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Morbark 950 Operators Safety Manual

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GRINDER
OPERATORS
MANUAL
MANUFACTURED BY;
MORBARK, INC.
950
TUB
SAFETY
1
76347-331C
11/03
11/03

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  • Page 1 GRINDER OPERATORS SAFETY MANUAL MANUFACTURED BY; 76347-331C MORBARK, INC. 11/03 11/03...
  • Page 2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
  • 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 &...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS LOCKOUT PROCEDURES ..................6 SPECIFICATIONS ....................7 MAIN COMPONENTS ..................... 8 SAFETY ........................10 SAFETY SIGNS ......................14 CRIME PREVENTION................... 16 ENGINE CONTROLS ..................... 19 REMOTE CONTROL ..................... 24 VALVE BANK CONTROLS ................... 26 SAFETY OPERATION .................... 27 NEW POWER UNIT BREAK-IN ......................
  • Page 5 TABLE OF CONTENTS HAMMERMILL MAINTENANCE ............... 41 ROTOR MAINTENANCE ......................... 41 CHANGING GRATES ........................43 CHANGING HAMMERS ........................44 HAMMER PATTERNS ........................46 MILL BEARING INSTRUCTIONS ....................47 OPERATION OF THE BRUNEL TORQUE LIMITER ............... 48 ADJUSTING CONVEYOR BELT ...................... 50 CENTERING CONVEYOR BELT .....................

  • Page 6: Lockout Procedures

    Failure to lock out while performing mainte- nance could result in serious personal injury or death! Morbark equipment is designed to be quickly and easily locked out whenever maintenance or repairs are performed. Train your...

  • Page 7: Specifications

    SPECIFICATIONS General Length ..........................28 ft (8.5 m) Transport Width ........................ 8.4 ft (2.5 m) Height ..........................8 ft (2.4 m) Gross Weight ......................11,820 lb (5,361 kg) Electrical ............................ 12 Volt Power Options Caterpillar, Cummins, John Deere and Perkins .........157 - 205 Hp (117 - 152 Kw) Outside Opening ........................

  • Page 8: Main Components

    MAIN COMPONENTS 11/03...
  • Page 9 MAIN COMPONENTS 11/03...

  • Page 10: Safety

    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 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 12 SAFETY AVOID CONTACT WITH MOVING PARTS There are hazards associated with conveyor belts, V- belts and chains. Objects or body parts can become crushed between conveyor belts and rollers, between V-belts and pulleys and between 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. Immediate surgery is required to remove oil. Do not use finger or skin to check for leaks. Lower load or relieve hydraulic pressure before loosening fittings.

  • Page 14: Safety Signs

    SAFETY SIGNS 11/03...
  • Page 15 SAFETY SIGNS 11/03...
  • Page 16 SAFETY SIGNS 11/03...

  • Page 17: Crime Prevention

    EXACTLY as they appear on the plates. These numbers can be found in your Morbark parts manual supplied with your machine and on the various components. Check that the complete and correct numbers appear on all documentation (insurance, financial, warranty etc.) Keep all documents in a safe...

  • Page 18: Reduce Vandalism

    CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE 1. Remove ignition key, lock the main power switch box. 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.

  • Page 19: Fire Protection

    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 tongue near the front) to the investigating officer and insurance carrier.

  • Page 20: Engine Controls

    ENGINE CONTROLS (Typical Control Panel) Actual control panel layout and controls are determined by engine type and model. Please check the Engine Operator Manual supplied with your machine. 11/03...
  • Page 21 ENGINE CONTROLS 1. TACHOMETER\SPEED SWITCH - The tachometer measures the revolutions per minute of the power unit. CAUTION: Refer to lor manual for speed switch setting procedure. ENGINE MANAGEMENT SYSTEM - Provides all infomation and control for the engine 3. TUB STOP OVERIDE SWITCH - ON (UP) - Auto tub stop is on and tub will stop rotating at a preset RPM's and and continue when RPM increases.
  • Page 22 JOHN DEERE ENGINE CONTROLS 1. POWER VIEW DISPLAY - Displays all engine functions including diagnostics. (Refer to oem manual.) 2. THROTTLE SWITCH - Push toggle up to increase, push down to decrease engine R.P.M. 3. TACHOMETER\SPEED SWITCH - The tachometer measures the revolutions per minute of the power unit.

