BIG POWER IN ALL PLACES
Boxer X7 Chipper Owner’s Manual Serial No.s 4582 & Higher Part No. 76340-262
Phone: Sales - 800-831-0042 Parts and Service - 800-255-8839 www.boxerequipment.com
Morbark®, LLC. 8507 S. Winn. Rd., P.O. Box 1000, Winn, Michigan 48896 www.morbark.com
MANUAL REVISION LOG Revision: Date Issued:
Pages Affected:
Description of Changes:
-
July 14, 2015
All
Initial Release
A
Oct. 7, 2015
x, 103, 104
Added Appendix B
B
Oct 15, 2015
105
Added Trailer Schematic
C
Sept. 9, 2016
108
Update Schematic
D
Oct. 12, 2018
96-97
Updated Illustration & BOM
E
Nov. 16, 2018
14
Removed Decal 39510232ES per ECO 17380
iii
Write your machine Serial Number in the space below for future reference. The serial number is located on the metal tag on the left side of the machine frame.
MANUFACTURED BY: WINN, MICHIGAN, USA DATE OF MANUFACTURE S.N.
MODEL NO. ENGINE SERIAL NO. WEIGHT POWER
LB
KG
HP
KW
MORBARK, INC Sales (800) 831-0042 Parts and Service (800) 255-8839 www.morbark.com
Record SERIAL NUMBER here
Figure 1.1- S/N Tag
iv
Boxer Product Warranty Morbark, LLC. (Morbark) warrants to the original purchaser that this product will be free from defects in materials and workmanship under normal use and operating conditions subject to the conditions and exclusions stated below. No representative, agent or dealer of Morbark or any other person is authorized to modify, expand or extend this warranty in any manner or make any representation on Morbark’s behalf in connection with the sale of any product covered by this warranty. The warranty period starts with the start-up in-service date. See the Warranty Period Chart for information on the warranty period.
EXCLUSIONS This warranty shall not apply to:
1. Product which has been subject to misuse, neglect, modification, alteration, accident or lack of normal maintenance or service. 2. Fire damage. 3. Labor, unless provided by an authorized Morbark dealer.
REMANUFACTURED PARTS Morbark reserves the right to use re-manufactured parts, when available, for warranty replacement parts. The re-manufactured component has the same warranty as if it was new.
PURCHASER’S EXCLUSIVE REMEDY The exclusive remedy of the purchaser in the event the product does not conform to this Warranty shall be repair or replacement of the product (at the option of Morbark) without charge to the purchaser, when the product is returned to Morbark’s factory at 8507 South Winn Road, Winn, Michigan, 48896 or at such other locations as may be designated by Morbark. Morbark shall have sole discretion to determine whether and to what extent the product is defective in material or workmanship. The acceptance by Morbark of any product returned is not an admission that the product is defective and if Morbark determines the product is not covered by this Warranty, the product may be returned to the purchaser at purchaser’s expense.
DISCLAIMER OF WARRANTY This warranty is in lieu of all other warranties express or implied. Morbark makes no other warranties regarding the equipment and in particular, makes no implied warranty of merchantability or fitness for a particular purpose, which are expressly disclaimed.
LIMITATION OF DAMAGES Morbark shall not be liable for any incidental or consequential damages, directly or by subrogation, including, but not limited to, any claims for fire damage, lost profits, downtime or loss of use in the event the product is defective.
v
Morbark, LLC. 8507 S. Winn Rd., P.O. Box 1000, Winn, Michigan 48896 Phone: Sales - 800-831-0042, Parts and Service - 800-255-8839 www.morbark.com
LIMITATION OF DAMAGES Morbark Manufactured Components
Product Description
Vendor Purchased Components
Extended Coverage
New Boxer Compact Utility Loaders
One (1) year/1,000 hours; whichever comes first
Warranty from vendor Can purchase prior to applies, minimum of one start-up (1) year
Used Equipment
As stated on equipment order
N/A
N/A
New Engines
N/A
See Engine Warranty Statement
Can purchase prior to start-up or possibly up to two (2) years after startup depending on the programs offered by the engine supplier
Wear Items including but not limited to such items as, lubricants, anti-freeze, fluids, filters, belts, bearings, hoses and fittings, etc…
Manufacturer’s limited warranty extended to the original purchaser to cover conditions that are reasonably considered to have been within the manufacturer’s control. Conditions not within the manufacturer’s control such as irregular wear, lack of maintenance, damage due to accidents or vandalism are not covered.
Manufacturer’s limited warranty extended to the original purchaser to cover conditions that are reasonably considered to have been within the manufacturer’s control. Conditions not within the manufacturer’s control such as irregular wear, lack of maintenance, damage due to accidents or vandalism are not covered.
N/A
vi
Boxer® Warranty Registration Dear Customer,
Morbark, LLC., manufacturer of the Boxer® products, would like to thank you for your purchase. Morbark is committed to providing unsurpassed products and product support to our customers. To accomplish this, we need to update our database with information regarding your purchase. Currently, the warranty start date (in-service date) is listed as the date the Boxer® product left Morbark, LLC., which may be several months before you received and placed your new Boxer® product into service. To ensure you get the full warranty coverage for your purchase, Morbark, LLC. will restart the warranty start date (in-service date) if you complete the information below and return this form to us with a copy of the equipment invoice (bill of sale) verifying the in-service date of your Boxer® product. Without receipt of this form, we will continue to use the original equipment ship date as the warranty start date (inservice date) and not returning this form may result in denial of warranty entitlements. To restart the equipment in-service date, simply complete the form below and mail, e-mail, or fax the completed form and bill of sale to: Morbark, LLC. P.O. Box 1000 8507 S. Winn Road Winn, MI 48896-1000 E-mail:
[email protected] Fax: (989) 866-2280 FOLD
Company Name: __________________________ Contact Name: _______________________ Address: ____________________________________________________________________ City: ___________________ State/Province: __________ Zip/Postal Code: ______________ Phone:
________________ E-mail address: ______________________________________
Model No.________________ Serial No._______________ Engine S/N: _________________ Location Purchased: ____________________________
Date Purchased: _____________
I, (the purchaser), have read and fully understand the operator’s manual, safety instructions and warranty conditions provided with this equipment. In-service date restart will only be accepted if this form and a copy of the bill of sale is completed and returned within 30-days of the in-service date.
