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Morbark 6600 WOODHOG Operators Safety Manual

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MODEL
WOODHOG
OPERATOR
MANUAL
MANUFACTURED BY:
MORBARK, INC.
6600
SAFETY
1
76347-397
07/03
05/03

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  • Page 1 MODEL 6600 WOODHOG OPERATOR SAFETY MANUAL MANUFACTURED BY: 76347-397 MORBARK, INC. 07/03 05/03...
  • 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: 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 &...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ...................... 3 LOCKOUT PROCEDURES ..................6 SPECIFICATIONS ....................7 MAIN COMPONENTS ..................... 8 SAFETY ........................10 SAFETY SIGNS ......................14 CRIME PREVENTION................... 16 ENGINE CONTROLS ..................... 19 REMOTE CONTROLS................... 21 TETHER CONTROLS .................... 23 VALVE BANK CONTROLS ................... 24 SAFETY OPERATION ....................
  • Page 5 TABLE OF CONTENTS DISASSEMBLY OF SAFETY ELEMENTS ..................45 METHOD OF ASSEMBLING SAFETY ELEMENTS ................ 45 MOUNTING INSTRUCTION FOR SAFETY ELEMENTS .............. 45 DETENT POCKET EXTRACTION TOOL ..................46 CHANGING HAMMERMILL HAMMERS ..................47 CHANGING HAMMERMILL INSERTS ................... 50 HAMMER PATTERNS ........................51 MILL BEARING INSTRUCTIONS ....................

  • Page 6: Lockout Procedures

    LOCKOUT PROCEDURES 05/03...

  • Page 7: Specifications

    SPECIFICATIONS GENERAL LENGTH WIDTH 9'-8" HEIGHT GROSS WEIGHT 81,000 LBS. ELECTRICAL SYSTEM 24 VOLT POWER OPTIONS CATERPILLAR 1000 H.P. MILL FEATURES INFEED OPENING 48" X 53" DRUM SHAFT 8 1/2" DIA. ANVIL 4 SIDED GRATE (3) WEARFORM DISCHARGE SYSTEM BELLY CONVEYOR 48"...

  • Page 8: Main Components

    MAIN COMPONENTS 05/03...
  • Page 9 MAIN COMPONENTS 05/03...

  • 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, personal 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 05/03...
  • Page 15 SAFETY SIGNS 05/03...

  • Page 16: Crime Prevention

    Record Serial Number (S/N) of machine and identifi- cation numbers of engine, clutch hydraulic components, etc. 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 com ponents.
  • Page 17 CRIME PREVENTION PARK INDOORS OUT OF SIGHT WHEN POSSIBLE 1. Remove ignition key and lock the main power switchbox. 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 18: 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 side of the infeed bed near the front) to the investigating officer and insurance carrier.

  • Page 19: Engine Controls

    ENGINE CONTROLS CAT POWER UNIT IQAN DISPLAY - Refer to technical KEY SWITCH - Spring centered switch manual for operating information. used for starting. Turn to the right for start. OVERLOAD LIGHT (RED) - Indicates an overload on the pto system. DATA LINK HOOKUP –...
  • Page 20 ENGINE CONTROLS 1. TACHOMETER - This gauge indicates ENGINE WATER TEMPERATURE - engine speed (rpm). Shows the water temperature. (Read cat operation and maintenance manual before CAUTION: To help prevent engine damage, never start-up.) exceed the high idle rpm. Overspeeding can result in serious damage to the engine.

  • Page 21: Remote Controls

    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 22 REMOTE CONTROLS REMOTE CONTROL UP-YOKE FOWARD - Push toggle up to DANGER/CRUSH, ENTANGLEMENT operate the yoke foward. HAZARD: Keep everyone clear of feedworks during operation. DOWN-YOKE REVERSE - Push toggle down to reverse the feedworks. DOWN-THROTTLE DOWN - Push the UP-YOKE UP - Push and hold the toggle toggle down to decrease engine RPM.