  • Page 23: Safety Controls

    SAFETY CONTROLS CLUTCH SAFETY SWITCH - This TUB LOCK - This will prevent will not allow the machine to start with clutch accidental lowering of the tub engaged. Do not run machine without this in while servicing. operating condition. CLUTCH HANDLE LOCK - Used to prevent accidental engagement of the clutch.

  • Page 24: Remote Control

    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 errati- cally.

  • Page 25: Remote Control

    REMOTE CONTROL 1. REVERSE - Pushing ths button will slowly start reversing the tub direction untill it stops. 2. FORWARD - Pushing ths button will slowly start the tub in the forward direction. NOTE: You must push the reverse button (in forward direction) or forward button (in reverse direction) to bring the tub to neutral (stop.) 3.

  • Page 26: Valve Bank Controls

    VALVE BANK CONTROLS AUGER/CONVEYOR CONTROL - This lever will engage and disengage the discharge auger and the discharge conveyor. TUB TILT - This lever extends and retracts the cylinder which raises the tub for service. CONVEYOR TILT - This lever will fold or unfold the conveyor. CONVEYOR TILT - This lever will lift the conveyor up or down.

  • Page 27: 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 28: Pre-Operational Checklist

    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.

  • Page 29: Thrown Object Zone

    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 30: Proper Use Of The Tub Cover

    SAFETY OPERATION PROPER USE OF THE TUB COVER WARNING: Always wear a hard hat when oper- ating the tub grinder. Before engaging the clutch on the power unit, use 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 31: Starting Machine

    SAFETY OPERATION STARTING MACHINE 1. Adjust and level front stabilizer. 2. Place all hydraulics in the neutral position. 3. Place the clutch in the disengaged position and lock. 4. Turn the key switch to the ON position. 5. Position the permissive START switch in the start position.
  • Page 32 SAFETY OPERATION STARTING MACHINE CONT. DANGER/CRUSH HAZARD: Never allow anyone to stand under the conveyor. 15. Activate the lever to control the two cylinders used in folding and unfolding the conveyor. 16. Fold down and pin auger discharge chute and pin.

  • Page 33: Safety Procedures

    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, lift the tub without first making sure the mill has completely stopped. 2. Always wear appropriate safety equipment such as a hard hat and safety glasses.

  • Page 34: Machine Shut Down

    SAFETY OPERATION MACHINE SHUT DOWN 1. Throttle engine down to an idle. 2. Place all hydraulics in neutral. 3. Disengage clutch. 4. Allow engine to idle 3-5 minutes and then shut off. 5. Turn off main switch and remove ignition key. 6.

  • Page 35: Transporting

    SAFETY OPERATION TRANSPORTING Check to make sure the clutch is disengaged. Make sure the tub rotor has completely stopped, fold the conveyor up and over the tub. Then install the safety chains. Secure the conveyor with chains and binders for transport. Raise machine using the stabilizer to the height needed to hook the machine to the tractor.

  • Page 36: Routine Maintenance Schedule

    ROUTINE MAINTENANCE SCHEDULE 11/03...

  • Page 37: Routine Lubrication Schedule

    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 38: Routine Maintenance

    ROUTINE MAINTENANCE TIGHTENING TORQUE GUIDE Parts using rivet nuts 25 Ft. Lbs. Maximum. Always use the torque values above when specific torque values are not available. Do not use above values in place of those specified in other sections of this manual; special attention should be observed when using SAE Grade 6, 7 and 8 Capscrews.

  • Page 39: How To Use A V-Belt Tension Gauge

    ROUTINE MAINTENANCE HOW TO USE A V-BELT TENSION GAUGE DANGER/CRUSH, CUT HAZARD: Shut power unit off and follow all lockout procedures before any maintenance is performed. 1. Place a matched set of belts over the sheave grooves. Take up the slack until the belts appear fairly taut.

