Safety Manual

3036 NCL
DRUM CHIPPER
OPERATORS
SAFETY
MANUAL
MANUFACTURED BY 76347-231A
MORBARK INC. 04/04
1 04/04
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.
2 04/04
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 and
understand this manual carefully, page by page before operating machine. In addition to guidelines for
safe operation and maintenance that you will find included with this book, a seperate parts book will
be included with your machine showing parts listings and detailed assembly illustrations.
It is the responsibility of operators, maintenance, grounds crew, etc. to read and understand this
manual. Only qualified and properly trained personnel shall operate this machine.
The serial number of your drum chipper is located on the front of the machine on the tongue. If for
any reason you should find it necessary to correspond with us or one of our dealers, please include
this number.
This manual should be considered a permanent part of your machine. It shall remain with the machine
if/when sold to provide the next owner with important operating, safety and maintenance information.
Please contact us with any suggestions or comments (positive or negative) concerning the design or
operation of your machine. Your input is greatly appreciated and ensures product development that will
meet or exceed the needs of the professionals such as yourself.
Again, thank you and please call us for your future requirements.
3 04/04
TABLE OF CONTENTS
LOCKOUT PROCEDURES ..................................................................................... 6
SPECIFICATIONS .................................................................................................... 7
MAIN COMPONENTS ............................................................................................. 8
SAFETY ....................................................................................................................... 9
SAFETY SIGNS ........................................................................................................ 13
CRIME PREVENTION........................................................................................... 14
ENGINE CONTROLS ............................................................................................. 17
REMOTE CONTROLS........................................................................................... 20
RADIO CONTROL .................................................................................................. 20
TETHER CONTROLS ............................................................................................ 23
CENTER SECTION CONTROLS ........................................................................ 26
SAFETY OPERATION ............................................................................................ 27
NEW POWER UNIT BREAK-IN ...................................................................................................... 27
PRE-OPERATIONAL CHECKLIST ................................................................................................... 28
MOUNTING AND DISMOUNTING ................................................................................................. 29
STARTING MACHINE ...................................................................................................................... 30
CHIPPING SAFETY PROCEDURES ................................................................................................ 32
CHIPPING WOOD ............................................................................................................................ 33
MACHINE SHUT DOWN ................................................................................................................. 34
TRANSPORTING ............................................................................................................................... 35
ROUTINE LUBRICATION SCHEDULE ............................................................. 36
ROUTINE MAINTENANCE .................................................................................. 40
TIGHTENING TORQUE GUIDE ....................................................................................................... 40
HOW TO USE A V-BELT TENSION GAUGE ................................................................................... 41
BELT CLEANING INSTRUCTIONS ................................................................................................. 42
4 04/04
TABLE OF CONTENTS
BELT INSTALLATION ....................................................................................................................... 42
CHANGING CHIPPER KNIVES ....................................................................................................... 43
KNIFE GRINDING ............................................................................................................................ 44
MILL BEARING INSTRUCTIONS .................................................................................................... 46
B-LOC HUB MAINTENANCE ......................................................................................................... 47
INSPECTING ANVIL CLEARANCE ................................................................................................ 48
TIGHTENING FEEDWHEEL CHAIN DRIVES ................................................................................. 49
TIGHTENING THE INFEED BED CHAIN ........................................................................................ 49
CLEAN ENGINE AREA ..................................................................................................................... 50
ENGINE OIL ...................................................................................................................................... 50
FUEL SPECIFICATIONS ................................................................................................................... 51
STORING FUEL ................................................................................................................................. 51
FILING FUEL TANK ......................................................................................................................... 51
RADIATOR ......................................................................................................................................... 52
CLEAN RADIATOR EXTERIOR ....................................................................................................... 52
ADJUSTING THE CLUTCH .............................................................................................................. 52
BATTERIES ........................................................................................................................................ 53
SERVICING BATTERIES ................................................................................................................... 53
UNDERSTANDING HYDRAULICS...................................................................... 54
SERVICING HYDRAULICS ................................................................................... 56
ENGINE CORROSION .......................................................................................... 58
AIR FILTER MAINTENANCE .............................................................................. 61
TROUBLE SHOOTING .......................................................................................... 63
HYDRAULIC SYSTEM ..................................................................................................................... 63
CHIPPER AND FEED WHEELS ........................................................................................................ 64
STEPS TO FOLLOW IF YOU FEEL YOU HAVE A WARRANTABLE FAILURE ............................ 66
WARRANTY ............................................................................................................. 67
5 04/04
LOCKOUT PROCEDURES
6 04/04
SPECIFICATIONS
General
Length 25' 6"
Width 8' 4"
Height 12'
Weight 25,880 lbs
Electrical system 24 Volt
Power Options
Cummins, John Deere and Caterpillar 325 h.p. - 450 h.p.
Infeed System
Infeed Opening 30" x 33"
Cat Chain Feed Table 5' x 8'
Top Feed Wheel 16" x 30"
Chipper
Drum diameter 36"
Drum width 30"
Knife length 10 1/2"
Knife configuration 6
Capacity 18" Roundwood
Tank Capacities
Diesel fuel 143 Gal
Hydraulic fluid 102 Gal
7 04/04
DEFLECTOR SWIVEL SPOUT
INFEED BED
POWER UNIT
PRECLEANER YOKE
8
MAIN COMPONENTS
RADIATOR SCREEN FUEL TANK CHIPPER
HYDRAULIC TANK
04/04
SAFETY
OBSERVE SAFETY SIGNS AND MESSAGES
THINK SAFETY: Safety is a combination of operator common sense and alertness at all times when
the machine is being operated or serviced.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. The sign will have the
color combination of red and white.
WARNING indicates a potentially hazardous situation, which if not

avoided, could result in death or serious injury. The sign will have the
color combination of orange and black.
CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. The sign will appear
on the machine with the color combination of yellow and black.
OBSERVE "CAUTION" MESSAGES
Messages labeled “Caution” (without the safety symbol) will appear in your operator's manual to
provide specific instructions for performing adjustments, services etc. 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 personal injury
or death.
BEFORE OPERATING
Read and understand the operator's manual, instructions and safety signs on the machine and all con-
trols affecting machine functions.
9 04/04
SAFETY
OPERATE SAFELY
CAUTION: Do not allow familiarity
(gained from frequent use of your ma-
chine) 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.
Be sure shields and guards are in place and in good

condition.
Never attempt to clean infeed bed area unless power

unit is shut off.
Never leave the machine running and unattended.
Always wear proper personal protective equipment at

all times.
Always stay clear of all hazards such as ditches and

power lines.
Always wear gloves when changing or servicing the

knives.
Always use grab rails and safety steps.
Never smoke, weld or use any type of flame near the

machine during refueling.
CAUTION: All personnel shall read this

manual thoroughly before start-up.
PROTECT AGAINST NOISE
Prolonged exposure to a loud noise can cause impair-

ment or loss of hearing. Wear appropriate hearing
protective device such as earmuffs (A) or earplugs (B)
to protect against uncomfortably loud noises.
10 04/04
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.
Never attempt to unplug the infeed bed or drum

chipper until power unit is off and lockout/tagout
procedures are followed.
Do not hand feed this machine for any reason.
DO NOT MODIFY MACHINE

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
BEFORE WELDING ON MACHINE/UNIT
EQUIPPED WITH AN ELECTRONIC ENGINE,
THE FOLLOWING PRECAUTIONS SHOULD BE
OBSERVED:
1. Disconnect all cables to the machine/unit batteries.
2. Disconnect both ECM connectors (J1/P1 and J2/P2).
3. Disconnect Remote Radio Connections (if applicable.)
4. Do not use the ECM or engine ground stud for
grounding of the welder.
5. Locate the welding ground as close as possible to
the welding area.
AVOID FIRES
Never refuel with power unit running.
Never smoke or have an open flame when refueling.
Use only in a well ventilated area and away from any

sparks or flames.
Clean dirt, oil, chips and bark material from engine area.
11 04/04
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.
BATTERY SAFETY
Batteries generate explosive gases. Keep sparks,

flames, burning cigarettes or other ignition sources
away at all times. Always wear safety goggles when
working near batteries.
AVOID SHARP EDGES
When handling any steel with sharp or jagged edges

use caution at all times.
AVOID ELECTRICAL HAZARDS
Understand all electrical schematics before attempt-

ing any maintenance. Shut main power switch OFF.
12 04/04
SAFETY SIGNS
13 04/04
CRIME PREVENTION
GOOD ADVICE
Keep your machine damage-free.
Follow the advice on these pages to reduce vandalism,

discourage theft and help recover your machine if it is
stolen.
RECORD IDENTIFICATION NUMBERS
1. Record Serial Number (S/N) of machine and

identification 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 components.
2. Check that the complete and correct numbers appear
on all documentation (insurance, financial, warranty,
etc.) Keep all documents in a safe location.
3. If available, participate in an "owner applied num-
bering program" and mark your own machines.
MAINTAIN DOCUMENTED PROOF OF OWNERSHIP
1. Keep in safe location all documents (invoices,

warranty, etc.) that accompanied your machine at
the time of purchase.
2. Take color photographs of each machine from all
sides and several different angles.
3. Maintain an up-to-date inventory of all equipment
and machines. Check regularly to insure no
machines have been stolen.
4. Update all documents and photographs when a
major change is performed to your machine -
changing power unit, clutch, loader, etc.
14 04/04
CRIME PREVENTION
PARK INDOORS OUT OF SIGHT WHEN POSSIBLE
1. Remove ignition key and lock the engine

control 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.
3. Secure all openings to storage
buildings.
PARKING OUTDOORS
1. Park out of sight as much as possible.