Customer Signature: ______________________________________ Date: _______________
vii
- fold here -
Affix Stamp Here
Morbark, LLC. 8507 S. Winn Rd. P.O. Box 1000 Winn, MI 48898
viii
TABLE OF CONTENTS
Section 1 - Safety............................................................................. 1 Safety Labels (Dangers, Warnings & Cautions) & Notices.............1 Safety Notes....................................................................................2 General....................................................................................... 2 Refueling Operations.................................................................. 2 Operating Area............................................................................ 2 Personal Protective Equipment...................................................... 3 Safety Check List........................................................................... 4 Safety Decals & Locations............................................................. 6 Lockout Procedure....................................................................... 16 Engine Lockout......................................................................... 16 Chipper Hood & Disc Lockout................................................... 17 Section 2 - Machine Description/Overview���������������������������������� 21 Major Components....................................................................... 21 EngineComponents..................................................................... 23 Engine Controls & Indicators....................................................... 24 Discharge Chute.......................................................................... 25 Section 3 - Operating Procedures................................................ 27 Transporting the Machine............................................................ 27 Connecting the Trailer............................................................... 27 Pre-Towing Checklist................................................................. 28 Safety Tips for Driving While Towing......................................... 29 The Chipping Cycle (Overview)................................................... 31 Machine Setup/Op Area Setup.................................................. 31 Brush Preparation..................................................................... 32 Feeding Brush Into the Chipper................................................ 33 Machine Setup/Preparation....................................................... 35 Pre-Start Checklist....................................................................... 36 Engine Startup............................................................................. 38 Chipping Wood............................................................................. 39 Engine Shut-down........................................................................ 40 Section 4 - Service & Maintenance Procedures�������������������������� 41 Routine Maintenance Schedule................................................... 41 Engine.......................................................................................... 42 Checking Engine Oil.................................................................. 42 Oil & Filter Replacement........................................................... 43 Air Filter Replacement............................................................... 44 Drive Belt Replacement............................................................... 46 Adjusting Belt Tension.................................................................. 47 Battery Maintenance.................................................................... 49 Tire Maintenance......................................................................... 50 Tire Replacement...................................................................... 51 Hydraulic...................................................................................... 52 General..................................................................................... 52 Testing the Hydraulic Oil........................................................... 53 Changing the Hydraulic Oil & Filter........................................... 54 Checking & Filling Hydraulic Oil Level...................................... 56 ix
TABLE OF CONTENTS, CONT.
Hydraulic Oil Filter Replacement............................................... 57 Refueling...................................................................................... 58 Fuel Specifications.................................................................... 58 Filling & Storage of Fuel............................................................ 59 Discharge Chute Cleaning........................................................... 59 Chipper Disc Knives..................................................................... 60 General Guidelines................................................................... 61 Accessing the Chipper Knives.................................................. 61 Inspecting the Chipper Knives.................................................. 62 Replacing the Chipper Knives................................................... 63 Sharpening the Chipper Knives................................................ 64 Anvil Maintenance........................................................................ 66 General Notes........................................................................... 66 Accessing the Anvil................................................................... 67 Inspecting the Anvil................................................................... 69 Flipping or Replacing the Anvil.................................................. 70 Adjusting Anvil Clearance......................................................... 71 Lubrication................................................................................... 73 Lubrication Points...................................................................... 73 Machine Storage.......................................................................... 75 Torque Tables............................................................................... 75 Troubleshooting........................................................................... 78 Hydraulic................................................................................... 78 Chipper...................................................................................... 80 Tachometer Setup & Operation.................................................... 81 Tachometer Description............................................................ 81 Tach Functions.......................................................................... 81 Section 5 - Parts Breakdown......................................................... 83 Major Assemblies ........................................................................ 83 Frame Assembly.......................................................................... 84 Infeed Assembly........................................................................... 8 8 Infeed Tower Assembly................................................................ 92 Bump Bar Assembly..................................................................... 9 4 Yoke Assembly............................................................................. 9 5 Base Assembly............................................................................ 96 Disc Assembly.............................................................................. 98 Discharge Assembly.................................................................... 99 Hydraulic Tank Assembly........................................................... 100 Fuel Tank Assembly................................................................... 102 Engine Assembly....................................................................... 104 Appendix A - Routine Maintenance Replacement Parts����������� 106 Appendix B - Hose List............................................................... .106 Appendix C - Schematics........................................................... .107
x
Section 1 - Safety Safety Labels (Dangers, Warnings & Cautions) & Notices Be Prepared - Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol. Wherever it appears, either in this manual or on safety signs on the machine, you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures. Learn the Signal Words Used with the Safety Alert Symbol The words “DANGER”, “WARNING”, and “CAUTION” are used throughout this manual and on labels on the machine to indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe the precautions indicated whenever you see the Safety Alert symbol no matter which signal word appears next to the Safety Alert symbol.
DANGER Indicates a hazardous situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.
WARNING Indicates a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice.
CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice.
NOTICE This type of statement is used to draw attention to a procedure that needs to be followed to prevent machine damage. 1
Section 1 - Safety Safety Notes General Before operating this machine: • Read this manual and be familiar with all the safety procedures • Be aware of all the dangerous areas • Follow the operating procedures in this manual and take heed of all DANGERS, WARNINGS & CAUTIONS described within it • Make sure all equipment components and safety features are undamaged and in proper working order • Perform all pre-operational and daily maintenance checks While operating this machine: • Do NOT become complacent when operating this machine • Always wear personal protective equipment listed in this manual • NEVER allow small children to be in the vicinity of the machine • Keep away from all moving parts • Use caution and keep your balance when working around machine Refueling Operations • Turn the engine off and allow to cool before adding fuel • Fuel and fuel vapors are highly flammable: Do not add fuel around an open flame or where sparks are likely to occur • Do not store fuel in the machine; use only approved containers for fuel storage • Never transport flammable liquids on the machine Operating Area • Make sure machine is a safe distance from exposed utility infrastructure (e.g., gas, water, phone & power lines) • Always set the machine on flat and stable ground (surface) - Do not operate the machine on sloped or unstable ground • Operate in a well ventilated area
2
Section 1 - Safety Personal Protective Equipment Always wear the personal protective equipment described below when operating this machine.
,
Plugs) & Face Shield (or Safety Glasses)
®
1. Hard Hat, Ear Muffs (or Ear
,
1
2
2. Long hair should be contained
in a hair net, or under the hard hat
3. Shirt must be close fitting with shirt tails tucked in
4. Gloves (without cuffs). NEVER
wear gauntlet-style gloves (cuffs at the wrists)
5. Pants (without cuffs) - preferably
3
6. Hard-toe, non-skid work boots
4
tucked into boots
5 6
3
Section 1 - Safety Safety Check List Have the following equipment available at work site when operating:
q Emergency equipment: • communication device
• stocked first aid kit
• approved, charged fire extinguisher
q Personal clothing and protective gear:
• hard hat
• safety goggles
• ear protection
• hard toe work boots with non-skid soles
• gloves without cuffs (note: Never wear gauntlet style gloves due to the possibility of snagging).
