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Summary of Contents for Morbark 2400XL HURRICANE
- Page 1 MODEL 2400XL HURRICANE OPERATORS SAFETY MANUAL MANUFACTURED BY: 76347-264 MORBARK, INC. 02/02 02/02...
- 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ......................4 LOCKOUT PROCEDURES .................... 5 LOCATION OF CHIPPER COMPONENTS ..............6 DESCRIPTION OF CHIPPER COMPONENTS ............7 SAFETY ..........................8 OBSERVE SAFETY SIGNS AND MESSAGES ....................8 OBSERVE "IMPORTANT" MESSAGES ......................8 DO NOT MODIFY MACHINE ........................8 BEFORE OPERATING ............................ -
Page 4: Introduction
INTRODUCTION Congratulations on your purchase of a new Morbark brush chipper. The brush chipper, designed and introduced by the world's leading manufacturer of portable chippers, is produced with the finest components and workmanship available. If you show proper care and maintenance, your brush chipper will prove to be a safe and reliable unit. -
Page 5: Lockout Procedures
LOCKOUT PROCEDURES Lockout procedures should be used at all times when maintenance is being done or the machine is being shut down. This will prevent bodily injuries and prevent the machine from accidentally being started by passersby. The power source of any equipment, machine or process to be setup, adjusted, repaired, serviced, installed or where maintenance work is to be performed, and unintended motion or release of energy would cause personal injury, such a power source shall be locked out by each employee doing the work. -
Page 6: Location Of Chipper Components
LOCATION OF CHIPPER COMPONENTS A. Frame F. Discharge Flipper K. Axle B. Hitch G. Fuel Tank L. Hood - Bolt On C. Infeed H. Belt Shield M. Hood - Hinged D. Jack Stand I. Anvil N. Discharge Spout E. Instrument Panel J. -
Page 7: Description Of Chipper Components
DESCRIPTION OF CHIPPER COMPONENTS Chipper Drum This is the component in which the knives are mounted. The chipper drum is dynamically balanced and should not be welded on or modified. Chipper Shaft This shaft is connected to the drum by means of two bushings, then rests on a pair of pillow block bearings for support. -
Page 8: Safety
SAFETY OBSERVE SAFETY SIGNS AND MESSAGES THINK SAFETY. Safety is a combination of operator com- mon sense and alertness at all times when the machine is being operated or serviced. CAUTION: This message is used for general reminders of good safety practices or to direct attention to unsafe practices. The message will appear in your operator's manual and/or the sign will appear on the machine with the color combination of yellow and black. -
Page 9: Wear Protective Clothing
SAFETY WEAR PROTECTIVE CLOTHING Wear close-fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impaired or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. -
Page 10: Safety Stickers
SAFETY SAFETY STICKERS READ SAFETY SIGNS CAREFULLY Carefully read and follow all safety signs. Danger signs identify the most serious hazards. Keep safety signs in good condition. Replace any missing or damaged safety signs. Signs are attached to machine near specific hazard areas. - Page 11 SAFETY SAFETY STICKERS CON’T (OPTIONAL) 02/02...
- Page 12 SAFETY SAFETY STICKERS CON’T 02/02...
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Page 13: Safety Operation
This special safety manual and the accompany- ing video tape have been prepared for all own- ers and operators of Morbark hand-fed brush and tree chippers. SAFETY IS NO ACCIDENT. Like all good things worth having, proper safety... - Page 14 These decals should never be removed. If they are worn or frayed, new decals should be ordered from your local Morbark brush chipper dealer. Prior to starting the chipper each day, a prestartup walk-around inspection should be performed.
- Page 15 SAFETY OPERATION If the chipper is not hitched to a vehicle, the tongue should be blocked and wheel chocks should be placed under both wheels to keep the chipper from moving. Do not operate unit unless hitched to a tow vehicle or equipped with a rear support leg.
- Page 16 SAFETY OPERATION Again, the single most important chipper safety rule is: NEVER BREAK THE PLANE OF THE INFEED CHUTE WITH YOUR HANDS, AND NEVER, FOR ANY REASON, AT- TEMPT TO KICK BRUSH IN WITH YOUR FEET! To safely feed short material into the chipper. Place the feed system in the neutral position, lay the short material on top of longer material, and engage the feed system.
- Page 17 SAFETY OPERATION Brush and limbs should always be fed butt end first. At least two people should be on the job site at all times. No one should ever operate the chipper alone. It is the operator's responsibility to insure that other workers or bystanders are kept away from the path of discharged chips.
- Page 18 SAFETY OPERATION When refueling the chipper, always be certain there is no open flame or source of a spark in the vicinity of the machine. Always remove the ignition key when the machine is left unattended for any reason. No one should ever operate the chipper when under the influence of drugs, alcohol or medications which could in any way affect the operator's performance and concentration.
