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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.
Table Of CONTeNTs lOCKOUT PROCeDURes ����������������������������������������������������������������������������������������������������������������������������6 sPeCIfICaTIONs �������������������������������������������������������������������������������������������������������������������������������������������7 MaIN COMPONeNTs �������������������������������������������������������������������������������������������������������������������������������������8 safeTY ��������������������������������������������������������������������������������������������������������������������������������������������������������10 OBSERVE SAFETY SIGNS AND MESSAGES ........................10 OBSERVE "CAUTION" MESSAGES ............................10 DO NOT MODIFY MACHINE ..............................10 BEFORE OPERATING ................................10 OPERATE SAFELY ..................................11 PROTECT AGAINST NOISE ..............................11 AVOID CONTACT WITH MOVING PARTS ..........................
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Table Of CONTeNTs ROUTINe MaINTeNaNCe sCHeDUle ������������������������������������������������������������������������������������������������������40 ROUTINe lUbRICaTION sCHeDUle ��������������������������������������������������������������������������������������������������������42 ROUTINe MaINTeNaNCe ���������������������������������������������������������������������������������������������������������������������������44 TIGHTENING TORQUE GUIDE ..............................44 HOW TO USE A BELT TENSION GAUGE ..........................45 CHANGING CHIPPER KNIVES ..............................47 CHANGING KNIFE HOLDERS ..............................48 KNIFE GRINDING ..................................50 CHIPPER KNIFE BABBITTING ..............................
Failure to lock out while performing mainte- no unintended motion will occur, or test the equipment and ma- nance could result in serious personal injury or death! Morbark chine 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.
sPeCIfICaTIONs General Length..................................33 Ft 6 In Width .....................................8 Ft 6 In Height ..................................11 Ft 10 In Gross Weight ................................42,000 Lb Electrical system ................................24 Volts Power Options John Deere, Cummins, and Caterpillar ....................... 500 - 630 Hp Infeed system Infeed Opening ..............................40 In x 24 In Feed Bed ..............................
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.
safeTY aVOID CONTaCT WITH MOVING PaRTs There are hazards associated with V-belts, and chains. Objects or body parts can become crushed between 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.
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 en- gine, clutch, hydraulic components etc. EXACTLY numbers as they appear on the plates •...
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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 fifth wheel plate to make hookups more difficult.
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 front of the tongue) to the investigating officer and insurance carrier.
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eNGINe CONTROls IQaN DIaGNOsTICs - Refer to technical manual for more information. IQaN DIsPlaY - Displays all the information about the automatic grinding cycles.Refer to technical manual for operat- ing information. MaIN baTTeRY DIsCONNeCT - Supplies power to the cab and engine. This switch should always be shut off at the end of a shift.
eNGINe CONTROls IQaN DIaGNOsTICs - Refer to technical manual for more information. IQaN DIsPlaY - Displays all the information about the automatic grinding cycles.Refer to technical manual for operat- ing information. MaIN baTTeRY DIsCONNeCT - Supplies power to the cab and engine. This switch should always be shut off at the end of a shift.
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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...
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.
ReMOTe CONTROls MONITOR - GREEN means transmitter is on. RED means that the battery is low. THROTTle sWITCH - Push switch up to increase, push switch down to decrease engine RPM. eMeRGeNCY eNGINe sTOP sWITCH - Push up and hold the switch for three seconds. This will shut the engine off. Push the switch down to reset after engine has stopped or to activate the horn.
CeNTeR seCTION CONTROls feeDWORKs sTOP bUTTON - This button will stop the feedworks. CaUTION: This button should only be used for emergency shut down� HORN bUTTON - Push button to sound horn. CaUTION: Use horn to clear the area before start up and to warn someone they are too close to the work area� INfeeD YOKe sWITCH - This switch will either raise or lower the infeed yoke.
safeTY CONTROls ClUTCH safeTY sWITCH - This machine is equipped with a clutch safety switch. This will not allow the machine to start with clutch engaged. ClUTCH HaNDle lOCK MaIN baTTeRY DIsCONNeCT sWITCH - Supplies power to - Used to prevent accidental engagement of the clutch.