• shirt is close fitting and tucked in.
• pants without cuffs.
• long hair is contained in a hair net or wrapped underneath
the hard hat. Daily Maintenance
q All recommended grease points are greased (see Maintenance section). q Hydraulic oil, engine oil, and fuel is at their proper levels and clean. Machine Inspection
q Machine is clean and debris is removed from around the engine, muffler, chipper housing, infeed, and discharge chutes.
q All safety devices and controls (safety cables, locking pins) are in good condition and operating properly.
q Shields and guards are in place and in good condition. q Battery cables, electrical wiring, and connections are in good shape and do not have cracks. 4
Section 1 - Safety
q Fuel and oil line connections are securely attached to the fittings and there is no sign of fluid leakage. Tubes and hoses are in good condition.
q Filler caps and drain plugs are securely attached to the machine. q Hood latches and pins are in place. q Components, parts, and hinges are not broken or cracked. q Hardware (e.g., bolts, nuts, pins) are in place and tightened. q All tires are properly inflated according to the manufacturer’s specifications.
q All safety decals are clean and legible. If not, replace all missing or damaged labels.
q The product manuals are in good shape and in the manual holder. Work Site
q At least two trained operators at the work site. Never leave one person at the work site alone.
q Foreign objects are removed from the work area. q The machine is set up in a safe environment (e.g.: no power lines) and in an area that is well lit and ventilated.
q All spectators are at a safe distance from the machine. Set Up
q The machine is set up on a flat and stable ground or surface. q If the chipper is attached to a truck or van, the hitch is secure, the safety chains are properly attached, the brake is on, and no one is in the vehicle.
q If the chipper is not attached to a vehicle, ensure chocks are placed under the wheel.
5
Section 1 - Safety Safety Decals & Locations (1 of 10)
1
2
3
4
Figure 1 Item No. 1 2 3 4
6
Part No. 39511-312ES 39513-588 39510-206 39510-207
Description SAFETY CONTROL BAR X7 LOGO KIT GREASE GREASE
Section 1 - Safety
Safety Decals & Locations (2 of 10)
10 3 1
2
9 8 6
7
5
4
Figure 2
Item No. 1 2 3 4 5 6 7 8 9 10
Part No. 39510-212ES 39510-212ES 39510-228ES 39511-010ES 39513-588 39510-238ES 39510-203ES 39510-298ES 39513-588 39511-213ES
Description DANGER, MOVING PARTS DANGER, MOVING PARTS WARNING, STAY CLEAR MANUFACTURED IN USA X7 LOGO KIT HYDRAULIC OIL DANGER, CRUSH HAZARD NOTICE, RAISE INFEED TRAY X7 LOGO KIT CAUTION, BOLTS MUST BE PROPERLY LUBRICATED AND TORQUED
7
Section 1 - Safety Safety Decals & Locations (3 of 10) 1
2
3 4 5 6
Figure 3
Item No. 1 2 3 4 5 6
8
Part No. 39510-225ES 39511-399S 39510-008 39510-206 39510-206 39510-235
Description WARNING, CHIPPER LOCK ADVERTENCIA OPERATOR AND PARTS MANUAL ARE IN THIS CONTAINER GREASE GREASE CHIPPER LOCK
Section 1 - Safety Safety Decals & Locations (4 of 10) 1
Figure 4 Item No. 1
Part No. 39510-228ES
Description WARNING, STAY CLEAR
9
Section 1 - Safety Safety Decals & Locations (5 of 10)
1
3 2 4
5
6
7 8
11
9
10 Figure 5
Item No. 1 2 3 4 5 6 7 8 9 10 11
10
Part No. 39510-205ES 39510-222ES 39510-254ES 39510-215ES 39511-211ES 39510-206 39510-300 39510-301S 39510-209ES 39510-216ES 39510-216ES
Description DANGER, CRUSH HAZARD WARNING FLAMMABLE NOTICE, BELT TENSION WARNING, READ BEFORE OPERATING NOTICE BEFORE WELDING ON MACHINE GREASE NOTICE, SPARKS AVISO NOTICE, HYDRAULIC OIL SIGHT GAGE WARNING, AUTOMATED FEED SYSTEM WARNING, AUTOMATED FEED SYSTEM
Section 1 - Safety
Safety Decals & Locations (6 of 10)
1
2
Figure 6 Item No. 1 2
Part No. 39510-240ES 39510-231ES
Description CONTROL BAR POSITIONS DANGER, CRUSH HAZARD, ENTANGLEMENT HAZARD
11
Section 1 - Safety Safety Decals & Locations (7 of 10)
1
2
Figure 7 Item No. 1 2
12
Part No. 39510-241ES 39510-249ES
Description CONTROL BAR POSITIONS DANGER, CRUSH HAZARD, ENTANGLEMENT HAZARD
Section 1 - Safety
Safety Decals & Locations (8 of 10)
2
3 4
5
6 7
1
11
10
8
9
Figure 8 Item No. 1 2 3 4 5 6 7 8 9 10 11
Part No. 39510-206 39510-204ES 39510-206 39510-207 39510-208ES 39510-327 39510-219ES 39510-308ES 39510-220ES 39511-752 39510-218ES
Description GREASE DANGER, ROTATING BLADES AND THROWN DEBRIS HAZARD GREASE GREASE WARNING, WEAR PROPER SAFETY GEAR X7 CONSUMABLES WARNING, DO NOT REMOVE DECALS FROM THIS MACHINE WARNING, WHEEL TORQUE REQUIREMENTS NOTICE, TOWING MORTHANE INDUSTRIAL COATING WARNING, MOVING PARTS CAN CRUSH AND CUT DO NOT OPERATE WITH GUARD REMOVED
13
Section 1 - Safety Safety Decals & Locations (9 of 10) 1
2 3
12
4
11
10
5 9
6
8
7 Figure 9
Item No. 1 2 3 4 5 6 7 8 9 10 11 12
14
Part No. 39510-311ES 39510-310ES 39510-207 39513-588 39510-298ES 39510-203ES 39510-226ES 39510-248 39513-588 39510-230ES 39510-207 39510-212ES
Description FLYING MATERIAL ROTATING BLADES AND THROWN DEBRIS HAZARD GREASE X7 LOGO KIT NOTICE, RAISE INFEED TRAY DANGER, CRUSH HAZARD YOKE LOCK GASOLINE X7 LOGO KIT PATENTS OR PATENTS PENDING GREASE MOVING PARTS CAN CRUSH AND CUT FOLLOW LOCKOUT PROCEDURES BEFORE SERVICING
Section 1 - Safety
Safety Decals & Locations (10 of 10)
1
Figure 10
Item No.