2. Remove ignition key and lock the
engine control box.
3. Make law enforcement aware of your
presence in an area and provide them
with a contact person to assist them in
dealing with suspicious activity.
4. Solicit assistance from neighbors or
merchants who permanently reside near
the parking area.
REDUCE VANDALISM
1. Install vandal protection devices,

especially if parking machine in high
risk areas.
2. Solicit assistance for watching machine
from individuals living in the area.
3. Take written notes and report to law
enforcement all suspicious vehicles or
persons.
15 04/04
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
roadside of the tongue near the front) to the
investigating officer and insurance carrier.
3. If available, provide the investigating officer
with photographs of the actual machine, manu-
facturers literature and knowledge of any iden-
tifiable marks that would assist in identifying
the machine.
4. Ask for verification that the stolen machine has
been entered into the National Crime Informa-
tion Center (NCIC) operated by the FBI in
Washington D.C.
5. Regularly check the identification plates on all
machines and report any missing or destroyed
plate.
FIRE PROTECTION
1. Perform daily maintenance.

2. It is the operator's responsibility to remove debris and accumulated oil, grease and other
flammable material around the power unit and around bearings daily. Pressure wash your
machine weekly. During dry conditions or heavy leaf fall periods, clean the unit twice daily
or as frequently as needed.
3. Inspect battery cables, connections, wiring and electrical components weekly. Use the battery
disconnect switch whenever the machine is left unattended.
4. Have an approved, charged fire extinguisher on the machine or on the site AT ALL TIMES.
Check the extinguisher regularly to be sure it remains charged. Other fire suppression
equipment should be installed on the unit. Water tanks are very good fire suppression units
as is a halon gas extinguisher.
5. Have the operator watch and check the equipment for 15-20 minutes after shut down to
ensure adequate "cool down time."
CAUTION: Many fires occur after shut down.
6. Park the machine a minimum of 50 ft. from other equipment in an area cleared of excess
debris to minimize fire spread.
7. Maintain a proper level of coolant in the radiator to avoid overheating.
8. Never transport flammable liquids on the machine in separate containers (gas cans, jugs, etc.)
9. When refueling, shut off power unit and DO NOT SMOKE.
10. Keep all sparks and flames away from batteries.
16 04/04
ENGINE CONTROLS
JOHN DEERE POWER UNIT
1. TACHOMETER - The tachometer 2. OIL PRESSURE GAUGE - Normal
measures the revolutions per minute of engine oil pressures @ 225ºF. (107ºC) oil
the power unit. temperature.
a. @ Idle Speed 15 PSI. (103 kPa)
CAUTION: Never let engine RPM drop b. @ Rated Speed 45/70 PSI.
below 1700 RPM when operating. (310/483 kPa)
Note: Individual engines may vary from the

normal pressures. Observe and record the
pressure when the engine is new to serve as
a guide for an indication of progressive engine
condition. (High oil pressure during start up is
not a cause for alarm.)
10
1 2 9
8
3
6 5 4
17 04/04
ENGINE CONTROLS
JOHN DEERE POWER UNIT cont...
3. ENGINE TEMPERATURE GAUGE 10. MAIN BATTERY DISCONNECT -
A water temperature of 160 to 200 F. Supplies power to the engine. This switch
(71 to 93 C) is the best assurance that the should always be shut off at the end of
working parts of the engine have expanded each shift and padlocked to help prevent
evenly to the most favorable oil clearances. vandalism and electrical fires.
Maximum engine coolant temperatures
should not exceed 200 F (93 C). 11. CLUTCH HANDLE - Used to engage
and disengage clutch.
CAUTION: Never add cold water to a hot
engine; cracking of the engine compo- CAUTION: Never engage or disengage the
nents may occur. Allow the engine to cool, clutch at engine speeds exceeding 800 RPM's.
then add coolant. Clutch failures are almost never covered under
warranty. Most failures are attributed to
4. AMMETER - Shows the amount of operator abuse.
charge or discharge on the batteries.
5. KEY SWITCH - Used in conjunction with

the permissive start button to start engine.
6. PERMISSIVE START BUTTON -

Used in conjunction with the start switch to
start engine.
7. THROTTLE SWITCH - Push toggle up

to increase RPM, push toggle down to
decrease engine RPM.
8. DIAGNOSTIC SWITCH - Refer to

engine manual
9. 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.
18 04/04
ENGINE CONTROLS
CAT POWER UNIT
1. MASTER BATTERY SWITCH.
2. TACHOMETER\SPEED SWITCH -The tachometer measures the revolutions per minute of the
power unit.
NOTE: Refer to LOR manual for speed switch setting procedures.
CAUTION: Never let engine RPM drop below 1700 RPM when operating.
3. ENGINE OIL PRESSURE - Measures the pressure of the oil in the engine.
4. ENGINE TEMPERATURE GAUGE - This gauge measures the temperature of the engine.
5. VOLTMETER - The ammeter reading shows the voltage of the electrical system.
6. CAT DATA LINK HOOKUP - Provides access for cat tech computer.
7. DIAGNOSTIC LIGHT - See schematic supplied with your machine for individual function.
8. DIAGNOSTIC LIGHT- See schematic supplied with your machine for individual function.
11. START AID - Push the button several times to aid in starting engine.
12. KEY SWITCH - Spring centered switch used for starting. Turn to the right for start.
13. THROTTLE SWITCH - Push toggle up to increase RPM, push toggle down to decrease engine
RPM.
14 FEEDWORKS SWITCH - This switch will power up the infeed bed
14
3 6 11
1
7
4 8 12
9
10
5 13
19 04/04
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. To prevent injury to personnel or machine damage, do not use the remote control system when
interference is present. Under these conditions the machine can be safely operated by using the manual
controls.
TRANSMITTER
The remote control transmitter is equipped with an LED light to indicate the operating condition of the
transmitter. When the transmitter is switched to the on position, the LED light glows steadily GREEN
for 3 seconds followed by a rapidly blinking GREEN light (about 2 blinks per second). This indicates
that the unit is operating normally and that the batteries are in good condition.
WARNING:If the LED fails to light when the unit is switched to the on position or the
LED glows RED, the batteries are low and must be replaced before machine operation
begins. If the LED turns to RED during use, safely stop all machine operations and
replace the batteries. Failing to do so may cause the operator to lose control of the
machine. Use only non-rechargeable AA Alkaline batteries in this transmitter.
WARNING: Improper operation of these controls can cause serious injury to personnel
and damage equipment. Do not allow anyone to operate this equipment before completely
reading the manual.
CARE AND HANDLING OF SYSTEM

1. Transmitter should be turned off when not in use.
2. Do not store transmitter in direct sunlight or wet areas.
3. Handle transmitter with care. Do not drop, throw or subject to severe physical shock.
4. For reliable radio operation, stay within working radius (For individual working distance refer to
your OEM Manual). Specified operating ranges are based upon line-of -sight conditions. Physical
obstructions especially those with high metal content, may reduce operating range. Avoid obstruc-
tions or relocate receiver antenna.
5. Transmitter should face towards receiver antenna.
20 04/04
REMOTE CONTROLS
REMOTE TRANSMITTER
1. MONITOR - (GREEN) means its on. 5. POWER SWITCH - This switch will
(RED) means that the battery is low. power up the remote transmitter.
2. ENGINE STOP SWITCH - This switch 6. SPOUT DEFLECT SWITCH - This

will shut down the engine. switch will raise or lower the spout.
3. THROTTLE SWITCH - This switch will 7. SPOUT TURN SWITCH - This switch
increase or decrease the throttle. will turn the spout right or left.
4. YOKE SWITCH - This switch will raise or 8. FEEDWORKS SWITCH - This switch
lower the yoke. will run the feed bed forward or reverse.
THE LIST READS FROM LEFT TO RIGHT

STARTING FROM THE TOP ROW
21 04/04
REMOTE CONTROLS
REMOTE TRANSMITTER W/CHIP DEFLECT
1. MONITOR - (GREEN) means its on. 6. SPOUT DEFLECT SWITCH - This
(RED) means that the battery is low. switch will raise or lower the spout.
2. ENGINE STOP SWITCH - This switch 7. SPOUT TURN SWITCH - This switch
will shut down the engine. will turn the spout right or left.
3. THROTTLE SWITCH - This switch will 8. FEEDWORKS SWITCH - This switch

increase or decrease the throttle. will run the feed bed forward or reverse.
4. YOKE SWITCH - This switch will raise or 9. OPTIONAL CHIP DEFLECT

lower the yoke. SWITCH - This switch will raise or
lower the spout.
5. POWER SWITCH - This switch will
power up the remote transmitter.
THE LIST READS FROM LEFT TO RIGHT