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Page 19: Safety Hints
SAFETY OPERATION As an owner or operator of a Morbark chipper, you know what a useful tool it is. With anti- burning and anti-burying regulations spreading across the country, it is absolutely necessary that we have brush chippers to dispose of and recycle brush and wood waste. -
Page 20: New Engine Break-In
SAFETY OPERATION For a safe and productive operation, follow the procedures discussed in this section. All personnel must observe these guidelines when working with the equipment. NEW ENGINE BREAK-IN Proper break-in will lead to trouble free operation and increased engine life. The factory test given to a new engine is not sufficient to establish the polished surfaces which are so necessary for good performance and long life. -
Page 21: Brush Preparation
SAFETY OPERATION BRUSH PREPARATION Inspection and organizing the brush prior to chipping will allow the job to be performed more effi- ciently and provide added safety in performing the job by minimizing the danger of foreign material, vines, etc. entering the chipper. Pre-trimming and proper de-limbing will allow the brush to be drawn easily through the chipper. - Page 22 SAFETY OPERATION BRUSH PREPARATION con’t Know the limitations of your chipper. Never attempt to feed material to large for your chipper. Always pre-cut large crotches to ensure adequate clearance through the transition area. When preparing large material for feeding the chipper, properly trimming the crotches will greatly reduce the amount of downtime clearing transition/feed roller jammed materials.
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Page 23: Inspecting Chipper Knives
SAFETY OPERATION INSPECTING CHIPPER KNIVES CAUTION BEFORE INSPECTING KNIVES ALWAYS REMOVE IGNITION KEY AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. Remove chipper hood lock pin and open the hood. Turn drum by hand until first knife is accessible. -
Page 24: Machine Warm-Up
SAFETY OPERATION MACHINE WARM-UP 1. Check all engine fluids. 2. Start the engine according to your Engine Operator's Handbook which is located in the rear of this manual. 3. Let the engine idleaccording to your Engine Operator's Handbook. until engine is warmed up CHIPPING WOOD 1. -
Page 25: Disengaging Cutter Disc
SAFETY OPERATION DISENGAGING CUTTER DISC Disengage the hydraulic feed system by moving the feed control bar to the NEUTRAL or center position. Push the throttle control in to reduce engine speed to idle. When the engine and cutter disc reach idle speed, disengage clutch. Turn off the ignition switch and remove the key. -
Page 26: Feeding Brush To The Chipper
SAFETY OPERATION FEEDING BRUSH TO THE CHIPPER Keep the working area clear of limbs and debris. Tripping or entanglement CAN allow the operator to be dragged into the chipper causing serious injury or death. Do not throw clean up sweepings into the cutter mechanism. Foreign mate rial such as stones, wire or metal scrap CAN cause blade failure, resulting in serious personal injury. -
Page 27: Engine Controls
ENGINE CONTROLS 1. ENGINE TEMPERATURE - Indicates 6. TACHOMETER\SPEED SWITCH the engine coolant temperature. The tachometer measures the revolutions per minute of the power unit. 2. AMMETER -Indicates the status of the Engine Idle Speed - Set @ manufacture. Charging System. Max. -
Page 28: Feed Controls
FEED CONTROLS The feed rollers are controlled by pushing or pulling the feed control bar whick is located on the top and both sides of the feed chute. The 3 (Three) control positions are FEED - Pulls material into the chipper cutting zone. NEUTRAL - Stops movement of the feed rollers. -
Page 29: Cab Controls Joysticks
JOYSTICK CONTROLS YOKE UP - This button raises the Feed Yoke. YOKE DOWN - This button lowers the Feed Yoke. GRAPPLE LEFT - This button turns the Grapple to the left. GRAPPLE RIGHT - This button turns the Grapple to the right. 1, 2 3 , 4 02/02... - Page 30 JOYSTICK CONTROLS GRAPPLE - Open and Close This valve operates the Loader Grapple. Push outside to open, pull inside to close Grapple. (Note: In cold weather the Hydraulic Components may be slow to operate.) MAIN BOOM - Up and Down This valve operates the Main Boom.
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Page 31: General Maintenance Schedule
GENERAL MAINTENANCE SCHEDULE GENERAL EVERY 8 HRS WEEKLY Check engine oil level Check radiator fluid level Check battery water level (fill with distilled water) Check hydraulic fluid Check clutch engagement torque Check tightness of engine bolts* Check tire pressure before moving machine Replace engine air, fuel and oil filters refer to engine manual CHIPPER... -
Page 32: General Maintenance
GENERAL MAINTENANCE Safety and daily maintenance are the two most important things to remember when operating machinery. A small amount of daily maintenance will make the weekly or monthly maintenance much easier and less expensive. While maintaining your brush chipper, please follow the safety guidelines which are written in bold print. -
Page 33: Changing Chipper Knives
GENERAL MAINTENANCE CHANGING CHIPPER KNIVES CAUTION BEFORE CHANGING CHIPPER KNIVES ALWAYS REMOVE IGNITION KEY AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. Remove chipper hood lock pin and open the hood 2. -
Page 34: Inspecting And Adjusting Theknife Anvil Clearance
GENERAL MAINTENANCE INSPECTING AND ADJUSTING KNIFE ANVIL CLEARANCE The anvil should be adjusted to a minimum of .045 and a maximum of .080 from the cutting edge of the highest chipper knife. To inspect and adjust the knife anvil clearance, follow these steps: 1. -
Page 35: What You Should Know About Chipper Knife Maintenance
GENERAL MAINTENANCE WHAT YOU SHOULD KNOW ABOUT CHIPPER KNIFE MAINTENANCE 02/02... - Page 36 GENERAL MAINTENANCE 02/02...