Part No.
1
39513-588
Description X7 LOGO KIT
15
Section 1 - Safety Lockout Procedure
DANGER Failure to properly secure/lockout the machine as described in this manual may result in serious injury or death. Engine Lockout Locking out the machine prevents unexpected start-up or motion, release of stored energy, and operation of the machine. It is mandatory the machine is locked out when left unattended, shutdown, or while performing maintenance. As a safety and crime prevention method, electrical power (battery) must be disconnected when the machine is being stored. Only authorized personnel shall perform maintenance on this machine. Maintenance personnel shall always lockout the machine using the steps below, prior to performing maintenance. 1. Place the control bar in the stop position. 2. Shut down engine and remove the key from the ignition switch. 3. Disconnect the negative (-) battery cable from the battery. 4. See Figure 11. Close battery box lid and secure using a pad lock.
Figure 11 5. Disconnect all spark plug leads from spark plugs. 16
Section 1 - Safety
NOTICE If maintenance being performed requires you to access the chipper disc perform the Chipper Hood & Disc Lockout procedure. Chipper Hood & Disc Lockout 1. See Figure 12. Remove hood lock pin (A) and disc lock pin (B) from holders. A
B Figure 12 2. See Figure 13. Remove nuts (A) & bolts (B) securing hood to base. B
A
Figure 13 17
Section 1 - Safety 3. See Figure 14. Unplug the hood safety switch (A) from the plug receptacle. A
Figure 14
18
Section 1 - Safety 4. See Figure 15. Manually rotate the discharge/hood assembly to the open position. 5. Insert hood lock pin (A) through housing and secure with lynch pin. 6. Manually rotate the chipper disc in direction of arrow until hole in disc is aligned with hole in housing. Insert disc lock pin (B) through housing into hole in disc.
B
A
Figure 15 (Parts Hidden for Clarity)
19
Section 1 - Safety
THIS PAGE INTENTIONALLY LEFT BLANK
20
Section 2 - Machine Description/Overview Major Components (1 of 2) 2
4 3
1
5
17
6 7 9 15 16
14
13
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
10
12
FIGURE 16
8
11
Description Adjustable Deflect Adjustable Discharge Chute Chipper Disc Housing Control Bar Safety Cables Infeed Yoke Lock Pin Jack Mount Feed Wheel Motor Wheel/Axle Assembly Fuel Gauge (Fuel Tank) Fuel Fill Cap (Fuel Tank) Jack Mount Lockable Battery Box Jack Hitch Engine
21
Section 2 - Machine Description/Overview Major Components (2 of 2)
14
13
15 1
2 3 4
12
6 11 10
8 9 FIGURE 17
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
22
Description Document Holder Discharge Lock Pin Hood Safety Plug Chipper Housing Lock Pin Tail Light Connector Holder Trailer Light Trailer Frame Jack Mount Chipper Disc Lock Pin Tail Light Hydraulic Oil Tank Infeed Tray Infeed Tray Lock Feed Wheel (Yoke) Hydraulic Pump
7
5
Section 2 - Machine Description/Overview Engine Components
10 1
2 3
9
8
7 6 5
4
FIGURE 18 Item No. 1 2 3 4 5 6 7 8 9 10
Description Air Filter Assembly Throttle Key Switch Muffler/Exhaust Oil Drain Plug Oil Cooler Oil Filter Fuel Filter Oil Fill Cap Oil Dip Stick
23
Section 2 - Machine Description/Overview Engine Controls & Indicators 1
2
3
4
FIGURE 19 1. Engine Throttle – Moving the control lever to the left increases the engine speed and moving the lever to the right slows the engine to idle speed 2. Key Switch – Starts and stops the engine. 3. Indicator Light (Red) – Check Engine Light: Illuminates to indicate an engine malfunction has occured. This light also illuminates whenever the throttle is advanced too quickly. To extinguish, shutdown the engine, inspect and resolve any engine malfunctions then perform the start up procedure again. 4. Indicator Light (Red) – Illuminates to indicate an engine low oil pressure and/or low oil level condition.
24
Discharge Chute
Section 2 - Machine Description/Overview
1 2
3
4
FIGURE 20 1. Deflect Adjustment Handle - Push forward to direct the flow of chips down, pull back to direct the flow of chips up. 2. Deflect Adjustment Friction Lock Handle - Locks the deflect in place once
adjusted by tightening clockwise. Lock handle must be loosened by turning counter-clockwise before adjusting deflect.
3. Discharge Adjustment - Handles allow operator to manually rotate (turn) the
discharge to adjust/direct the flow of chips once friction lock handle is loosened.
4. Lock Pin - Engages a detent in the discharge swivel plate to lock discharge
in place once adjusted. Pin must be pulled down away from detent in order to manually turn discharge.
25
Section 2 - Machine Description/Overview
THIS PAGE INTENTIONALLY LEFT BLANK
26
Section 3 - Operating Procedures Transporting the Machine Connecting the Trailer It is recommended that a safety observer be used to guide the tow vehicle 1. Using the jack, raise the tongue/hitch of the machine until is high enough to safely back the tow vehicle under it. 2. Slowly and carefully back up the towing vehicle until the hitch ball is beneath the hitch. 3. Using the jack, lower the hitch onto the ball until is fully engaged. 4. Lock the hitch onto the ball. 5. Fold the jack up into the transport position. 6. Attach the safety chains to the tow vehicle. 7. Plug the chippers electrical connector to the tow vehicles electrical receptacle. 8. Verify tail lights work properly. 9. Make sure the area is clear and components on trailer/machine are secure.
Ball hitch connection
Electrical connection
Chain connection
Figure 21 27
Section 3 - Operating Procedures Pre-Towing Checklist Before transporting/towing the machine, make sure maintenance on your vehicle is current as towing puts additional stress on the tow vehicle. Use the following checklist to aid in making sure all safety and maintenance checks are in place: • Check tire pressure on both the tow vehicle and trailer. Service tires, as required • Make sure the wheel lug nuts/bolts on the tow vehicle and trailer are tightened to the correct torque • Make sure the tow vehicle is rated (has the capacity) to tow the machine • Make sure the hitch ball is the correct size and is rated for the weight of the machine being towed • Be sure the hitch, coupler, draw bar, and other equipment that connect the trailer and the tow vehicle are properly secured and adjusted • Check that the wiring is properly connected - not touching the road, but loose enough to make turns without disconnecting or damaging the wires • Make sure all running lights, brake lights, turn signals, and hazard lights are working properly • Verify that the brakes on the tow vehicle are operating correctly • Check that all items are securely fastened on the trailer • Be sure the trailer jack, tongue support, and any attached stabilizers are raised and locked in place • Check load distribution to make sure the tow vehicle and trailer are properly balanced front to back and side to side • Check side and rear-view mirrors to make sure you have good visibility • Check routes and restrictions on bridges and tunnels. • Make sure you have wheel chocks and jack stands.