ValVe baNK CONTROls lefT sIDe fRONT sTabIlIZeR ValVe - This valve helps stabilize the center section of machine. RIGHT sIDe fRONT sTabIlIZeR ValVe - This valve helps stabilize the center section of machine. lefT sIDe ReaR sTabIlIZeR ValVe - This valve levels the machine and raises and lowers it for transport. RIGHT sIDe ReaR sTabIlIZeR ValVe - This valve levels the machine and raises and lowers it for transport.
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. CaUTION: Remember, this is a dangerous piece of equipment if not maintained and operated properly.
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 infeed bed or lying in the engine area.
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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 04/08 •...
safeTY OPeRaTION sTaRTING MaCHINe Review the condition of the machine. Place all hydraulics in the neutral position. Make sure clutch is in disengaged and locked position. Turn main power switch, then the key to the ON position. DaNGeR/CRUsH, eNTaNGleMeNT HaZaRD: This machine is equipped with a clutch safety switch�...
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safeTY OPeRaTION sTaRTING MaCHINe cont��� Adjust the front and (rear stabilizers if applicable), so the frame is level. DaNGeR/THROWN DebRIs HaZaRD: Never allow anyone to stand under discharge spout� Engage the clutch by bumping the clutch handle in and out gently, until the chipper drum is turning, then fully engage the handle.
safeTY OPeRaTION YOKe lOCK PROCeDURe Throttle engine down to an idle and disengage the clutch. DaNGeR/THROWN DebRIs, CUT, PINCH HaZaRD: Make sure the drum has come to a complete stop before attempting any maintenance� CaUTION: Do not use your hand to check for drum movement� urn yoke control switch (see center section controls) to the raise position and hold.
safeTY OPeRaTION CHIPPING safeTY PROCeDURes Always make sure all filler plugs, caps, and guards are in place. DaNGeR/THROWN DebRIs, CUT HaZaRD: Never, under any circum- stances, open the drum hood without first making sure the drum has completely stopped� WaRNING: Do not use your hand to check for drum movement� Always wear appropriate safety equip-ment such as a hard hat and safety glasses.
safeTY OPeRaTION CHIPPING WOOD • Use the warning horn as often as needed to alert workers of DaNGeR • Set up some simple hand signals with the ground crew, skidder operators and truck drivers. Simple instructions can be understood from a safe distance during chipping •...
safeTY OPeRaTION MaCHINe sHUT DOWN Throttle engine down to an idle. Position loader on the ground or on the conveyor end for transport. Place all hydraulics in neutral, and engage parking brake. Close up cab. Shut off heater, a/c, fan etc, before leaving the cab. Dismount machine carefully.
safeTY OPeRaTION TRaNsPORTING Check to make sure the clutch is disengaged and clutch lock installed. Turn off main ignition key and remove. Turn off main battery disconnect switch and lock. Hook up the electrical connections and air brake lines. Check the tire pressure for proper load range. Check the brakes, turn signals and tail lights.
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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 04/08 •...
1) Engine compression may change indicator. Therefore, try to reset the indicator by pressing the rubberized button before cleaning pre-cleaner or changing air filters. 2) According to procedures in your Morbark Operators Manual. 3) During first day check all belts and bolts frequently, after first day every 8 hours, after first week follow above procedures.
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4) Apply a coat of Loc-Tite 242 (blue) to each bolt before tightening. Run a tap through threads if necessary. 5) During first 24 hrs check all belts and bolts frequently, after first day check every 8 hours. After first week week follow above procedures. 6) According to specifications listed in your Morbark Operators Safety Manual. 04/08 •...
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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 difficult, adjust the specified intervals accordingly.
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.
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, and conduct machine lockout. Remove the belt guard. If maintenance is required, loosen the engine bolts, remove the belt, and fix before setting belt tension. Inspect and/or repair the following: •...
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ROUTINe MaINTeNaNCe HOW TO Use a belT TeNsION GaUGe 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.
ROUTINe MaINTeNaNCe CHaNGING CHIPPeR KNIVes Throttle engine down to a idle and disengage the clutch and install clutch lock. DaNGeR/THROWN DebRIs, CUT, PINCH HaZaRD: Make sure the drum has come to a complete stop before attempting any maintenance� CaUTION: Do not use your hand to check for drum movement� DaNGeR/THROWN DebRIs HaZaRD: Do not use the clutch for changing knives for any reason�...