  • Page 40: Belt Cleaning Instructions

    ROUTINE MAINTENANCE BELT INSTALLATION Keep the following suggestions in mind when installing drive belts. 1. Clean oil and grease from the sheaves, remove any rust or burrs from the grooves. 2. Loosen adjuster bolts until the belts can be put on the sheaves without forcing or prying.

  • Page 41: Hammermill Maintenance

    4. Inspect all wear plates top, side and horse shoe. 5. Check wedgelock torque after the first 100 hours and every 1000 hours thereafter. Torque for model 950 tub grinder is 185 Ft. lbs ROTOR MAINTENANCE WARNING: Read maintenance safety...
  • Page 42 ROUTINE MAINTENANCE ROTOR MAINTENANCE CON'T 4. If cracks are found it is highly recommended that you make the repairs before an unneces- sary failure occurs. 5. The cracks will need to be ground out. The proper procedure is to grind the crack the full length with a gouge 1/8"...

  • Page 43: Changing Grates

    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. 1. Disengage the clutch and install clutch lock. WARNING: After clutch is disengaged, rotor will coast (rotate) for several minutes before it completely stops.

  • Page 44: Changing Hammers

    ROUTINE MAINTENANCE CHANGING HAMMERS WARNING: Read maintenance safety proce- dures carefully before beginning. WARNING: Always use tub lock when chang- ing hammers. 1. Disengage the clutch and install clutch lock. WARNING: After clutch is disengaged rotor will coast (rotate) for several minutes before it completely stops.
  • Page 45 ROUTINE MAINTENANCE CHANGING HAMMERS CONT. CAUTION: Hammers need to be weighed before being installed into the rotor. Always have the same weight hammer across from each other for proper rotor balance. Excessive vibration of the rotor from improper balance can cause many problems.

  • Page 46: Hammer Patterns

    ROUTINE MAINTENANCE 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 47: Mill Bearing Instructions

    ROUTINE MAINTENANCE MILL BEARING GREASING INSTRUCTIONS WARNING: To ensure that the drive location of the bearing. Apply light coating of oil does not start unexpectedly, turn off to sleeve O.D. and lockout or tag power source before proceeding. C. Bearing - Make sure the internal clearance has been written down.

  • Page 48: Operation Of The Brunel Torque Limiter

    We recom- mend that each safety element be given two pumps of MOBIL XTC grease (Morbark P/N 18683- 082) or equivalent every time the torque disengages or once a week.
  • Page 49 ROUTINE MAINTENANCE FIGURE 3 Every 2 Months Remove safety elements (3-6) see "removing safety elements from torque limiter assembly" (page 4-9) and inspect the detent pocket (2-11), detent (2-9) and flanged bushing (2-8) for wear, looseness or distress. While the safety elements are removed check the ball bearings (3-7) for wear by successively lifting and lowering the drive shaft and observing the amount of movement of the outer hub (3-3) with respect to the housing carrier (3-1).

  • Page 50: Adjusting Conveyor Belt

    ROUTINE MAINTENANCE ADJUSTING CONVEYOR BELT Loosen four (4) bolts that hold top bearings down, turn adjuster bolt clockwise. Tighten four (4) bolts holding bearings down. Run conveyor to make sure it is centered. CENTERING CONVEYOR BELT Loosen four (4) bolts that hold top bearings down.

  • Page 51: Tub Bin Guide Wheels/Wear Slides

    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.

  • Page 52: Servicing Tires

    ROUTINE MAINTENANCE SERVICING TIRES DANGER/EXPLOSION HAZ ARD: Failure to implement proper procedures when mount- ing a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Never attempt to mount a tire unless you have the proper equipment and experience to perform the job.

  • Page 53: Clean Engine Area

    ROUTINE MAINTENANCE CLEAN ENGINE AREA CAUTION: Never clean engine with engine running. A combination of dirt, oil, wood dust and chip material in the engine area presents a risk of fire. Clean engine and rotor area daily by blowing debris out from around power unit with com- pressed air.