28
Section 3 - Operating Procedures Safety Tips for Driving While Towing Take time to practice before driving on main roads and never allow anyone to ride in or on the trailer. Before you leave, remember to check routes and restrictions on bridges and tunnels. Consider the following safety tips each time you drive with a trailer. General Handling • Use the driving gear that the manufacturer recommends for towing • Drive at moderate speeds. This will place less strain on your tow vehicle and trailer. Trailer instability (sway) is more likely to occur as speed increases • Avoid sudden stops and starts that can cause skidding, sliding, or jackknifing • Avoid sudden steering maneuvers that might create sway or undue side force on the trailer • Slow down when traveling over bumpy roads, railroad crossings, and ditches • Make wider turns at curves and corners. Because your trailers wheels are closer to the inside of a turn than the wheels of your tow vehicle, they are more likely to hit or ride up over curbs • To control swaying caused by air pressure changes and wind buffeting when larger vehicles pass from either direction, release the accelerator pedal to slow down and keep a firm grip on the steering wheel Braking • Allow considerably more distance for stopping • Always anticipate the need to slow down. To reduce speed, shift to a lower gear and press the brakes lightly Acceleration and Passing • When passing a slower vehicle or changing lanes, signal well in advance and make sure you allow extra distance to clear the vehicle before you pull back into the lane • Pass on level terrain with plenty of clearance. Avoid passing on steep upgrades or downgrades 29
Section 3 - Operating Procedures • If necessary, down shift for improved acceleration or speed maintenance • When passing on narrow roads, be careful not to go onto a soft shoulder. This could cause your trailer to jackknife or go out of control Downgrades and Upgrades • Down shift to assist with braking on downgrades and to add power for climbing hills • On long downgrades, apply brakes at intervals to keep speed in check. Never leave brakes on for extended periods of time or they may overheat • Some tow vehicles have specifically calibrated transmission towmodes. Be sure to use the tow-mode recommended by the manufacturer Backing Up • Put your hand at the bottom of the steering wheel. To turn left, move your hand left. To turn right, move your hand right. Back up slowly. Because mirrors cannot provide all of the visibility you may need when backing up, have someone outside at the rear of the trailer to guide you, whenever possible • Use slight movements of the steering wheel to adjust direction. Exaggerated movements will cause greater movement of the trailer. If you have difficulty, pull forward and realign the tow vehicle and trailer and start again Parking • Try to avoid parking on grades. If possible, have someone outside to guide you as you park. Once stopped, but before shifting into Park, have someone place blocks on the downhill side of the trailer wheels. Apply the parking brake, shift into Park, and then remove your foot from the brake pedal. Following this parking sequence is important to make sure your vehicle does not become locked in Park because of extra load on the transmission. For manual transmissions, apply the parking brake and then turn the vehicle off in either first or reverse gear • When uncoupling a trailer, place blocks at the front and rear of the trailer tires to ensure that the trailer does not roll away when the coupling is released. 30
Section 3 - Operating Procedures • An unbalanced load may cause the tongue to suddenly rotate upward; therefore, before un-coupling, place jack stands under the rear of the trailer to prevent injury
The Chipping Cycle (Overview) Machine Setup/Op Area Setup Before any chipping can begin, there are three important areas to inspect, set-up, and prepare each time you use the chipper. The work site, the brush and the chipper. Work Site Preparation • Clear objects containing metal, stones, etc. that may damage the machine • Clear any objects that may trip or entangle the operator • Check that the area is clear of utility and power lines • Be sure the area is well lit with good ventilation (when indoors) • Set-up a sufficient space to work in • Designate an area for the brush pile and chipped wood • Create a clear walking path for loading the brush • Ensure emergency equipment is available on the work site • Always have two trained personnel dressed in safety gear on the work site at all times Proper preparation and organization of the brush and branches will provide an efficient chipping process, as well as creating safe working conditions and reducing the possibility of unexpected maintenance expenses.
31
Section 3 - Operating Procedures Brush Preparation
DANGER Foreign material (metal, stones, glass) in the chipper will cause damage and potentially shatter the chipper knives resulting in property damage, serious injury or death. Vines left on the wood may cause entanglement of operating personnel, or hide foreign material resulting in equipment damage, serious injury or death. Always remove vines from the material to be chipped. Do not leave vines in the work area or place vines in the chipper.
CAUTION Lifting heavy objects may cause serious back injury. Always use proper lifting technique when loading the machine. To prepare the wood and brush: • Cut the lead end of the brush at an angle. This will help ease the feed wheel open and facilitate feeding • Cut the brush into lengths long enough to be safely fed into the chipper without the operators hands entering the infeed chute. The average length should be no shorter than 4 feet long NOTE: Place short pieces on top of longer pieces. • Cut the wood into a weight that can be easily lifted without injury to the operator • The chipper is designed to process clean wood. Brush and wood should be clear of debris and dirt or any items that may damage the machine 32
Section 3 - Operating Procedures Feeding Brush Into the Chipper The engine throttle must be advanced to the full (max) position for the safety control bar functions to be enabled. When you are about to feed brush into the chipper, move the safety control bar to the feed position, see Figure 24, Engine Startup procedure. Note: At least two trained operators must be on the work site at all times. The work site is an area where the operators can see, hear, and react to an emergency in a few seconds. To feed the brush: 1. Pick up a limb from the brush pile that is light enough to easily maneuver. Keep your back straight and lift with your legs. The cut-end should be facing towards the infeed. NOTE: When breaking in a machine, it is recommended that you begin by feeding 2”-3” diameter pieces into the chipper, gradually working up to the larger diameter pieces during the first 4-8 hours of work. 2. Insert the brush onto the infeed tray making sure your hands do not enter the infeed chute area. When you feel the material pull away, release the material and let it pull through the feed wheel. Note: To safely feed shorter pieces, place the safety control bar into the neutral position as the longer material enters the feed wheel. Lay the shorter material on top of the longer material (before entering the infeed!) then place the safety control bar back into the forward position and begin the chipping process again. 3. Quickly turn, and face away from the infeed. Keep moving along your motion path. 4. Check the discharge chute and make sure the wood chips are projecting at the correct angle. If necessary adjust the discharge chute. Note: It is the operators responsibility to keep all bystanders away from the work site.