  • Page 23: Tether Controls

    TETHER CONTROLS DANGER/CRUSH, ENTANGLEMENT HAZARD: Keep everyone clear off feedworks during operation. 1. THROTTLE SWITCH - Push toggle up to increase RPM, push toggle down to decrease engine RPM. 2. EMERGENCY SHUT DOWN BUTTON - Push button in and hold until power unit stops. The drum will continue to turn until power unit completely stops or clutch is disengaged.

  • Page 24: Valve Bank Controls

    VALVE BANK CONTROLS VALVE BANK (CONVEYOR) DISCHARGE CONVEYOR TOP SECTION FOLD - This lever will raise and lower the top conveyor section. DISCHARGE CONVEYOR BOTTOM SECTION FOLD - This lever will raise and lower the bottom conveyor section. DISCHARGE CONVEYOR - This lever will engage and disengage the discharge conveyor. BELLY CONVEYOR - This lever will engage and disengage the belly conveyor.

  • Page 25: 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 26: 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 27: Starting Machine

    SAFETY OPERATION STARTING MACHINE HYDRAULIC CLUTCH 1. Review the condition of the machine. 2. Place all hydraulics in the neutral position. 3. Make sure PTO is in disengaged. 4. Turn main power switch to the ON position. 5. Give several blasts of the warning horn to clear area with remote or tether Turn switch to the START position.
  • Page 28 SAFETY OPERATION STARTING MACHINE cont... 10. Engage the feedworks system to forward feed. (Note: the feedworks will not engage until the engine RPM reach the HI dynapar setting.) 11. Engage the belly conveyor, and look to make sure it is turning to eliminate plug- ging.

  • Page 29: 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, open the hood without first making sure the mill has completely stopped. 2. Always wear appropriate safety equipment such as a hard hat and safety glasses.

  • Page 30: Yoke Lock Procedure

    SAFETY OPERATION YOKE LOCK PROCEDURE Raise yoke with remote and hold in the up position. Lift lock handle until top of the lock is above the base sidewall and rotate towards yoke wheel until it drops completely into notch in side of wall.

  • Page 31: Regrind Lock Procedure

    SAFETY OPERATION REGRIND LOCK PROCEDURE For more production when doing regrind, this lock when used will keep the yoke wheel up off of material to allow for faster processing of materials. Raise yoke with remote and hold in the up position. Push in regrind lock and then turn handle counterclockwise until seated.

  • Page 32: Hood Lock Procedure

    SAFETY OPERATION HOOD LOCK PROCEDURE Raise yoke with remote and hold in the up position. Lift lock handle until top of the lock is above the base sidewall and rotate towards yoke wheel until it drops com- pletely into notch in side of wall. Repeat procedure for the other side.
  • Page 33 SAFETY OPERATION HOOD LOCK PROCEDURE CON'T Lift hood lock bar to yoke and install pin DANGER/CRUSH HAZARD: Clear the hood area before raising hood. Raise yoke and disengage yoke locks and lower yoke Lower hood, this will raise the hood completely. Push in and lock hood pin in place.

  • 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.

  • Page 35: Transporting

    SAFETY OPERATION TRANSPORTING Turn off main ignition key and remove. Check to make sure the clutch is disengaged. Turn off main battery disconnect switch. Make sure the mill has completely Hook up the electrical connections and stopped, fold the conveyor up and air brake lines.

  • Page 36: 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 difficult, adjust the specified intervals accordingly. GENERAL PROCEDURES visual inspection (condition, leaks)
  • Page 37 Morbark parts and service the solution to your problems. Buying yor parts elsewere just does not pay. To keep your equipment performing at its peek use GENUINE MORBARK PARTS 800-255-8839 800-832-5618 fax www.morbark.com 05/03...