  • Page 54: Fuel Specifications

    ROUTINE MAINTENANCE FUEL SPECIFICATIONS No. 2D diesel fuel is recommended for use in all diesel power units. In extreme cold tem- peratures see engine mfg for recommended fuel options. In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to vaporous state and condensed, thus elimi- nating all sediment and residue.

  • Page 55: Radiator

    ROUTINE MAINTENANCE RADIATOR CAUTION: 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.

  • Page 56: Batteries

    ROUTINE MAINTENANCE BATTERIES The battery is located on the side of the frame. All models are equipped with 1-12 volt low maintenance battery. SERVICING BATTERIES 1. 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 57: Understanding Hydraulics

    UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY BE CAREFUL OF: If a motor or a cylinder does not work or 1. Leaks works slowly, the fluid must be slipping through a. Puddles of fluid are slippery and hazard- it or bypassing the work completely. Trace the ous.
  • Page 58 UNDERSTANDING HYDRAULICS TESTING HYDRAULIC FLUID Test the fluid regularly. A number of formal test kits are available to evaluate 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 59: 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 60 SERVICING HYDRAULICS PROBABLE CAUSES can turn in one direction only. NOISY PUMP Intake clogged: Make sure tank is cleaned periodically. Fluid must be kept 3/4 full. Air in the system: Check fittings, cracked Air leak in intake: If any air is going through hoses and other parts on the pump intake.

  • Page 61: Engine Corrosion

    ENGINE CORROSION CAVITATION CORROSION/EROSION LINER PITTING Modern high speed diesel engines contain cast iron replacement cylinder liners that are subject to accelerated corrosion due to a process commonly known as liner pitting. When plain water is used as a coolant, liners can be penetrated in a matter of 500 hours of operation when conditions are severe. It is important to understand the causes of this liner pitting and how to prevent it.

  • Page 62: Preventative Maintenance

    ENGINE CORROSION THE EFFECT OF ENGINE CONDITIONS ON LINER PITTING The formation of bubbles in coolant during cavitation corrosion/erosion is very similar to the way bubbles are formed when boiling water. Remember how water in a pressure cooker boils at a higher temperature because of the higher pressure? In the same way, anything that affects the local pressure or the local temperature around the liners will impact on the ease with which bubbles are formed and will effect the potential for liner pitting.
  • Page 63 ENGINE CORROSION The problem only gets worse in construction/mining fleets where cooling system capacities can vary from 5 to over 100 gallons. Coolant leakage can really cause a problem when using automotive antifreeze plus SCA. Typically the system is topped off with antifreeze and water and no thought is given to the SCA concentration.

  • Page 64: Air Filter Maintenance

    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: 1. Leaking dust cup to air cleaner body joint;...
  • Page 65 AIR FILTER MAINTENANCE BASIC ELEMENT SERVICE PRECAUTIONS 11/03...

  • Page 66: Trouble Shooting

    TROUBLE SHOOTING HYDRAULIC SYSTEM PROBLEM PROBABLE CAUSES AND SOLUTIONS Noisy pump 1. Check inlet hose for damage. Replace hose. cavitation 2. Fluid viscosity too high. Replace oil. (pump starving) 3. Operating temperature too low. Allow system to warm up. 4. Excessive drive speed. Do not exceed 2100 RPM's. Overheating of 1.

  • Page 67: Port Relief Pressures

    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 68: Steps To Follow If You Feel You Have A Warrantable Failure

    Ship the warranty consideration parts to: MORBARK, INC., 8507 S. Winn Road, Winn, MI 48896, ATTENTION: Warranty Returns Use the pink copy of the claim, along with a copy of the Morbark invoice as a packing slip. The customer keeps the golden rod copy for his records and any future inquiries concerning the claim.

  • Page 69: Warranty

    8507 South Winn Road, Winn, Michigan or at such other locations as may be designated in writing by Morbark. Morbark is not responsible for the cost of transport or related charges in connec- tion with the return of any equipment to Morbark under this Warranty. Morbark shall have sole discre- tion to determine whether and to what extent the equipment is defective in materials or workmanship.

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