33
Section 3 - Operating Procedures No wider than infeed opening
Place short pieces on top of long pieces
Trimming the “V” areas off of the brush can reduce down time in having to stop and clear away jammed material
No shorter than 4 ft. in length
Cut lead end at an angle Cut end should be facing the chipper infeed
Figure 22
34
Section 3 - Operating Procedures Machine Setup/Preparation
DANGER
8
Before operating, always block the wheel with wheel chocks (as shown below) and ensure the chipper is on stable level ground when not attached to a vehicle. Failure to do so will result in unexpected movement, serious injury or death.
Wheel chocks FIGURE 23
DANGER The chipper MUST stay connected to the tow vehicle when operating. Operating the chipper while disconnected from the tow vehicle is unstable and may cause injury or death to personnel. Before starting operation the chipper must first be placed on a stable surface and secured so that it does not move. The chipper can only be operated by while hitched to a tow vehicle When operating the chipper: 35
Section 3 - Operating Procedures • The vehicle used to tow the machine must be capable of towing the machine • Park the vehicle and the chipper on a level surface • The vehicle must be completely stopped, with the parking brake set • There must NOT be a driver in the vehicle • The hitch must be properly secured to the vehicle with locking pins installed • Connect safety chains and cables to the vehicle. Two lengths of chain must be used. The lengths of chains should be equal in length and shall be crossed under the tongue of the chipper and properly attached to the towing vehicle • Hook up electrical connections and check that tail lights and turn signals are in working order • The chipper must be level, with the machine parallel to the ground Adjusting the Discharge Chute Once you have the machine secured and level, the next step in machine preparation is setting up the discharge chute. See Features and Function section for more detail. • Be sure the infeed chute is clear of any debris • Rotate the discharge chute in the direction you want the wood chips projected. The discharge chute can rotate 270º. Adjust the height of the discharge chute if necessary • Adjust the deflector for the desired angle of projection. Direct chips away from the work area and bystanders
Pre-Start Checklist 1. Make sure the chipper is securely connected to the tow vehicle. 2. Make sure machine is located on level stable ground. 3. Make sure the chipper disc lock pin is removed and in the stowed position. 36
Section 3 - Operating Procedures 4. Perform an inspection of all safety devices to ensure they are in proper working condition. 5. Check all fluid levels (fuel, engine oil and hydraulic fluid). Service as required. 6. Make sure discharge is positioned so wood chips are directed to a clear, safe area. 7. Make sure infeed tray is in the down position and infeed area is clear of all debris. 8. Make sure the yoke lock pin is removed and stowed properly. 9. Make sure wheel chalks are in place. 10. Make sure air filter covers are latched and secure. 11. Make sure engine and exhaust area are clean and free from debris.
37
Section 3 - Operating Procedures Engine Startup 1. Perform the Pre-Start Checklist. 2. See Figure 24. Place the control bar in the neutral position. Stop stops movement of the feed wheel Forward pulls material into the feed wheel Stop stops movement of the feed wheel Safety control bar
Reverse pushes material out of the feed wheel
Figure 24 3. Place the throttle control lever on the slow setting. 4. Turn the key switch to engage the starter. 5. Release the key switch when engine has started. 6. Slowly increase throttle to full (max) RPM. 7. Proceed to Chipping Wood procedure (next page). 38
Section 3 - Operating Procedures Chipping Wood 1. Make sure you read and understand all the dangers, warnings and cautions in this manual before feeding the chipper. 2. Refer to the Brush Preparation section and Figure 25 below. Make sure brush is fed into the machine as described.
Keep moving
Turn away from the chipper Release the brush
Keep this area clear of debris to prevent entanglements during the chipping process. Do not feed from directly in front of infeed.
Feed the cut-end into the chipper
Motion path
Figure 25
39
Section 3 - Operating Procedures Engine Shut-down 1. Slowly reduce throttle to low (min) RPM. 2. Shut down engine by placing the key switch in the OFF position. 3. Allow machine to cool. 4. Clean all brush and debris away from the infeed, discharge and engine exhaust areas. 5. Perform Lockout procedure, as required.
40
Section 4 - Service & Maintenance Procedures Routine Maintenance Schedule Table 1 describes the tasks that you should perform on a regular basis to ensure the proper operation of the machine. Always refer to the OEM literature where applicable when servicing components. Table 1 - Routine Maintenance Schedule
Component
Task
Interval
Complete machine
Inspect all components for excessive wear/damage (see also Safety section)
Before operating
Engine
Check oil level. Fill as required
Before operating
Replace oil (@ interval or annually)
100 hours
Replace oil filter
200 hours
Replace air filter(s)
300 hours
Replace spark plugs & set gap
500 hours
Chipper Disc Knives
Inspect, sharpen and/or replace when chip quality deteriorates
40 hours
Knife Bolts
Inspect when changing knives. Replace when worn or damaged.
40 hours
Knife Clearance
Check/adjust when changing knives
40 hours
Anvil
Inspect when changing knives. Adjust or replace when worn or damaged.
40 hours
Fan Blades
Inspect when changing knives. Replace when worn or damaged.
40 hours
Drive Belts
Inspect. Replace when worn.
8 & 40 hours
Feed Wheel Teeth
Inspect. Cut off and replace when worn.
Before operating
Tires
Check pressure. Fill as required
Before operating or transporting
Check tires for excessive wear/damage. Repair/replace as required
Before operating or transporting
Hydraulic Oil Filter
Replace
200 hours
Hydraulic Oil
Replace, check, fill as required
400 hours
EFI Fuel Filter
Replace
200 hours
41
Section 4 - Service & Maintenance Procedures Engine Only the most common tasks specific to servicing the engine are described here. Refer to the OEM manual for more complete and detailed information regarding the inspection, repair and maintenance of the engine. Checking Engine Oil
NOTICE To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicated on dipstick. 1. See Figure 26. Remove dipstick and wipe clean with a clean rag. 2. Check oil level. Level should be near the top (H) level indicator. 3. If oil level is low, add oil as required. Refer to Table 2. Select oil viscosity based on air temperature at time of operation. 4. Re-install dipstick and oil fill cap.