STARTING FROM THE TOP ROW
22 04/04
TETHER CONTROLS
REMOTE CONTROL
DANGER/CRUSH HAZARD: Keep

everyone clear of feedworks during
operation.
1. SPOUT TURN - This button allows the horn.
operator to turn the spout right and left.
CAUTION: Use horn to clear the area
2. SPOUT DEFLECT - This button allows before start-up and to warn someone
the operator to adjust the height of the chip they are too close to the work area.
discharge, in and out.
6. EMERGENCY SHUT DOWN BUTTON
3. YOKE Raise/Lower - Turn the switch to Push button in and hold until power unit
the left to raise the infeed yoke, turn the stops.
switch to the right to lower the infeed yoke.
CAUTION: This button should only
4. FEEDWORKS - Turn the switch to the be used for emergency shut down.
left to operate the feedworks in the forward
position, turn the switch to the center to 7. THROTTLE SWITCH - Push toggle
stop the feed works, turn the switch to the switch up to increase engine RPM, push
right to operate the feedworks in reverse. toggle switch down to decrease engine RPM.
THE LIST READS FROM RIGHT TO LEFT
23 04/04
TETHER CONTROLS
REMOTE CONTROL W/OPTIONAL CHIP DEFLECT
operation.
1. OPTIONAL CHIP DEFLECT horn.
SWITCH - This switch will raise or lower
the spout. CAUTION: Use horn to clear the area
2. SPOUT TURN - This button allows the they are too close to the work area.
3. SPOUT DEFLECT - This button allows Push button in and hold until power unit
the operator to adjust the height of the stops.
chip discharge in or out.
4. YOKE Raise/Lower - Turn the switch to be used for emergency shut down.
the left to raise the infeed yoke, turn the
switch to the right to lower the infeed 8. THROTTLE SWITCH - Push toggle
yoke. switch up to increase engine RPM, push
toggle switch down to decrease engine RPM.
5. FEEDWORKS - Turn the switch to the
left to operate the feedworks in the
forward position, turn the switch to the
center to stop the feedworks, turn the
switch to the right to operate the
feedworks in reverse.

24 04/04
TETHER CONTROLS
REMOTE CONTROL W/OPTIONAL BLOWER
1. THROTTLE SWITCH - Push toggle 5. YOKE Raise/Lower - Turn the switch to

switch up to increase engine RPM, push the left to raise the infeed yoke, turn the
toggle switch down to decrease engine RPM. switch to the right to lower the infeed
yoke.
Push button in and hold until power unit 6. SPOUT DEFLECT - This button allows
stops. the operator to adjust the height of the
chip discharge in or out.
be used for emergency shut down. 7. SPOUT TURN - This button allows the
horn. 8. OPTIONAL CHIP DEFLECT
SWITCH - This switch will raise or
CAUTION: Use horn to clear the area lower the spout.
they are too close to the work area.
4. FEEDWORKS - Turn the switch to the

left to operate the feedworks in the
forward position, turn the switch to the
center to stop the feedworks, turn the
switch to the right to operate the
feedworks in reverse.

operation.

25 04/04
CENTER SECTION CONTROLS
1. EMERGENCY SHUT DOWN BUTTON - Push button in and hold until power unit stops.
CAUTION: This button should only be used for emergency shut down.
2. INFEED YOKE SWITCH - This switch will either raise or lower the infeed yoke.
1 1 2
26 04/04
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.
NEW POWER UNIT BREAK-IN
The power unit on your machine has been set up and

started in the shop and then was run during a final check-
out. This amount of time is not enough for a proper power
unit break-in. Treat the power unit as brand new and follow
the power unit operator's and maintenance manual for
proper break-in procedures.
27 04/04
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.
3. Check for foreign objects lying on the infeed bed
and engine area. Keep these areas clear. Check for
broken or cracked components.
4. Make sure the access doors are closed and secured.
5. Make sure all other chain and belt guards are in their
proper place.
6. Make sure all walking surfaces are free of dirt, debris,
grease, snow and ice. Clean as often as needed to
maintain safe mounting and dismounting.
7. Make sure you are set up in a safe, open area away
from power lines and ditches whenever possible.
8. Grease all recommended grease points.
CAUTION: It is your responsibility as an owner/operator to

make sure that all bystanders are a safe distance from the equip-
ment at all times. NEVER operate a machine with unsafe con-
ditions existing.
9. Loose or missing hardware shall be replaced or tightened

as required to manufacturers specifications with OEM
hardware.
10. Check for fluid leaks. Hydraulic system leaks must be
corrected before the machine is operated. Inspect all
hydraulic hoses and replace if necessary. Secure all caps
and filler plugs for all systems. Check for proper fluid NOTE: After start-up,
levels and change as required. perform a functional check of
11. Be sure all tires are properly inflated per manufacturers all systems. Refer to this operation
specifications. and maintenance manual for
12. Check that all safety decals and placards for cleanliness proper machine function.
and legibility. Replace all missing or damaged decals and
placards. Ensure that the applicable safety operation
and maintenance manual is enclosed in the storage box
provided.
28 04/04
SAFETY OPERATION
MOUNTING AND DISMOUNTING
1. Make sure all walkways are clear.
2. Walk at all times - do not run.
3. Always use the grab rail and safety steps.
4. Never jump from machine unless it is an

absolute emergency.
5. Always lower and secure all equipment

before dismounting.
29 04/04
SAFETY OPERATION
STARTING MACHINE
1. Place all hydraulics in the neutral position.
2. Place the clutch in the disengaged position

and lock.
3. Turn main power switch on the engine to

the ON position.
4. Give several blasts of the warning horn to

clear area.
5. Turn key to ON position.
6. Position the permissive START switch in the

start position (If applicable.)
7. Turn the ignition switch to the on position.
8. Once the engine has started, hold permis-

sive START switch until oil pressure builds
up. This will take approximately 10-20
seconds.
9. Release permissive start switch to the RUN

position.
10. Let power unit idle at 800 RPM until all

gauges reach normal operating range.
CAUTION: In cold weather, it is good practice

to let your hydraulic system idle for approxi-
mately 15 minutes before actual machine opera-
tion. In extremely cold weather the cold oil will
cause the pumps to cavitate, voiding
manufacturer's warranty.
30 04/04
SAFETY OPERATION
STARTING MACHINE CONT
DANGER/THROWN OBJECT HAZ-

ARD: Never allow anyone to stand
under discharge spout.
11. Engage the clutch by bumping the clutch

handle in and out gently, until the chipper
drum is turning, then fully engage the
handle.
CAUTION: Never engage or disengage the

clutch at engine speeds over 800 RPM. This
will damage your clutch. Clutch failures are
almost never covered under warranty. Most
failures are attributed to operator abuse.
WARNING: Never engage the clutch

without the safety guards in place and
the discharge spout bolted down.
CAUTION: The clutch requires a wear-

in period. Check the clutch adjustment
before being placed in service. Check again
after the first 10 hours of operation. Until
"worn-in," check periodically. Refer to the
clutch manual for more information.
12. Throttle up power unit all the way.
DANGER/ENTANGLEMENT,
CRUSH HAZARD: Never hand-feed
this chipper for any reason.
DANGER/CRUSH, CUT HAZARD:

Never leave the operator's seat
unattended without first placing
feedwheels in a neutral position,
idling engine.
DANGER/CRUSH, ENTANGLE-
MENT HAZARD: This machine is
equipped with a clutch safety switch.
This will not allow the machine to
start with clutch engaged. Do not run
machine without this in operating
condition.
31 04/04
SAFETY OPERATION
CHIPPING SAFETY PROCEDURES
1. Always make sure all filler plugs,
drain caps and guards are in place.
2. Never attempt to unplug the chipper

infeed spout with chipper running.
3. Never, under any circumstances,

open the chipper hood without first
making sure the chipper drum has
completely stopped.
4. Always wear appropriate safety

equipment such as a hard hat and
safety glasses.
5. Keep the machine under control and

do not work it over its capacity.
32 04/04
SAFETY OPERATION
CHIPPING WOOD
As the operator, you are responsible for the safety of workers in your area. Use the warning horn as
often as needed to alert workers of DANGER.
As the operator, you should 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.
A good skidder operator will spot the trees which need trimming and will drop them before reaching
the machine. If a tree needs trimming during the chipping operation, move the tree to the far right or
left of the machine. Then, load trees into the chipper from the opposite side of the machine. This will
protect the chain saw operators and allow for continuous chipping.
1. Bring logs up onto the end of the deck. The butt should be at the end of the deck and the top
should be in line with the feedwheel.
2. Begin by feeding the butt of the tree into the infeed.
3. As the butt of the tree reaches the center feedwheel, start raising the yoke up to allow the tree to
slip under the feedwheel.
CAUTION: Never force wood into the chipper. This will cause heat and excessive wear.
4. Once the tree starts under the feedwheel, release the feedwheel lever, lower the tree to the
conveyor chain and open the grapple.
WARNING: Operate machine at a safe distance from power lines.
33 04/04
SAFETY OPERATION
MACHINE SHUT DOWN
1. Throttle engine down to an idle.
2. Place all hydraulics in neutral, lower blade,

engage parking brake.
3. Dismount machine carefully.
4. Disengage clutch and install clutch lock.
5. Allow engine to idle 3-5 minutes. Allowing the

engine turbos to slow and cool.
6. Turn off main switch and remove ignition key.
7. Clean around the machine. This will help elimi-

nate fire hazards and improve conditions around
the machine for maintenance.
WARNING: Read and follow all mainte-

nance procedures carefully before attempt-
ing any maintenance.
WARNING: When the above procedure

