conjunction with ASME B18.16.6-2017, M14 x 2.0 ASME B18.6M-2004, SAE J1701-FEB2017, SAE J1701M-NOV2017.

  • Page 46: How To Use A Belt Tension Gauge

    ROUTINE MAINTENANCE HOW TO USE A BELT TENSION GAUGE Before adjusting the belt tension: Throttle the engine down and disengage the clutch. 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.
  • Page 47 ROUTINE MAINTENANCE HOW TO USE A BELT TENSION GAUGE CON’T Figure 1 Figure 3 Small 0’ ring Table 1 Deflection Small Sheave Deflection force in lbs. for Force V-belt- Scale Drive Speed Ratio of; Sec- Speed tion Range Diameter 4.0+ 1200 - 1800 1200 - 1800 Figure 2...

  • Page 48: Servicing Batteries

    ROUTINE 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. All models are equipped with two 12 volt 8D low maintenance batteries. SERVICING BATTERIES 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 49: Hammermill Maintenance

    ROUTINE MAINTENANCE HAMMERMILL MAINTENANCE Hammermill Inspection - 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” for repair instructions. Inspect rod and rotor sections for excessive wear.
  • Page 50 ROUTINE MAINTENANCE ROTOR MAINTENANCE CON'T 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" deep. Preheat mill plate to the temperature on the chart (see below.) Check temperatures 4"...

  • Page 51: Changing Hammers

    ROUTINE MAINTENANCE CHANGING HAMMERS DANGER/CRUSH HAZARD: Always use tub lock when changing hammers. Disengage the clutch. Activate rear valve bank by pushing in rear valve bank lever. Pull tub floor pins and activate the valve on the rear valve bank to raise tub floor.
  • Page 52 ROUTINE MAINTENANCE CHANGING HAMMERS CON'T WARNING: Never stand or jump on wrench to break bolts loose. Rotate rod locking plate to access hammer rods. CAUTION: Two (2) people are required at all times when changing hammers. Using eyebolt puller supplied, thread into the end of hammer rod and pull or with optional rod pusher operate switch on tether to push rod out.

  • Page 53: Tub Deflector

    ROUTINE MAINTENANCE CHANGING HAMMERS CON’T CAUTION: The fewer hammers in your hammermill, the more aggressive your grinding capabilities. Maintenance should be performed on a regular basis to insure that your hammers, hammer inserts and hammer rods are in good working order. Failure to do so will result in damage to equipment and harm to personnel and may void your warranty.
  • Page 54 ROUTINE MAINTENANCE CHANGING HAMMERS CON'T 08/15 • •...

  • Page 55: Anvil Replacement

    ROUTINE MAINTENANCE ANVIL REPLACEMENT Rotor Anvils This tub grinder is equipped with two anvil types: A primary grind anvil (see A, Figure A) that has a straight edge and is used for initial grinding, and a re-grind anvil (see B) that has an angled edge and is used for processing materials that have already been processed once using the primary grind anvil, or for wet heavy yard waste, palm trees or grass clippings.
  • Page 56 To change the anvils follow these steps: Retention Bolt Washer (Typical) (Typical) Nut (Typical) Reduce engine RPM to idle. Disengage the clutch. DANGER! Make sure rotor has come to a complete stop before continuing. Remove anvil retention bolt, nut and washers as shown in Figure D and set aside.

  • Page 57: Changing Grates

    ROUTINE MAINTENANCE CHANGING GRATES WARNING: Read maintenance safety procedures carefully before beginning. DANGER/CRUSH HAZARD: Always use tub lock when changing hammers. DANGER/THROWN DEBRIS, CRUSH, CUT HAZARD: Shut power unit off before any maintenance is performed. Disengage the clutch. WARNING: After clutch is disengaged, rotor will coast (rotate) for several minutes before it completely stops.

  • Page 58: Mill Bearing Greasing Instructions

    ROUTINE MAINTENANCE MILL BEARING GREASING INSTRUCTIONS The mill bearings support the mill shaft and should be cleaned and Slide the bearing onto tapered sleeve. Match the inner taper repacked twice a year or every 1,000 hours. on the bearing. Slide the washer onto the shaft. The tabs should be pointed away from the bearing.