(L)
(H) Oil Dipstick
Oil Fill Oil Fill Cap
Figure 26 42
Section 4 - Service & Maintenance Procedures Table 2. Oil Viscosity Selection
Oil & Filter Replacement
CAUTION Let engine cool before performing maintenance to avoid burns caused by hot components or fluids. NOTE: Change oil while engine is still warm, but not hot. 1. Clean area around oil fill cap, dipstick and drain plug. 2. Place a container under oil drain plug to catch oil. 3. See Figure 27. Remove drain plug (A). Allow oil to drain completely.
B
A Figure 27 43
Section 4 - Service & Maintenance Procedures 4. Clean area around oil filter. 5. Place a container under filter to catch any oil then remove filter (B). 6. Wipe off mounting surface with a clean cloth. 7. Place new oil filter in shallow pan with open end up. 8. Fill the new oil filter with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by filter material. 9. Reinstall oil drain plug. Torque to 10 ft. lb. (13.6 Nm). 10. Apply a thin film of clean oil to rubber gasket on new oil filter. 11. Refer to instructions on oil filter for proper installation. 12. Fill crankcase with new oil. Level should be at top of indicator on dipstick. 13. Start engine; check for oil leaks. 14. Stop engine; correct leaks and recheck oil level, as required. 15. Dispose of used oil and filter in accordance with local ordinances. Air Filter Replacement 1. See Figure 28, next page. Unhook retaining clips and remove end caps (A) 2. Check and clean inlet screen (if equipped). 3. Pull air cleaner element (B) out of housing and replace. Check condition of inner element (C); replace when dirty. 4. Check all parts for wear, cracks, or damage, and that ejector area is clean. 5. Install new element(s). 6. Reinstall end cap(s) with dust ejector valve/ EN screen down; secure with retaining clips.
44
Section 4 - Service & Maintenance Procedures A
B
C
A
Figure 28
45
Section 4 - Service & Maintenance Procedures Drive Belt Replacement 1. Refer to the Lockout procedure. Lockout the machine to avoid inadvertent starting of the machine. 2. See Figure 29. Remove bolts, nuts & washers (A) from belt shield in seven locations shown and set aside. 3. Carefully lift and remove belt shield (B) away from drive components and set aside.
B
A
A
A A
Figure 29 4. See Figure 30, next page. Manually push down on tensioner pulley (A) to provide slack in the belt. 5. Carefully remove the belt from the drive pulleys. 46
Section 4 - Service & Maintenance Procedures 6. Install replacement belt in reverse order. 7. Install belt shield using existing hardware.
A
Figure 30 (Parts Hidden for Clarity)
Adjusting Belt Tension The T-Max belt tensioner pulley is adjusted at the factory and should not be tampered with. The following procedure describes the tension adjustment and should only be used in cases where something has occurred unexpectedly that requires a new tension adjustment. 1. See Figure 31. Using a socket wrench, break the tension and slightly loosen bolt (A). B 2. See Figure 31 (right) and Figure 32 (next page). Using a calibrated torque wrench and socket placed over the hex head (B, part of housing) rotate counterclockwise until the torque wrench reads 15 ft-lbs. A Figure 31 - T-Max Housing 47
Section 4 - Service & Maintenance Procedures
TORQUE WRENCH
Figure 32 (Parts Hidden for Clarity) 3. See Figure 33. While holding that tension on the belt, mark a reference line ACROSS the base and housing as shown.
REFERENCE MARK
Figure 33 (Parts Hidden for Clarity) 48
Section 4 - Service & Maintenance Procedures 4. Relax tension and set the torque wrench aside. 5. See Figure 34. Using a box wrench (A) rotate the housing counterclockwise putting tension on the belt until the reference marks drawn in Step 3 are aligned then lock into place by tightening the retention bolt (B) to 30 ft-lbs. 6. Re-install covers/shields, as required to put machine back into service. A
B
Figure 34 (Belt Hidden for Clarity)
Battery Maintenance
WARNING The battery generates explosive gas during normal operation. Keep ignition sources away at all times. Battery acid can cause severe burns. Wear protective gear when handling the battery. Follow these guidelines when handling and maintaining the battery: • When connecting or disconnecting the cables, always handle the negative (-) terminal first. 49
Section 4 - Service & Maintenance Procedures • After completing the connection, reconnect and tighten the cables to the terminals. • Apply grease to the terminals to prevent corrosion • Check the battery terminals for corrosion (white or yellowish powder) • Remove corrosion by covering the terminals with a solution of baking soda and water. After the mixture bubbles and turns brown, wash it off with water. If there is severe corrosion, clean with a wire brush, and dry with a paper towel.
Tire Maintenance
DANGER Over inflated tires will cause a tire to explode and result in serious injury or death. Always maintain a safe distance away from the tire during inflation. Use a hose with a pressure gauge. Never over inflate a tire! Improper support of the chipper during a tire change will result in the machine tipping over and causing serious injury or death. Always set up on a flat, solid surface and ensure the machine is properly supported. • Maintaining proper air pressure in the machine’s tires is critical to safe operation. Correct air pressure provides balance and stability during transportation and operation. Never exceed maximum inflation pressures when sealing tire beads on rims. • To add air to the tires remove the stem cap and place the air pump nozzle securely on the stem. Avoid twisting or bending the stem while adding air. Inflate the tire to the recommended pressure listed on the tire. After inflating the tire, replace the stem cap. Doing so will prevent loss of air pressure. • Repairing or replacing a tire should only be done by an individual that has the proper equipment and training. In the absence of either always 50
Section 4 - Service & Maintenance Procedures have a qualified tire repair service conduct the maintenance. Detailed tire mounting instructions, including safety precautions, are available from the Rubber Manufacturers Association or the tire manufacturer. • The chipper comes with high-grade tires. Replace with a similar grade. Tire Replacement 1. See Figure 35. Install wheel chocks (A) on side opposite of the tire to be removed. 2. See Figure 36. Install jack (A) to frame (on the side the tire is to be removed from) and secure with pin (B). 3. Remove wheel lugs and wheel/tire. A Figure 35 B
A Figure 36 4. Repeat Steps 1 through 3 in reverse order to install tire.
51
Section 4 - Service & Maintenance Procedures Hydraulic
WARNING Hydraulic oil will vaporize and potentially ignite resulting in explosion, fire and possible serious injury. Keep hydraulic oil away from ignition sources (e.g.: flame, smoking etc.). Hydraulic oil leaks will result in puddles and slippery conditions which may result in serious injury. Always clean up spills and fix leaks immediately. Pressure may be stored in the hydraulic system even after the power unit is turned OFF. Relieve hydraulic pressure and lockout the machine before conducting maintenance. Hydraulic oil is under pressure. Spraying fluid from a leak can burn or penetrate the skin and cause serious injury. If fluid penetrates the skin, immediately seek medical attention to have it surgically removed! The hydraulic components (pump, motor) and oil are hot during operation and can cause severe burns. Always wear protective face gear and clothing during operation and maintenance. General When conducting maintenance on the hydraulic system; be cautious of leaks, hot components (pumps, motors, relief valves) and stored energy. Always follow safety warnings and procedures when conducting maintenance on the hydraulic system.