(NO. 9) is used, it should be the very last
thing done at the end of the day. Never
use a torch or welder around diesel fuel.
34 04/04
SAFETY OPERATION
TRANSPORTING
1. Check to make sure the clutch is 8. Check the tire pressure for proper load
disengaged and clutch lock installed. range.
2. Turn off main ignition key and remove. 9. Check the brakes, turn signals and tail
lights.
3. Turn off main battery disconnect
switch. 10. Before you leave site, spot check the
area for wrenches, chain binders and
4. Hook up the electrical connections and other miscellaneous tools that may have
air brake lines. been dropped while performing main-
tenance.
11. Obtain all permits before leaving

worksite area.
35 04/04
ROUTINE LUBRICATION SCHEDULE
CAUTION: Never exceed the specified PSI relief valve setting.
36 04/04
Please note that the
following maintenance
intervals apply for normal start
operating conditions only. up 4 hou 8 hou 40 ho 160 ho400 ho1000 hours
CHIPPER PROCEDURES
Complete machine visual inspection (condition, leaks) X X
clean X
Drum bearings clean and repack1) X
check clearance when repacking
Drum knives inspect X
sharpen or replace when chip quality deteriorates
Drum knife bolts inspect when checking drum knives2) X
replace when changing knives
Drum knife holders inspect when checking drum knives X
replace when worn or damaged
Drum knife holder bolts 2)
inspect when checking drum knives X X
replace when changing holders
Drum knife clearance adjust when changing drum knives X
37
Drum anvil inspect when checking drum knives X
replace when worn or damaged
Drum drive belts inspect2) X X
3)
tighten to proper tension
replace when worn
1) Use only EP rated grease

such as;
Exxon - Lidox EP2
Shell - Acvania EP2
Chevron - Duralith EP2
2) During 1st week check

3) According to specifications listed in your Morbark Operators Safety Manual
04/04
MAIN FRAME
1 2 7
3,5 4
38 04/04
Please note that the following maintenance intervals apply for normal operating
rs
p
conditions only. Intervals are hours of operations based on 8 hours per day, 5 days
start u
8 hou
per week. If your operating conditions are difficult, adjust the specified intervals
MAIN FRAME X = 1 SHOT OF GREASE

1) Bed chain idler bearings (2 places) X X
2) Bed chain drive bearings (2 places) X X
3) Top yoke cylinder bushing (4 places) X X
4) Top wheel bearings (2 places) X X
5) Top yoke pivot pin (2 places) X X
6) Spout turn (4 places) X X
7) Stabilizer cylinder front and rear (2 places) X X
39 04/04
ROUTINE MAINTENANCE
TIGHTENING TORQUE GUIDE
1. Parts using rivet 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 Capscrews.
4. The above is based on use of clean, dry threads.
5. Reduce torque by 10% when engine oil is used as a lubricant.
6. Reduce torque by 20% if new plated capscrews are used.
7. Capscrews threaded into aluminum may require reductions in torque of 30% or more of Grade 5 capscrews torque and must
attain two capscrew diameters of thread engagement.
CAUTION: If replacement capscrews are of a higher grade than originally supplied, adhere to torque specifications for
that placement.
**Based on IFI 5th Edition Technical Data N-12/N-16, using Equation (1) and a torque coefficient, K=0.20 for nonplated steel fasteners
and K=0.15 for plated fasteners.
These Figures represent an estimate of torque (torque being the measurement of friction, not tension) required to induce given preload
(clampload) in a bolt for noncritical applications only. For critical or special applications where greater control is desired this should be
experimentally determined. This applies to washer faced or double chamfered hex nuts (or bolts, if bolt is torqued) having a width
across flats of approximately 1.5 times the nominal diameter and having threads free of interference.
Because of the many interrelated variables that directly or indirectly affect friction, such as surface texture, type of coating or finish, lubrication,
speed of tightening, human error, etc., it is possible to experience as much as ± 25% deviation in preload (clampload) with the use of a torque
wrench.
40 04/04
ROUTINE MAINTENANCE
HOW TO USE A V-BELT TENSION GAUGE
WARNING: Before doing maintenance
or tensioning on belt drives, turn equip-
ment off and lock out the power source. 1.
Use guards on machinery when running.
1. Place a matched set of belts over the
sheave grooves. Take up the slack until
the belts appear fairly taut.
2. With the drive stopped, measure the belt
span length of your drive (see table 1.) Set
the rubber O-ring on the body of the ten-
sion gauge (S/N 29841-093) at the dimen-
sion equal to 1/64" for every inch of
span length. For example, the deflection
2.
for a 32" span is 1/64" x 32-1/2".
3. Set the O-ring on the plunger at 0 against
the body of the tension gauge.
4. With the tension gauge perpendicular to
the span, apply a force to a belt in the
center of the span. Deflect the belt until
bottom of the large O-ring is even with
the top of the next belt, or the bottom of
a straightedge laid across the top of other
belt(s) on the drive. Release pressure
and read pounds of force used at O-ring
on plunger. Note: All belts can be found in the Parts Book
supplied with your machine
Note: When new belts are installed on a drive,
the tension will drop rapidly during the first few Note: A new belt for tension purposes is a belt
hours. Thus, for new belts, tighten to the initial with zero running time.
installation deflection force shown in the table
Note: After a belt has been in operation for two
5. Check tension frequently during the first 24 minutes it is considered used.
hours of operation. Subsequent retensioning
should fall between the minimum and max- Note: The best set of matched belts will not
imum forces shown in the tables. perform well if either the drive or driven sheaves
are worn out. These sheaves should be inspected
6. Compare the force required in step 4 with any time the belts are replaced. If the sheaves
the ranges in table 2. Tighten or loosen show signs of excessive wear they should be
belts to bring them into the recommened replaced so that maximum belt life can be ob-
range. tained.
Note: The proper tension for V-belt drive is CAUTION: Failure to follow these guidelines
the lowest tension at which the belts won't slip could result in premature belt failure, belt rollover,
under peak load conditions. and P.T.O. bearing failure.
41 04/04
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.
3. Make sure that the sheaves are correctly
aligned, that the shafts are parallel and there
is clearance for the drive to run. Check all
bearings during set up.
4. Work belts around in the groove by hand,
so that the slack of all belts is on the top
or the slack of all belts is on the bottom.
CAUTION: Never pry or force a belt onto the

sheave with screwdrivers, crowbars, wedges,
etc. Damage to the belt and drive can result.
Note: All new belts have an initial stretch. It

will be necessary to adjust the tension at shorter
intervals until the belt is properly seated and the
initial stretch is eliminated.
WARNING: Never attempt to check or

adjust belts while the machine is run-
ning.
BELT CLEANING INSTRUCTIONS

Remove grease and oil as quickly as possible
before they can penetrate into the belt, causing
rapid deterioration.
Clean belts by wiping them with a clean cloth.

Use a nonflammable cleaner or solvent to
remove excessive grease and oil. Water and a
detergent soap can be used, but it is not as
satisfactory as a nonflammable cleaner.
WARNING: Never attempt to clean the

belts while the machine is running.
Never use flammable cleaning solvents.
42 04/04
ROUTINE MAINTENANCE
CHANGING CHIPPER KNIVES
DANGER/THROWN DEBRIS, PINCH,
CUT HAZARD: Make sure the drum
has come to a complete stop before
attempting any maintenance.
1. Disengage the clutch and install clutch lock.

CUT HAZARD: Shut power unit off
before any maintenance is performed.
2. Remove hood bolts and open hood.
CAUTION: Two (2) people are required

at all times when changing chipper
knives.
Fig 1
3. Remove the bolts from the knife.
WARNING: Never stand or jump on

chipper wrench to break bolts loose.
4. Remove knife. Always wear leather gloves.

5. Blow dirt and debris out of the knife
pocket with compressed air.
6. Inspect knife holder for wear.
CAUTION: The knife holder must be replaced
if the holder face has a groove worn more than
1/4" (Fig 1.)
7. Place newly sharpened knife into the knife

pocket. Keep knives in sets at all times.
8. Replace and tighten knife bolts.
CAUTION: Lubricate and torque knife and
holder bolts to specifications listed in the torque
chart.
9. Rotate drum to the next set of pockets.

10. Repeat Steps 4-9 for each pocket.
11. Once all knives have been changed, rotate
drum backwards to check for clearance.
12. Inspect anvil clearance.
(See inspecting anvil clearance.)
13. Close and bolt hood before start-up.
43 04/04
ROUTINE MAINTENANCE
KNIFE GRINDING
The time between knife grinding will vary with the

type of wood and operating conditions. Sharp
knives are very essential to good chip quality and
nothing is gained by running the chipper with dull
knives. Indications of dull knives are poor chips,
excessive oversize, fines and poor feed characteris-
tics of chipper. A few more hours chipping may
sometimes be gained by hand honing the knives
while still in the disc.
The chipper knife is factory ground to a 31° bevel.