  • Page 59: 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 60: Tub Chain Adjustment

    ROUTINE MAINTENANCE TUB CHAIN ADJUSTMENT The tub drive motor is spring loaded which applies a constant pressure at all times. If the chain is loose or "sagging" check motor mount and spring to see if it has reached its maximum travel. If this is the case, remove 1" pusher bolt from storage nut, remove nut from bolt and place bolt through pusher hole.
  • Page 61 08/15 • •...

  • Page 62: Clean Engine Area

    ROUTINE MAINTENANCE CLEAN ENGINE AREA CAUTION: Never clean engine with engine running. CAUTION: A combination of dirt, oil, wood dust, and chip material in the engine area presents a risk of fire. Clean the engine and chipper area daily by blowing debris out from around power unit with compressed air. NOTE: See power unit operations and maintenance manual for furthur information.

  • Page 63: Fuel Specifications

    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.

  • Page 64: Radiator

    ROUTINE MAINTENANCE RADIATOR WARNING: Never open cap on a hot radiator. Prior to cold weather, be sure the cooling system has a proper amount of antifreeze. Use a quality brand of permanent-type eth- ylene glycol antifreeze which contains a rust inhibitor and lubricant. Use a 50/50 ethylene glycol antifreeze and clean soft water.

  • Page 65: Batteries

    ROUTINE MAINTENANCE BATTERIES The batteries are located near the engine. Two 12 volt batteries are provided to make 24 volts. SERVICING BATTERIES Keep battery and battery box clean. Keep all connections clean and tight. Remove all corrosion and wash terminal with a solution of baking soda and water.

  • Page 66: Understanding Hydraulics

    UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY Be careful of: Leaks a. Puddles of fluid are slippery and hazardous. b. Most hydraulic oils will vaporize and ignite, disastrous fires are possible. c. Leaking fluid may be hot and can produce severe burns. d. Fluid can squirt out under high pressure with dangerous force. Pin hole jets can pierce skin and damage eyes. WARNING: Escaping fluid under pressure can penetrate the skin, causing serious personal injury.
  • Page 67 UNDERSTANDING HYDRAULICS Example: If the pump is pumping six gallons in 30 seconds and the pump is a 12 GPM, then you know that it is performing at capacity. If it will only pump two or three GPM in 30 seconds, you know that the pump is only performing at 50% of its capacity.If the pump is performing properly, the relief valve is defective.If the pump isn't performing right, it will need repairing or replacement.

  • Page 68: Servicing Hydraulics

    SERVICING HYDRAULICS THE SEVEN STEPS OF TROUBLE SHOOTING Talk to the operator. Test probable causes. Know the system - schematics. Repair the system. Inspect the machine. Check for root causes. List probable causes. GATHER INFORMATION (STEPS 1, 2 AND 3) Information is very important.
  • Page 69 SERVICING HYDRAULICS NOTE: Never fill hydraulic tank completely full at any time. System drainage will cause the tank to overfill and spill out. Cavitation (vacuum in pump): Check for clogged or restricted intake line or plugged air vent in tank. Loose or worn pump parts: Look for worn gaskets and replace if necessary.

  • Page 70: Air Filter Maintenance

    AIR FILTER MAINTENANCE 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. ALWAYS CLEAN THE INSIDE OF THE FILTER HOUSING AND THE GASKET SEALING SUFACES CAREFULLY - Use a clean damp cloth to wipe every surface clean.

  • Page 71: Trouble Shooting

    TROUBLE SHOOTING HYDRAULIC SYSTEM PROBLEM PROBABLE CAUSES AND SOLUTIONS Noisy pump cavitaiton (Pump starving). Check inlet hose for damage. Replace hose. Fluid viscosity too high. Replace oil. Operating temperature too low. Allow system to warm up. Overheating of system. Continuous operation at relief setting: A.

  • Page 72: Electrical

    TROUBLE SHOOTING 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 73: 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 74: Warranty

    Warranty shall be the repair or replacement of the equipment (at the option of Morbark) without charge to the purchaser, when the equipment is returned to Morbark’s factory at 8507 South Winn Road, Winn, Michigan or at such other locations as may be designated in writing by Morbark.
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