Morbark 4036 Operators Safety Manual

Drum chipper
Table of Contents

Advertisement

Quick Links

MORBARK
MODEL 4036
DRUM CHIPPER
OPERATOR
SAFETY MANUAL
76347-233
04/08
04/08
1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 4036 and is the answer not in the manual?

Questions and answers

Summary of Contents for Morbark 4036

  • Page 1 MORBARK MODEL 4036 DRUM CHIPPER OPERATOR SAFETY MANUAL 76347-233 04/08 04/08 •...
  • 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

    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 ..........................
  • Page 5 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 ..............................
  • Page 6: Lockout Procedures

    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.
  • Page 7: Specifications

    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 ..............................
  • Page 8: Main Components

    MaIN COMPONeNTs fuel Tank Hydraulic Oil Tank Chipper Infeed bed Tool box battery box air Compressor...
  • Page 9 MaIN COMPONeNTs engine Panel Yoke Spout Deflect belt shield Valve bank serial Number Plate (located in front of tongue) 04/08 •...
  • Page 10: 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 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 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 12: Avoid Contact With Moving Parts

    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.
  • 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 finger or skin to check for leaks • Lower load or relieve hydraulic pressure before loosening fittings baTTeRY safeTY Batteries generate explosive gases.
  • Page 14: Safety Signs

    safeTY sIGNs...
  • Page 15: 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 identification numbers of en- gine, clutch, hydraulic components etc. EXACTLY numbers as they appear on the plates •...
  • Page 16 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.
  • Page 17: 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 front of the tongue) to the investigating officer and insurance carrier.
  • Page 18: Engine Controls

    eNGINe CONTROls...
  • Page 19 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.
  • Page 20 eNGINe CONTROls...
  • Page 21: Work Lights

    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.
  • Page 22 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...
  • Page 23: 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 24 ReMOTe CONTROls...
  • Page 25: Throttle Switch

    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.
  • Page 26: Center Section Controls

    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.
  • Page 27: Safety Controls

    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.
  • Page 28: Valve Bank Controls

    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.
  • Page 29: 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. CaUTION: Remember, this is a dangerous piece of equipment if not maintained and operated properly.
  • Page 30: 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 infeed bed or lying in the engine area.
  • Page 31 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 •...
  • Page 32: Starting Machine

    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�...
  • Page 33 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.
  • Page 34: 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 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.
  • Page 35: Chipping Safety Procedures

    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.
  • Page 36: Chipping Wood

    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 •...
  • Page 37: Machine Shut Down

    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.
  • Page 38: Transporting

    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.
  • Page 39 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 •...
  • Page 40: Routine Maintenance Schedule

    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.
  • Page 41 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 •...
  • Page 42: Routine Lubrication Schedule

    ROUTINe lUbRICaTION sCHeDUle...
  • 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 difficult, adjust the specified intervals accordingly.
  • 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 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, 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: •...
  • Page 46 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.
  • Page 47: Changing Chipper Knives

    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�...
  • Page 48: Changing Knife Holders

    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�...
  • Page 49 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.
  • Page 50: Knife Grinding

    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.
  • Page 51 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.
  • Page 52: Chipper Knife Babbitting

    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.
  • Page 53: 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 54: Inspecting Anvil Clearance

    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�...
  • Page 55 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.
  • Page 56: 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.
  • Page 57: Fuel Specifications

    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.
  • Page 58: Radiator

    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.
  • Page 59: Batteries

    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.
  • Page 60: Servicing Tires

    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�...
  • Page 61: 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 components can result in a failure of suspension components� further use of any visibly worn component can result in a failure�...
  • Page 62 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 63: 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 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.
  • Page 64 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.
  • Page 65: 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 66: Noisy Pump

    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.
  • Page 67: 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 Gas- KeT sealING sUfaCes CaRefUllY - Use a clean damp cloth to wipe every surface clean.
  • Page 68 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: •...
  • Page 69: Troubleshooting

    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 70: General

    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.
  • Page 71: Pressure Sheet

    TROUblesHOOTING PRessURe sHeeT HYD OIl TeMPeRaTURe MINIMUM 100° TOP YOKe feeD WHeel 2250 PSI CHARLYNN DRIVE TOP YOKe feeD WHeel 13 RPM DIA. 28" FT/MIN. 96 beD CHaIN 2250 PSI CHARLYNN DRIVE CaT CHaIN 40 RPM DIA. 9.6" FT/MIN. 100 ReVeRsING faN PUSH PRESSURE SET @ 2500 PSI...
  • Page 72: 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 73: 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.

Table of Contents