There are exceptional conditions where the angle
may vary from 29° to 31° to improve performance.
CAUTION: Angle should never exceed 31°.
The most suitable angle for any particular condition

can only be determined by the trial and error
method right on the job.
To achieve longer knife life follow these steps.
1. Grind the knives at 31°.
2. Cut the very tip of the knife off by using a 10

inch single cut bastard mill file.
3. File the tip down to the width of a ball point

pen line thickness (approx. .008). This can be
done with a couple of passes of the file.
4. Using a file, sharpen the backside of the flat

side of the knife to a 45° angle off the
front edge.
44 04/04
ROUTINE MAINTENANCE
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 neces-
sary to do some experimenting with this back
grind for your particular application. For ex-
ample, with tougher or drier wood, you may
have to file a larger 45° back grind on the knife.
A good thing to remember is to make the edge

of the knife as blunt as possible, yet still maintain
a good chipper feed.
CAUTION: Morbark Inc. knives are recom-
mended.
Listed below are several recommendations which

are important for a quality knife grinding opera-
tion:
1. Sometimes hand-honing the knives when

they are still in the disc and appear ready
for changing may result in additional knife
life between grinding.
2. Always use a grinding machine that will
repeat the desired angle and grind true and
straight, avoiding the straight wheel grind-
ing.
CAUTION: Straight wheel grinding will give a
hollow or concave effect. This shortens the life
of the knife and produces poor chips.
3. The grinder should never overfeed the

grinding machine. (A straw brown or blue
color will appear on the back side of the
knife if the machine is overfeeding.) All
knives should be ground with the cutting
edge up so that any heat that might develop
will be pulled from the cutting edge rather
than on to it.
4. We recommend a non-petroleum base
coolant such as De Santo (orange label)
grinding coolant, mixed approximately one
part coolant to 50 parts of water. The
coolant should be applied on the wheel
about 1" above the knife with full pressure.
This will keep the wheel clear and free to
cut without burning or damaging knives.
45 04/04
ROUTINE MAINTENANCE
MILL BEARING INSTRUCTIONS B. Adapter - Slide adaptoer onto the shaft,
WARNING: To ensure that the drive threaded end outboard to the approximate
is not unexpectedly started, turn off location of the bearing. Apply light coating of oil
and lockout or tag power source to sleeve O.D.
before proceeding. Failure to ob-
serve these precautions could result C. Bearing - Make sure the internal clearance
in bodily injury. has been written down. Install bearing on
adapter sleeve, large end of tapered bore first.
INSPECTION Locate bearing in proper position on shaft.
Inspect shaft. Ensure that the shaft is smooth,
straight and clean. D. Lockwasher and Locknut - Install the
lockwasher (8” and smaller sizes only) on the
Inspect bearing. Do not allow bearing to be ex- adapter with inner prong located in the slot and
posed to any dirt or moisture. Do not remove toward the bearing. Install lock nut, chamfered
slushing compound, since it acts as both a face toward bearing.
protectant and lubricant and is also compatible 4” shaft and smaller - Tighten locknut using
with standard greases. spanner wrench and hammer until clearance
noted in step 2 is reduced by amount shown in
NOTE: Housing caps and bases are not inter- Table 1. During this step, shaft should be sup-
changeable. They must be matched with mating ported so all weight is off the bearing.
half. Install non-expansion bearing first. 4-13/16” to 10-1/2” shaft - Tighten locknut by
1. Apply a light coating of oil or other rust hand followed by light tapping on a bar inserted
inhibitor to the adapter area of the shaft. in notches on O.D. of locknut until snug against
2. Measure the internal clearance of the bearing. Tighten all micro mount screws evenly in
bearing before mounting. Place the sequence and in small increments (10° to 15°
bearing in an upright position. Seat the turns) until clearance is reduced. Loosen all
inner ring and roller elements by pressing screws until they are snug at large end of nut.
down firmly on the inner ring bore while Screws have been staked at factory to prevent
rotating the inner ring a few times. removal. However, restake if necessary. Tighten
Position the roller assemblies so that a locknut until it is tight against bearing. (Use drift
roller is at the top most position on both pin and hammer. Do not overtighten.)
sides. Press these top rollers inward
ensuring contact with center guide flange Find a lockwasher tab that aligns with a locknut
(above 6 1/2” only). Using a feeler slot and bend tab into slot. If slot is past tab, then
gauge, measure the clearance for both tighten - not loosen - locknut to allow prong to fit
sides by inserting as far as possible and in adapter slot. Lock plates for the 9” must be
sliding over top of roller. Write down the hand fitted on the job.
measured clearance for use in step 3D
NOTE: Do not rotate bearing when moving
feeler between roller and outer ring.
3. Install the bearing parts in the following
sequence:
NOTE: Bearing can only be correctly installed

one way.
A. Seal Ring - Install a seal ring on shaft.
46 04/04
ROUTINE MAINTENANCE
B-LOC HUB MAINTENANCE
47 04/04
ROUTINE MAINTENANCE
INSPECTING ANVIL CLEARANCE
When inspecting inside the spout every possible

safety precaution must be followed!

CUT HAZARD: Make sure the drum
has come to a complete stop before
attempting any maintenance.
1. Raise the center feedwheel yoke and pin.

Then install the yoke safety chain.
DANGER/CRUSH HAZARD: Never work

under the yoke without both lock pins fully
installed.

CUT HAZARD: Shut power unit off
before any maintenance is performed.
2. Crawl into the chipper spout with a feeler

gauge and a light.
3. Rotate drum backwards until the knife is

aligned with the anvil.
4. Check the distance between the knife and

anvil with the feeler gauge. Check both sides
to make sure the anvil is parallel with the knife.
5. The clearance should be kept at .045 to .050,

inspect the clearance of each pocket by rotat-
ing the drum backwards.
6. To adjust anvil, loosen anvil bolts slightly and

adjust with threaded eye bolts.
CAUTION: This procedure works best with two

people, one in the spout and one adjusting bolts.
(Adjustment bolts are found under the machine.)
7. Once proper clearance is set, tighten anvil

bolts and tighten jam nut on the adjuster bolts.
Rotate drum backwards to assure clearance.
48 04/04
ROUTINE MAINTENANCE
TIGHTENING FEEDWHEEL 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 (refer to torque chart.)
CAUTION: Lubricate all chains daily. When proper

maintenance schedules are kept, down time and
replacement parts can be cut to a minimum.
TIGHTENING THE INFEED BED CHAIN
The infeed bed chain must be kept tight

enough so as it leaves the idler (rear) sprocket
it doesn't buckle. If the bed chain is too loose,
it will make a klunking noise as each section
passes over the sprocket. If bed chain is run
too loose it will wear on itself and the drive
and idler sprockets more than normally.
1. To adjust bed chain, loosen tight-

ener bolts on idler sprockets and then
tighten puller bolts. Always keep idler
sprocket even on both ends by counting
revolutions of the puller bolt.
Example - 2 1/2 turns on left side, 2 1/2
turns on right side. When chain is prop-
erly adjusted, retighten bolts on idler
sprocket (refer to torque chart.)
49 04/04
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 engine and chipper area daily by blowing

debris out from around power unit with com-
pressed air.
CAUTION: See power unit operations and

maintenance manual for further information.
ENGINE OIL
Depending upon the expected air temperature

range during the drain interval, use oil viscosity
shown on the temperature chart.
Quality engine oils are blended, so additives are

neither required nor recommended.
Use only premium quality engine oils meeting

performance requirements of:
-API Service Classification CD/SC

-Military Specification MIL-L-2104C
At temperatures below - 22° F (-30°C), use

arctic oils meeting a minimum of API Service
Classification CC/SC, but at a shorter drain
interval.
CAUTION: See power unit manual for sug-

gested drain intervals.
50 04/04
ROUTINE MAINTENANCE
FUEL SPECIFICATIONS
No. 2D diesel fuel is recommended for use in
cat power units. In extreme cold temperatures
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 elimi-
nating all sediment and residue.
There is considerable variation in the composi-

tion of fuels distributed under the No. 2 grade
classifications. For desirable engine service it is
most important to give special attention to
cetane no., water and sediment, pour point,
cloud point and sulphur content.
STORING FUEL
Proper fuel storage is critically important.
Keep all dirt, water and other contaminants
out of fuel. Avoid storing fuel over long
periods of time.
FILING FUEL TANK