ROUTINe MaINTeNaNCe CHaNGING KNIfe HOlDeRs Throttle engine down to a idle and disengage the clutch and install clutch lock. DaNGeR/THROWN DebRIs, CUT, PINCH HaZaRD: shut power unit off before any maintenance is performed� DaNGeR/THROWN DebRIs, CUT, PINCH HaZaRD: Make sure the drum has come to a complete stop before attempting any mainte- nance�...
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ROUTINe MaINTeNaNCe CHaNGING KNIfe HOlDeRs CON'T Remove holder bolts (1) and set screws (2) from the Knife Holder. Insert extraction bolts into holes occupied by set screws, (do not cross thread the bolts) and turn clockwise until seated against drum. When both bolts are seated against drum, turn 1 bolt then rotate to the other bolt, con- tinue this procedure until you can remove Knife Holder.
ROUTINe MaINTeNaNCe KNIfe GRINDING When grinding the knives, extreme care must be taken to ensure that excessive heat isn’t put into the knife edge. Excessive heat (indicated by discoloration of the knife edge) will lead to microscopic cracks that can cause the knife to break when it is put back into service.
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ROUTINe MaINTeNaNCe KNIfe GRINDING CON'T Use a honing stone to remove any burr edges left from filing. This procedure has increased knife life up to three times and has reduced the amount of steel the grinder takes off the knife. It may be necessary to do some experimenting with this backgrind for your particular application.
ROUTINE MAINTENANCE CHIPPER KNIFE BABBITTING To maintain the desired chip size, it is important that you babbitt your knives after each grinding. CAUTION: Never babbitt a knife that measures less than 3 1/2 inches in width. To babbitt your knives, follow these steps: Warm knives and all babbitting hardware with a torch until all moisture is eliminated from the surface of the parts.
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.
ROUTINe MaINTeNaNCe INsPeCTING aNVIl CleaRaNCe When inspecting inside the spout every possible safety precaution must be fol- lowed! Throttle engine down to a idle and disengage the clutch and install clutch lock. DaNGeR/THROWN DebRIs, CUT, PINCH HaZaRD: Make sure the drum has come to a complete stop before attempting any mainte- nance�...
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ROUTINE MAINTENANCE TIGHTENING THE INFEED BED CHAIN DRIvEs Loosen four (4) bolts on the hydraulic motor foot mount. Slide motor back until chain has between 1/8" to 3/16" of slack. Check sprocket to chain alignment, make sure the motor is perpendicular to the chain. Tighten foot mount bolts (re- fer to torque chart.) CAUTION: Lubricate all chains daily.
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.
ROUTINe MaINTeNaNCe fUel sPeCIfICaTIONs No. 2D diesel fuel is recommended for use in power units. In extreme cold tem- peratures use No. 1D diesel fuel. 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 residue.
ROUTINe MaINTeNaNCe RaDIaTOR WaRNING: Never open cap on a hot radiator� 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. Use a 50/50 ethylene glycol antifreeze and clean soft water.
ROUTINe MaINTeNaNCe baTTeRIes The batteries are located near the engine. 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. Keep battery fully charged, especially during cold weather. Batteries are low maintenance, but not maintenance free.
ROUTINe MaINTeNaNCe seRVICING TIRes 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. CaUTION: Never attempt to mount a tire unless you have the proper equipment and experience to perform the job�...
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� further use of any visibly worn component can result in a failure�...
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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.
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 flow but there must be resistance a. Puddles of fluid are slippery and hazardous. for the flow to generate pressure.If a motor or a cylinder does b.
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UNDeRsTaNDING HYDRaUlICs TesTING HYDRaUlIC flUID Test the fluid regularly. A number of formal test kits are available to evalu- ate 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.
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 only. Intake clogged: Make sure tank is cleaned periodically. Fluid air in the system: Check fittings, 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.
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 Gas- KeT sealING sUfaCes CaRefUllY - Use a clean damp cloth to wipe every surface clean.
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aIR fIlTeR MaINTeNaNCe CaUTION: Its the customer's responsibility to follow all steps of air filter mainte- nance 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: •...
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.
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 prob- lem 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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