  • Page 38: Routine Lubrication Schedule

    ROUTINE LUBRICATION SCHEDULE 05/03...
  • Page 39 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 40: Routine Maintenance

    ROUTINE MAINTENANCE TIGHTENING TORQUE GUIDE NOTES: 1. Parts using rivit nuts 25 ft. lbs. maximum 2. Always use the torque values above when specific torque values are not available. 3. 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 cap screws.

  • Page 41: How To Use A V-Belt Tension Gauge

    ROUTINE MAINTENANCE HOW TO USE A V-BELT TENSION GAUGE DANGER/PINCH HAZARD: Before doing maintenance or tensioning on belt drives, turn equipment off and lock out the power source. Use guards on ma- chinery when running. 1. Place a matched set of belts over the sheave grooves.

  • Page 42: Belt Installation

    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 on them.

  • Page 43: Operation Of The Brunel Torque Limiter

    We recommend 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. Note: for proper lubrication of the torque limiter, lubricate with elements disengaged.

  • Page 44: Removing Safety Element From Torque Assembly

    ROUTINE MAINTENANCE FIGURE 2 FIGURE 1 Remove safety elements (1-1)(See "removing safety elements from torque limiter assembly and inspect the detent pocket (2-16), detent ball (2-14) and flanged bushing (2-13) for wear, looseness or distress. While the safety elements are removed check the ball bearings (1-5) for wear by succes- sively lifting and lowering the driven sheave and observing the amount of movement of the outer hub (1-2) with respect to the housing carrier (1-1).

  • Page 45: Disassembly Of Safety Elements

    METHOD OF ASSEMBLING SAFETY ELEMENTS 1. Clean all components and coat all working surfaces with a suitable grease “MOBIL XTC” grease (Morbark P/N 18683-082) or equivalent. 2. Grease and install o-ring (2-6) into groove in housing (2-1). 3. Grease inside surfaces of the housing (2-1) and install the outer thrust race (2-3).

  • Page 46: Detent Pocket Extraction Tool

    ROUTINE MAINTENANCE DETENT POCKET EXTRACTION TOOL FIGURE 7 ITEM DESCRIPTION M12 - 1.75 X 150 LG Grade 8 Socket (or Hex) Head Cap Screw. M12 Heat Treated Nut. 2" X 2" X 3/8" Steel Plate 1/2" Hole In Center. JSE2-3001 Detent Pocket. 05/03...

  • Page 47: Changing Hammermill Hammers

    ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS CAUTION: Read maintenance safety procedures carefully before beginning. This procedure should be followed whether you are changing one hammer, all hammers or changing from a 12 hammer configuration or vice versa. Personnel performing this procedure should always wear proper safety clothing, including gloves.
  • Page 48 ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS CONT. 6. Remove the mill access panel and open the yoke access door for communication purposes. 7. Loosen but do not remove the six (6) bolts in the rod lock plate, with the inside man turning the mill until each bolt is accessible while the outside man loosens them.
  • Page 49 ROUTINE MAINTENANCE CHANGING HAMMERMILL HAMMERS CONT. 14. Insert the second rod in the 12 o’clock hole and attach the rod driver. 15. Position the second row of hammers, one at a time and drive the rod into position engag- ing the back of the first row of hammers and the front row of the second row of hammers.

  • Page 50: Changing Hammermill Inserts

    ROUTINE MAINTENANCE CHANGING HAMMERMILL INSERTS WARNING: Read maintenance safety procedures carefully before beginning. 1. Disengage the clutch at 800 RPM. 2. After clutch is disengaged the mill will coast (rotate) for several seconds until it completely stops. Check the drive belts to verify it has stopped turning before raising the top yoke.

  • Page 51: Hammer Patterns

    ROUTINE MAINTENANCE HAMMER PATTERNS 05/03...

  • Page 52: Mill Bearing Instructions

    ROUTINE MAINTENANCE MILL BEARING INSTRUCTIONS B. Adapter - Slide adaptoer onto the shaft, threaded end outboard to the approximate WARNING: To ensure that the drive location of the bearing. Apply light coating of oil is not unexpectedly started, turn off to sleeve O.D.