Fill fuel tanks at the end of each day's opera-
tion to prevent condensation as moist air
cools. Lock tanks after refueling.
Fuel capacity is 143 US Gal (541 liters.)
CAUTION: Do not fill tank com-

pletely to the top. Leave space in the
tank for gas vapor to expand with a
change in temperature. A completely
filled tank could overflow if exposed to
a rise in temperature, such as direct
sunlight.
DANGER/EXPLOSION HAZARD:
Never refuel with the power unit
running or while smoking and only
refuel in a well ventilated area.
CAUTION: Never steam clean or spray

water on a warm injection pump. This could
cause seizure of pump parts.
51 04/04
ROUTINE MAINTENANCE
RADIATOR
DANGER/BURN HAZARD: 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 anti-
freeze which contains a rust inhibitor and
lubricant.
Use a 50/50 ethylene glycol antifreeze and clean

soft water. CAUTION: The optional reversing fan is designed
for occasional purging of airborne debris from the
CAUTION: Artificially softened water should radiator screen. The reversing fan is not intended
not be used. for cleaning the radiator cores. It is the operators
responsibility to clean the radiator cores with
During extremely cold conditions a higher compressed air to maintain maximum cooling
concentrate of antifreeze will be needed. efficiency. The frequency of cleaning the radiator
Leave antifreeze in the cooling system during core is determined by the working conditions.
hot weather operation. Under normal working conditions the radiator core
should be cleaned at least once a week.
WARNING: Check coolant level only,
when engine is stopped and radiator CAUTION: Do not purge fan while engine is
cap is cool enough to touch with your under load. Immediate temp rise will occur.
hand.
CAUTION: During the purging process there is
CLEAN RADIATOR EXTERIOR no air flow through the radiator cores while the
fan is switching directions. If the temperature
At the end of each work period the exterior of remains high after purging screen, the radiator
the radiator should be cleaned. Remove all cores will need cleaning. Continuing to try to clean
branches and chips from around housing. Use the core with reversing fan will result in engine
compressed air to clean cores and screens. overheating.
ADJUSTING THE CLUTCH
During the break-in period, the clutch will need

adjustment periodically. To adjust refer to the
clutch manual or the inspection cover for the
proper care and adjustment procedures.
CAUTION: Never engage or disen-

gage the clutch at engine speeds ex-
ceeding 800 RPM's. Clutch failures are
almost never covered under warranty.
Most failures are attributed to operator
abuse.
52 04/04
ROUTINE MAINTENANCE
BATTERIES
The batteries are located near the engine.

One or two 12 volt batteries are provided
to make 12 or 24 volts depending on
engine size. (On machines with a cummins
engine 2-31S batteries are provided.)
SERVICING BATTERIES
1. Keep battery and battery box clean.

Keep all connections clean and tight.
Remove all corrosion and wash termi-
nal with a solution of baking soda and
water.
2. Keep battery fully charged, especially

during cold weather. Batteries are low
maintenance, but not maintenance free.
Add electrolyte as necessary.
CAUTION: Never attempt to charge

a frozen battery. Allow battery to
warm to 60° F (15.5° C) before
placing on charge.
3. When recharging battery, avoid sparks

by turning off charger before making
connections or disconnections. Discon-
nect both battery terminals before using
a charger.
CAUTION: Batteries generate

explosive gases. Keep sparks,
flames, burning cigarettes or other
ignition sources away at all times.
Always wear safety goggles or
glasses to protect your eyes when
working near batteries.
53 04/04
UNDERSTANDING HYDRAULICS
HYDRAULIC SAFETY
BE CAREFUL OF:
1. Leaks If a motor or a cylinder does not work or
a. Puddles of fluid are slippery and hazard- works slowly, the fluid must be slipping through
ous. it or bypassing the work completely. Trace the
b. Most hydraulic oils will vaporize and ignite, lines to the motor or the cylinder, then place a
disastrous fires are possible. pressure check on the working line.
c. Leaking fluid may be hot and can produce When the pump is working at the proper
severe burns. gallons per minute (GPM) and the pressure
d. Fluid can squirt out under high pressure checks out OK, you will find that in most cases
with dangerous force. Pin hole jets can your motor or your cylinder is defective.
pierce skin and damage eyes. If the pressure is too low, the pump or the
CAUTION: Escaping fluid under pres- relief valve is causing the difficulties. Clean relief
sure can penetrate the skin, causing valve thoroughly. Reassemble relief valve and
serious personal injury. Relieve pres- check the pressure again.
sure before disconnecting hydraulic or Example:
other lines. Tighten all connections If the pump is pumping six gallons in 30 sec-
before applying pressure. Use a piece onds and the pump is a 12 GPM, then you
of cardboard or paper to search for know that it is performing at capacity. If it will
leaks. Never use your hand! If any only pump two or three GPM in 30 seconds,
fluid is injected into the skin, it you know that the pump is only performing at
must be surgically removed within a 50% of its capacity.
few hours by a doctor familiar with this If the pump is performing properly, the relief
type of injury or gangrene may result. valve is defective.
2. Hot Components If the pump isn't performing right, it will need
a. Pumps and motors. repairing or replacement.
b. Relief valves. When the pump is pumping at the proper GPM
c. Anyplace fluid has been flowing. and the pressure is correct, you will find that in
most cases, your hydraulic motor or cylinder is
CAUTION: Always wear safety defective.
goggles or safety glasses during FILTERS
maintenance. The filters mounted on the hydraulic tank are
3. Stored energy - Even with the power unit off, 10 micron absolute and should not be replaced
there may be energy stored in the system due with any filter not meeting or exceeding this
to: rating.
a. Stalled feedwheels. HYDRAULIC OIL
b. Suspended loads, booms and stabilizers. Change hydraulic oil every 2000 operating
c. Charged accumulators. hours or one year under normal conditions and
d. Electrical voltage. every 1000 hours or 6 months, whichever
CAUTION: Never boost pressure settings comes first, when under extremely dirty condi-
on hydraulics. This will void the manufacturer's tions. If hydraulic component failure is a regular
warranty. maintenance problem, monthly testing of the
system will help determine your change periods.
A hydraulic pump makes oil flow but there CAUTION: Do not use any hydraulic oil that
must be resistance for the flow to generate does not contain anti-wear additives.
pressure.
54 04/04
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.
Don't neglect maintenance. Set up and adhere to a rigid preventative maintenance schedule. One of the
most important elements in such a program is changing or adding to the fluid on schedule.
WHEN TO CHANGE FLUID

Blotter spot test. This is a very simple test in which a drop of fluid is placed on a piece of blotter
paper. If the blotter remains colorless or develops only a light yellow ring, oxidation is under control.
Even when color develops but is uniform throughout, the oil is serviceable. If the sample shows distinct
rings, the fluid should be changed. When a distinct dark spot remains in the middle but lighter-colored
oil migrates outward in the blotter paper, the oil has or is about to dump sludge or other products into
the system. This indicates that the time for fluid replacement has passed.
Listen for a sound change. If the operating system changes in sound level usually louder or other
than normal sounds, it is time to evaluate the fluid's condition.
Test for acid content. A shift in the acid content may indicate a break down in the fluid. Acid test
kits are available from fluid suppliers, and the tests are easy to carry out.
55 04/04
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. Before you can determine why a machine isn't working, you need to
know:
-How it works.
-Correct pressure settings, gauge readings.
-What repairs and maintenance or modifications the machine has had.
-The symptoms of the failure, in detail.
-How the failure occurred.
Often, an operator can tell you something that will help, like whether the failure was sudden or gradual,
or whether there were any unusual noises when their machine stopped working.
ISOLATING AND REPAIRING THE TROUBLE (Steps 4, 5, and 6)

Based upon the information you have gathered, use your knowledge of hydraulics and information we
have supplied to analyze the problem.
There will probably be more than one possible cause of the malfunction.
Confirm or eliminate the easiest possible causes first. Save checks that involve downtime or major
disassembly for last.
Always proceed SYSTEMATICALLY, rather than randomly!
This means that every step you take should have a good reason behind it. The efficient trouble shooter
knows what he is looking for when:
-Asking questions.
-Reading schematics.
-Observing, testing or taking the machine apart.
PREVENTING FUTURE PROBLEMS (Step 7)

After repairing the machine, consider: Why did the fault occur? Could proper maintenance have pre-
vented the condition which led to the failure?
Take whatever steps are necessary to reduce the chances of a similar problem occurring again.
56 04/04
SERVICING HYDRAULICS
NOISY PUMP can turn in one direction only.