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Page 37: Knife Grinding
Soil is extremely hard on knives. C. Amount of chipper production. D. The quality of the knife. Knives should be sharp- ened professionaly with a coolant type surface grinder (MORBARK, Inc. knives are recom- mended.) Knives should be ground at 31 degrees. 02/02... -
Page 38: Tightening Torque Guide
GENERAL MAINTENANCE TIGHTENING TORQUE GUIDE NOTES: 1. Always use the torque values above when specific torque values are not available. 2. 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: B-Loc Hubs
GENERAL MAINTENANCE B-LOC HUBS 02/02... -
Page 40: Air Filter Maintenance
GENERAL MAINTENANCE AIR FILTER MAINTENANCE NOTE: It's the customer's responsibilty to follow all steps of air filter maintenance as required, depending on the operating conditions. Low pre-cleaner efficiency will cause short element life. Low pre-cleaning efficiency can be caused by: 1. -
Page 41: Basic Element Service Precautions
GENERAL MAINTENANCE BASIC ELEMENT SERVICE PRECAUTIONS 02/02... -
Page 42: Lubrication Schedule
GENERAL MAINTENANCE LUBRICATION SCHEDULE Axle & Chipper Bearings - clean and repack every 6 months. Pivot Arm, Lift Cylinders, Feedwheel Bearings - lubricate weekly until excess grease is present. Refer to your clutch manual for proper maintenance schedule. Follow engine manual guidelines for lubrication of engine. 02/02... - Page 43 THIS PAGE INTENTION- ALLY LEFT BLANK 02/02...
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Page 44: Lubrication Schedule
LUBRICATION SCHEDULE 02/02... - Page 45 LUBRICATION SCHEDULE LOADER DESCRIPTION EVERY 8 HRS Main Boom Pin 1 shot Main Boom Cylinder 1 shot Jib Boom Cylinder 1 shot Main Boom to Jib Boom Pin 1 shot Jib Boom To Knuckle 1 shot Knuckle to Grapple 1 shot Grapple Cylinder 1 shot Grapple Pivot Pin...
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Page 46: Adjusting The Belt Tension
GENERAL MAINTENANCE ADJUSTING THE BELT TENSION CAUTION BEFORE ADJUSTING BELTS ALWAYS REMOVE IGNITION KEY AND LOCK OUT ENGINE PANEL. CAUTION: MAKE SURE THE CHIPPER DRUM HAS COME TO A COMPLETE STOP. To check for proper tension of belts, follow the directions in V-Belt tension gauge on page 47. -
Page 47: How To Use A V-Belt Tension Gauge
GENERAL MAINTENANCE HOW TO USE A V-BELT TENSION GAUGE 02/02... -
Page 48: Transporting The Brush Chipper
GENERAL MAINTENANCE TRANSPORTING THE BRUSH CHIPPER The standard towing hitch on the brush chipper is a 2 1/2" Lunet ring. Be sure the towing vehicle hitch is properly equipped for the hitch on your brush chipper. The towing vehicle should be capable of handling a minimum of 1500# tongue weight. -
Page 49: Understanding Hydraulics
UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY If a motor or a cylinder does not work or works slowly, the fluid must be slipping through it or Be careful of: bypassing the work completely. Trace the lines to the 1. Leaks motor or the cylinder, then place a pressure check on a. -
Page 50: Testing Hydraulic Fluid
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 51: 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 52: Probable Causes
SERVICING HYDRAULICS PROBABLE CAUSES Intake clogged: Make sure tank is cleaned periodi- NOISY PUMP cally. Fluid must be kept 3/4 full. Air in the system: Check fittings, cracked hoses and other parts on the pump intake. Check hydrau- Air leak in intake: If any air is going through pump, lic tank. -
Page 53: Trouble Shooting The Chipper
TROUBLE SHOOTING THE CHIPPER 02/02... -
Page 54: Pressure Sheet
PRESSURE SHEET 02/02... -
Page 55: Steps To Follow If You Feel You Have A Warrantable Failure
48896, ATTENTION: Warranty Returns c. Use the pink copy of the claim form as a packing slip along with a copy of the Morbark invoice. d. The customer keeps the golden rod copy for his records and any future inquiries concerning the claim. -
Page 56: Warranty
WARRANTY 02/02...
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