  • Page 53: Centering The Belly Conveyor

    ROUTINE MAINTENANCE ADJUSTING THE BELLY CONVEYOR DANGER/THROWN DEBRIS, CUT, CRUSH HAZARD: Shut power unit off and follow lockout procedures before any maintenance is performed. If the conveyor belt is slipping but tracking OK, remove the wing pulley guard, loosen the jam nuts (B) turn the adjusting bolts (A) one full turn each clockwise.

  • Page 54: 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. Stop the conveyor and fold the discharge conveyor into the transport position.

  • Page 55: Replacing Grates

    ROUTINE MAINTENANCE REPLACING GRATES CAUTION: Read maintenance safety procedures carefully before beginning. CAUTION: 2 People required at all times when changing grates DANGER/THROWN DEBRIS, CUT, CRUSH HAZARD: Shut power unit off and follow lockout procedures before any maintenance is performed. 1.
  • Page 56 ROUTINE MAINTENANCE REPLACING GRATES CON'T 7. Remove grates by lifting out from behind mill. 8. Replace grates by lowering them back down between supports and guides. 9. Inspect grate clearance by turning the mill by hand. 10. Remove all lockouts and after insuring all personnel are clear, start machine.

  • Page 57: 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 per- form the job.

  • Page 58: 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 drum area daily by blowing debris out from around power unit with com- pressed air.

  • Page 59: 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 60: Radiator

    ROUTINE MAINTENANCE RADIATOR WARNING: 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 61: Batteries

    ROUTINE MAINTENANCE BATTERIES The batteries are located on the side of the frame. Two 12 volt-batteries are connected in series to furnish 24 volts. All models are equipped with two 12 volt 8D low maintenance batteries. SERVICING BATTERIES 1. Keep battery and battery box clean. Keep all connections clean and tight.

  • Page 62: 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.
  • Page 63 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. During 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. Failure to replace these components will result in damage to the hanger, spring seat and/or the radius rod.

  • Page 64: Understanding Hydraulics

    UNDERSTANDING HYDRAULICS HYDRAULIC SAFETY If a motor or a cylinder does not work or works slowly, the fluid must be slipping through BE CAREFUL OF: it or bypassing the work completely. Trace the 1. Leaks lines to the motor or the cylinder, then place a a.
  • Page 65 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 66: 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 67 SERVICING HYDRAULICS PROBABLE CAUSES can turn in one direction only. NOISY PUMP Intake clogged: Make sure tank is cleaned Air in the system: Check fittings, cracked periodically. Fluid must be kept 3/4 full. hoses and other parts on the pump intake. Air leak in intake: If any air is going through Check hydraulic tank.

  • Page 68: 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 69: 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 70 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 71: 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 72 AIR FILTER MAINTENANCE BASIC ELEMENT SERVICE PRECAUTIONS 05/03...

  • Page 73: Trouble Shooting

    TROUBLE SHOOTING PROBLEM PROBABLE CAUSES AND SOLUTIONS Bed Chain and Yoke 1. Engine RPM not up to max (strobe light not out). Wheel will not go forward. 2. Flow Controls not opened up. 3. Moisture in tether box switch. 4. Low alarm on dyna-par RPM set to high. 5.

  • Page 74: Hydraulic System

    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. Overheating of 1.

  • Page 75: Pressure Settings

    TROUBLE SHOOTING PRESSURE SETTINGS MODEL 6600 WOODHOG PSI FEED WORKS PUMP REXROTH STAND BY PRESS. 350 PSI _________ COMP PRESS. 2800PSI _________ INFEED BED ACTUAL 18 GAL 2800psi @ solenoid @ pump 2800psi @ solenoid @ pump REVERSING P.S.I. SWITCH 2600psi @ pressure switch CHAIN RPM 19.

  • Page 76: Steps To Follow

    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 77: Warranty

    WARRANTY 05/03...
  • Page 78 05/03...

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