Air in the system: Check fittings, cracked Intake clogged: Make sure tank is cleaned
hoses and other parts on the pump intake. periodically. Fluid must be kept 3/4 full.
Check hydraulic tank. The tank must be kept Air leak in intake: If any air is going through
3/4 full. pump, it will cause noise. Pour fluid over points
CAUTION: Never fill hydraulic tank com- suspected of leakage; if noise stops, you have
pletely full at any time. System drainage will found the leak.
cause the tank to overfill and spill out. Oil too heavy: If fluid is too heavy, some types
Cavitation (vacuum in pump): Check for of pumps cannot pick up prime. Fluid that is too
clogged or restricted intake line or plugged air heavy can do great damage to hydraulic sys-
vent in tank. tems. Drain and refill with oil of the proper
Loose or worn pump parts: Look for worn viscosity.
gaskets and replace if necessary. Check for LOW PRESSURE IN SYSTEM
clean and proper fluid. Relief valve setting too low: With an im-
Stuck pump vanes, valves, pistons, etc: proper setting, fluid may flow from the pump
Disassemble and clean thoroughly. Avoid the through the relief valve and back to the tank
use of files, emery cloth, steel hammers, etc, without reaching the point of use. To check
on a machined surface. Products of fluid relief setting, block pressure line beyond relief
deterioration such as gums, sludges, varnishes valve and check line pressure with a pressure
and lacquers may cause sticking. Use solvent gauge
to clean parts and dry thoroughly before Relief valve stuck open: Clean dirty relief
reassembling. If parts are stuck by corrosion valves (see maintenance). A stuck valve may be
or rust, they will probably have to be re- an indication that the system contains dirty or
placed. deteriorated hydraulic oil.
Pump out of alignment with drive: Check Broken, worn or stuck pump parts: Install
alignment. Misalignment may be caused by pressure gauge and block system just beyond
temperature variation. relief valve. If no noticeable pressure is devel-
OVERHEATING oped and relief is okay, look for mechanical
Viscosity too high: Check recommendations. trouble in pump. Replace worn and broken
Unusual temperature conditions may cause parts.
fluid of proper viscosity for working tempera- Valves sticking or binding: Check suspected
ture to thicken too much on the way to the parts for mechanical problems such as misalign-
pump. In this case, use of a fluid with higher ment, bent, worn etc then look for signs of dirt,
viscosity index may cure trouble. sludge, varnishes and lacquers caused by dete-
High discharge pressure: Such parts may rioration.
cause undue friction. Look for signs of exces- Sluggishness when machine is first started:
sive friction. Be sure all parts are in alignment. Sluggishness is often caused by fluid that is too
Low oil: Assure oil level is proper, at least thick at starting temperatures. If you can put up
3/4 full. If the tank is low, less fluid will be with this for a few minutes, fluid may thin out
available to carry away the heat, raising the oil enough to give satisfactory operation, but if it
temperature. does not thin out or if surrounding temperature
remains relatively low, you may have to switch
PUMP NOT PUMPING to a fluid with a lower pour point and lighter
Pump shaft turning in the wrong direction:
viscosity. Under severe conditions, immersion
Shut down immediately. Some types of pumps
heaters are sometimes used.
57 04/04
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.
Cylinder liners are installed in a press fit with the engine block. Gaskets, called crevice seals, are used
to seal the lube oil system from the cooling system across the liner.
The pistons strike the liners as they travel up and down due to the side thrust imparted by the con-
necting rods as the power is translated from the linear up and down motion of the piston to the rotary
motion of the crankshaft.
The clearance between the piston and the liner and the liner and the block allows this piston slap to be
translated into a high frequency vibration, much like the vibration of a bell when it is struck.
The side of the liner in contact with the coolant moves first toward the coolant and then away from it.
This rapid movement can cause small vapor bubbles to form as the liner moves away and to collapse
or implode as the liner moves back. Very large forces are generated in very small areas as this hap-
pens. This is known as cavitation corrosion/erosion. The violent shock waves caused by bubble col-
lapse hammer the liner surface. The resulting bare liner surface has been highly stressed and is very
active. The resulting corrosion/erosion is localized and effectively drills small vertical holes in the liner
wall. If allowed to progress, these holes will penetrate the wall and oil will flow into the coolant when
the engine is running and coolant into the oil when the engine is shut down.
Liner pitting can occur anywhere on the cylinder liner. Most frequently it is found on the side of the
liner where the piston strikes just after the cylinder fires and to a lesser degree on the opposite side
where the cylinder strikes on the up stroke. However, it can occur anywhere on the liner where the
highest level of vibration occurs. Because of variations from cylinder to cylinder and engine to engine,
no two liners will appear the same.
LINER PITTING IS CAUSED BY

IMPLODING VAPOR BUBBLES
58 04/04
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. Incorrect plumbing of the cooling system can cause local hot
spots or local low pressure areas near the liners making them more susceptible to liner pitting.
Air leaks in the cooling system can cause local hot spots because of the insulating properties of air. In
addition, when air is present in the coolant, more oxygen is available to accelerate corrosion in general.
HOW TO PREVENT LINER PITTING

Since the early days of high speed diesels, supplemental coolant additives (SCAs) have been used to
prevent liner pitting. In the early years, sodium chromate was used. Around 1969 borate/nitrate was
introduced. In 1984, Fleetguard introduced a state-of-the-art SCA containing phosphate/molybdate
under the trade name DCA4. All of these SCAs were effective in preventing liner pitting when used in
the cooling system in the recommended concentrations. Basically they all work by the same mechanism.
They form a protective microscopic film on the coolant side of the liner by transforming the ferric oxide
(rust), which is very soft, into Fe3O5, which is very hard. This very hard film resists damage from the
implosion of air bubbles. As long as the concentration of SCA is high enough, any damage to the
protective coating will be healed. Borate/nitrate SCAs are still commonly used, however, they rely on
nitrite for their protection against liner pitting. High concentrations of nitrate are aggressive against the
solder in the radiator. These inhibitors also rely on large amounts of silicate to protect against aluminum
corrosion. Silicate is already present in large amounts in many commercial antifreezes. The combined
silicate can cause silica gel to form, "green goo" that plugs coolant passages.DCA4 contains 30-40%
as much nitrite as the botrate/nitrite SCAs. Fleetguard discovered that a mixture of nitrite and molyb-
date provides better liner pitting protection that nitrite alone. This lower level of nitrite also allows
DCA4 to provide better protection against solder corrosion than botrate/nitrite SCAs.
CAUTION: THE RECOMMENDED CONCENTRATION LEVEL OF DCA4 IS ONE UNIT PER

GALLON ON COOLANT. THE LEVEL MUST NEVER EXCEED TWO UNIT PER GALLON
OR DROP BELOW ONE HALF UNIT PER GALLON OF COOLANT.
PREVENTATIVE MAINTENANCE
SCA is added to the coolant to provide necessary protection against liner pitting and scale. Most
often, the SCA is contained in a coolant filter which service the dual purpose of keeping the cooling
system clean of debris and providing a convenient way to add the necessary makeup SCA at the same
time other filters are changed. Sounds simple, but lots can go wrong.
There is frequent confusion regarding the initial SCA charge of a cooling system versus the service
dose used to maintain the concentration. The required recharge dose is three to four times the amount
added at the service interval. If maintenance personnel do not understand the need to precharge, the
SCA concentration is never sufficient to protect the cooling system.
The issue of precharging is further complicated because to do it right, cooling system capacity must be
known...information that is not always readily available. In a large over-the-road fleet with many differ-
ent vehicles, the cooling system capacity can range from 8-18 gallons. The same amount of SCA can
adequately precharge the 8 gallon system, but leave the 18 gallon system marginally treated at best.
59 04/04
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. If a vehicle loses more than 2 gallons of coolant in a service interval
(15-18,000 miles), changing the coolant filter or adding a pint of liquid SCA WILL NOT maintain
liner pitting protection.
The complications of precharge versus service and how to deal with coolant leaks, causes many
cooling systems to get out of control. When the SCA is under-treated, you can expect liner pitting.
There are two ways to maintain proper SCA concentration on a vehicle with a leaky cooling system.
You can resort to frequent coolant testing, or use Fleetguard's Compleat antifreeze for the initial fill
and subsequent topping off of the system. Compleat contains DCA4 and eliminates much of the
complexity involved in cooling system preventative maintenance.
TROUBLESHOOTING WHEN A PITTED LINER IS FOUND
Review maintenance records to see if the proper amount of chemical has been maintained in the syst-
em. The addition of large amounts of makeup water should be a signal that more than likely SCA
was not added every time water was. Review maintenance practices. Are radiators topped off above
the fill neck? If so, there is no expansion area remaining in the top tank, and when the engine warms
up, coolant will be forced out of the system. This leads to dilution of the SCA unless more SCA is
added every time the radiator is filled. Look at the liners. If there is a coating of any kind, most likely
the level of SCA was not adequate. The SCA in the proper amount will protect against the formation
of scale or oil coatings. The microscopic protective coating of ferrous oxide is invisible and will not be
seen by the naked eye. Review oil analysis records, if available, for traces of potassium which indicate
leakage of coolant into the oil and oil into the coolant.
COOLANT TESTING
The level of protective DCA4 chemicals can easily be determined using Fleetguard Coolant Test Kit
CC2626. This is the most effective field test kit for heavy duty engines available today. It will mea-
sure SCA protection levels, even if the system contains the old borate-nitrite based SCA, DCA4, or
any mixture of the two. In addition, Fleetguard offers Monitor-C (CC2700), a laboratory analysis
service for monitoring or troubleshooting diesel engine cooling system. In addition to measuring SCA
levels, Monitor C provides information on freeze protection and the level of corrosion products.
Analysis of fresh water samples is also available to measure sulfate, chloride, and total hardness levels.
60 04/04
AIR FILTER MAINTENANCE
BASIC ELEMENT SERVICE PRECAUTIONS
61 04/04
AIR FILTER MAINTENANCE
CAUTION: 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; cup must seal 360° around the
air cleaner.
2. A damaged or missing vacuator valve.
3. Plugging or buildup in the vanes of the

pre-cleaner.
4. Damage to the pre-cleaning section of

the air cleaner.
THE PROBLEM OF AIRBORNE

CONTAMINANTS ENTERING THE
ENGINE
1. Check to make sure the element has

not been damaged in handling. Examine
for dents and holes.
2. Check to make sure all gaskets are

sealing. Examine for dust trails which
indicate leaks. Check to be certain wing
nut is tight.
3. Examine the clean air transfer tubing for

cracks, loose clamps, or loose flange
joints.
4. Check ether fittings (if used) to be cer-

tain no contaminants are entering the
engine through these connections.
5. Check the service indicator for damage,

working lockup function and correct
calibration per engine manufacturer's
recommendation.
62 04/04
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 1800 RPM.
Overheating of 1. Continuous operation at relief setting:

system A. Stalling under load, etc.
B. Fluid viscosity too high.
2. Excessive slippage or internal leakage:
A. Check stall leakage past motors.
B. Fluid viscosity too low.
Pump picking 1. Low oil level. Refill to 3/4 full.

up air 2. Loose or damaged inlet hose. Replace hose.
3. Aeration of fluid in reservoir. Check oil return pipes in reservoir.
4. Worn or damaged pump shaft or seal. Replace.
Other Noises 1. Worn or damaged gears and housings. Replace pump.

2. Shaft misalignment. Realign shaft.
3. Worn or faulty bearing. Replace bearing.
No Pressure 1. Low oil level. Refill to 3/4 full.

2. Pump cartridge turning wrong direction. Reverse cartridge.
3. Pump shaft broken. Replace.
4. Relief valve sticking. Clean or replace.
5. Oil bypassing through solenoid valve. Replace solenoid valve.
Erratic Pressure 1. Contaminates in fluid. Replace fluid.

2. Worn or sticking relief valve. Clean or replace.
3. Pressure setting too low. Check and reset pressure at relief.
Solenoid valve not working 1. Faulty pump. (Refer to hydraulic information.)

2. Directional control shifting. Check voltage to solenoid coils.
3. Spool not shifting. Check internal pilot pressure for sticking.
4. Spool binding. Remove and clean.
Slow or erratic 1. Air in fluid.

operation 2. Low fluid level. Fill to 3/4 full.
3. Viscosity of fluid too high. Use recommended hydraulic oil.
4. Internal leakage through solenoid or manual valves. Replace
with new valves.
5. Worn pump. Replace pump.
6. Pump RPM too slow. (Refer to hydraulic information.)
7. Pump belts too loose. Tighten or replace.
63 04/04
TROUBLE SHOOTING
CHIPPER AND FEED WHEELS
PROBLEM PROBABLE CAUSES AND SOLUTIONS
Chipper feeding 1. The anvil is set too close to the knives. This will cause a
burning effect on the knives. Change setting.
2. Knives ground at incorrect angle. Grind knives at 31°.
(Refer to maintenance section.)
3. Wood is extremely dry or dirty.
4. Wood is frozen or very hard. Grind knives for frozen wood
according to knife grinding instructions.
5. Poor quality of chipper knives. We recommends knives
manufactured by MORBARK Inc.
6. Dull chipper knives. This tears the wood. Sharpen. Refer to
knife grinding instructions.
7. Chipper disc RPM is too slow. Do not operate chipper drum
above 980 RPM'S (with no load).
Wood packing
counter knife 1. Foreign material in pocket, not allowing the hardware to seat
properly. Always clean the knife pocket properly when chang-
ing knives.
DANGER/CRUSH HAZARD: Always install the center feed wheel yoke locks when
working under the center feed wheel. Never raise this wheel or work under it, even for a
few seconds without first inserting the lock bar in the cab and the opposite side of the
center feed wheel, clipping the hook into the holder.
64 04/04
TROUBLE SHOOTING
HYD OIL TEMPERATURE MINIMUM 100°
BED CHAIN 2250 PSI CHARLYNN DRIVE

TOP YOKE FEED WHEEL 2250 PSI CHARLYNN DRIVE
FRONT STAB BANK 2000 PSI

MAIN RELIEF 2000 PSI
SPOUT TURN 1500 PSI
NOTE: DUE TO VARIANCES IN DIFFERENT MANUFACTURES GAUGES, WE RECOM-

MEND YOU CONFIRM THE ACCURACY OF YOUR PRESSURE GAUGE WITH A SECOND
GAUGE
65 04/04
STEPS TO FOLLOW IF YOU FEEL YOU HAVE A WARRANTABLE FAILURE
1. Order the repair parts from Morbark. Contact us at (800) 255-8839.

a. Inform the Morbark parts person that it is a possible warranty and he will send a claim form
with instructions necessary for filing a claim.
b. All parts leaving Morbark will be invoiced to the customer. When the failed parts and
completed warranty claim form are returned to Morbark and the cause of failure is determined
to be a defect in materials or workmanship, a credit will be issued.
c. If labor expenses are to be considered for reimbursement, a completed and approved “Prior
Authorization” form must be on file at Morbark and attached to the warranty claim upon
completion.
2. Filling out the claim form:
a. Fill in the date.
b. Customers phone number.
c. Fill in failure date.
d. Dealer name does not apply on direct sales, region # and sales/service rep’s name if it is being
filled out by one of our field reps.
e. Model and S/N and hours on unit at time of failure.
f. Customer name, address.
g. Customer delivery date.
h. Customer complaint in detail. Attach more sheets if necessary.
i. Parts used, quantity, part number, description and price invoiced. Attach Morbark, Inc.’s
invoice. For any outside purchases, you’ll need to attach invoices from the supplier. Morbark
retains the right to refuse any claim where Morbark replacement parts were not used.
j. Authorized by: The contact person at the customer’s site if more information is required.
3. After replacing the defective components:

a. Box up the failed parts.
b. Ship the warranty consideration parts to: MORBARK, INC., 8507 S. Winn Road, Winn, MI
48896, ATTENTION: Warranty Returns
c. Use the pink copy of the claim, along with a copy of the Morbark invoice as a packing slip.
d. The customer keeps the golden rod copy for his records and any future inquiries concerning
the claim.
e. 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 be
received for warranty consideration.
If there are any questions or comments, please call the Warranty Department.
66 04/04
WARRANTY
67 04/04
68 04/04

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3036 NCL

Diesel engine exhaust and some of its constituents are

RADIATOR SCREEN FUEL TANK CHIPPER

DANGER indicates an imminently hazardous situation which, if not

WARNING indicates a potentially hazardous situation, which if not

CAUTION indicates a potentially hazardous situation which, if not

OBSERVE "CAUTION" MESSAGES

DO NOT MODIFY MACHINE

Be sure everyone is clear of the machine. Sound horn

Be sure shields and guards are in place and in good

Never attempt to clean infeed bed area unless power

Never leave the machine running and unattended.

Always wear proper personal protective equipment at

Always stay clear of all hazards such as ditches and

Always wear gloves when changing or servicing the

Always use grab rails and safety steps.

Never smoke, weld or use any type of flame near the

CAUTION: All personnel shall read this

PROTECT AGAINST NOISE

Prolonged exposure to a loud noise can cause impair-

Never attempt to unplug the infeed bed or drum

Do not hand feed this machine for any reason.

DO NOT MODIFY MACHINE

Never refuel with power unit running.

Never smoke or have an open flame when refueling.

Use only in a well ventilated area and away from any

AVOID HIGH PRESSURE FLUIDS

If injured, seek emergency medical help. Immediate

Do not use finger or skin to check for leaks.

Lower load or relieve hydraulic pressure before

Batteries generate explosive gases. Keep sparks,

AVOID SHARP EDGES

When handling any steel with sharp or jagged edges

AVOID ELECTRICAL HAZARDS

Understand all electrical schematics before attempt-

Keep your machine damage-free.

Follow the advice on these pages to reduce vandalism,

RECORD IDENTIFICATION NUMBERS

1. Record Serial Number (S/N) of machine and

MAINTAIN DOCUMENTED PROOF OF OWNERSHIP

1. Keep in safe location all documents (invoices,

1. Remove ignition key and lock the engine

1. Park out of sight as much as possible.

1. Install vandal protection devices,

1. If a theft occurs, notify the law enforcement

1. Perform daily maintenance.

Note: Individual engines may vary from the

5. KEY SWITCH - Used in conjunction with

6. PERMISSIVE START BUTTON -

7. THROTTLE SWITCH - Push toggle up

8. DIAGNOSTIC SWITCH - Refer to

9. HORN BUTTON - Push button to sound

CAUTION: Use horn to clear the area

CARE AND HANDLING OF SYSTEM

2. ENGINE STOP SWITCH - This switch 6. SPOUT DEFLECT SWITCH - This

THE LIST READS FROM LEFT TO RIGHT

3. THROTTLE SWITCH - This switch will 8. FEEDWORKS SWITCH - This switch

4. YOKE SWITCH - This switch will raise or 9. OPTIONAL CHIP DEFLECT

THE LIST READS FROM LEFT TO RIGHT

DANGER/CRUSH HAZARD: Keep

THE LIST READS FROM RIGHT TO LEFT

THE LIST READS FROM RIGHT TO LEFT

1. THROTTLE SWITCH - Push toggle 5. YOKE Raise/Lower - Turn the switch to

4. FEEDWORKS - Turn the switch to the