52
Section 4 - Service & Maintenance Procedures Before Conducting Maintenance: • Allow the machine to cool down • Relieve pressure within the hydraulic system. Examples of where energy may be stored include: stalled feed wheel, suspended loads, charged accumulators and electric voltage. • Check for leaks. Use a piece of cardboard to check for leaks. Never use your hand! The hydraulic system provides the fluid powering certain parts of the machine’s operation. The main components requiring maintenance include the hydraulic oil, filter and pump. Testing the Hydraulic Oil The hydraulic oil should be tested every 250 hours or if there are signs of oil degradation. Signs of degradation include: • A change in oil color • Bad aroma to the oil • Dirty or gritty feel to the oil • Regular hydraulic component failure • Louder than normal operation sound The oil quality may be checked using a commercially available test kit or a simple Blotter Spot test. The Blotter Spot test consists of placing a drop of oil 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 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.
53
Section 4 - Service & Maintenance Procedures Changing the Hydraulic Oil & Filter Under normal conditions hydraulic oil should be changed every 400 operating hours or yearly, which ever comes first. In more severe conditions it should be changed every 200 hours or six months. Always use hydraulic oil that contains anti-wear additives. Always keep the level of oil in the tank full. Failure to do so can result in air getting into the pump, a reduction of oil pressure, and slow operation.
WARNING To avoid burn injuries, make sure machine has been turned off long enough for hydraulic fluid to and associated parts to cool down. Place machine on level surface and make sure wheel chocks are in place to stabilize machine, as required. 1. See Figure 37. Remove hydraulic oil fill cap (A). 2. (NOTE: It may be necessary to rotate the filter clockwise and counterclockwise as you are pulling up to remove filter.) Remove filter (B) by pulling straight up on ring. B
A
Figure 37 (Parts Removed for Clarity) 54
Section 4 - Service & Maintenance Procedures 3. See Figure 38. Place a container below drain plug, then remove drain plug (A) and allow oil to fully drain. Make sure the old oil is disposed of in accordance with local ordinances/regulations. 4. Install drain plug. 5. Install new hydraulic oil filter then replace fill cap. 6. Fill hydraulic oil tank with an approved hydraulic fluid until full.
A Figure 38 (Parts Removed for Clarity)
55
Section 4 - Service & Maintenance Procedures Checking & Filling Hydraulic Oil Level Check the fluid level of the hydraulic oil reservoir before each use and service with approved hydraulic oil, as required. To check the fluid level: 1. See Figure 39. Remove the dipstick (A) and wipe clean with a clean rag. 2. Re-insert dipstick then remove. Visually check level. Level should indicate 3/4 tank full. To add fluid: 1. Remove fill cap (B) and add hydraulic fluid as required to obtain a full tank. 2. Wipe area clean of any spills to avoid buildup of debris and/or cause a fire hazard. A B
Figure 39 (Parts Removed for Clarity)
56
Section 4 - Service & Maintenance Procedures Hydraulic Oil Filter Replacement The hydraulic oil filter should be replaced after 200 hours of operation or when the hydraulic oil is changed. Always use a filter rated at 10 micron.
WARNING To avoid burn injuries, make sure machine has been turned off long enough for hydraulic fluid to and associated parts to cool down. 1. See Figure 40. Remove hydraulic oil fill cap (A). 2. (NOTE: It may be necessary to rotate the filter clockwise and counterclockwise as you are pulling up to remove filter.) Remove filter (B) by pulling straight up on ring. B
A
Figure 40 (Parts Removed for Clarity) 3. Make sure the old filter is disposed of in accordance with local ordinances/regulations.
57
Section 4 - Service & Maintenance Procedures Refueling
WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. Fuel Specifications
NOTICE NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable. Refer to the engine OEM manual for specific information regarding the type of fuel to use. Fuel must meet these requirements: • Clean, fresh, unleaded gasoline. • Octane rating of 87 (R+M)/2 or higher. • Research Octane Number (RON) 90 octane minimum. • Gasoline up to 10% ethyl alcohol, 90%unleaded is acceptable. • Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. • Do not add oil to gasoline. • Do not overfill fuel tank. • Do not use gasoline older than 30 days.
58
Section 4 - Service & Maintenance Procedures Filling & Storage of Fuel Fuel should be stored in approved containers and kept in a clean, protected environment. Avoid storing fuel over a long period of time. The fuel tank should be filled 3/4 full at the end of each days operation. This will help prevent condensation as the air cools and allow for vapor expansion when the temperature rises. The fuel could overflow if the tank is filled completely and there is an increase in temperature.
Discharge Chute Cleaning
DANGER Never attempt to remove material by starting the machine and engaging the chipper to blow material out. This is a very dangerous and unsafe practice. Two (2) people shall be involved when attempting to open the discharge chute. The chute must be securely supported while removing support bolts. Never stand directly under the chute as it can fall, causing injury.
CAUTION Machine components may be hot or have sharp edges which could cause serious injury. Always wear protective gear during operation and maintenance. Plugging is mainly caused by the engine RPM’s dropping too low. This drop can be caused by running the unit at less than full RPM’s, by dull knives that do not chip the wood efficiently or by trying to overfeed material that is either too large or too soft, which prevents chipping. If the unit has auto feed it should be set high enough to prevent a low RPM situation. 1. Perform the Engine Lockout procedure to prevent inadvertent operation of the machine. 2. Make sure the chipper disc has stopped turning. 3. Pull material out from the open end of the discharge. 59
Section 4 - Service & Maintenance Procedures 4. If required, perform the Chipper Hood & Disc Lockout procedure to access the lower section of the discharge chute to remove material. 5. Reinstall components and attempt chipping again using small material to determine if chipper discharges properly.
Chipper Disc Knives
DANGER A rotating chipper disc can pinch body parts, entangle loose clothing, jewelry, and long hair which may result in cuts, mutilation, serious injury or death. Before initiating maintenance throttle the engine down and shut the engine OFF. Wait for the chipper disc to completely stop rotating and insert the disc lock pin. The chipper disc will coast for several minutes after the machine is shut off. Do not open the chipper hood until the disc rotation has completely stopped. Serious injury, mutilation or death can occur. Debris may be projected during the maintenance of the chipper knives and result in eye injury, skin punctures, and cuts. Always wear protective equipment and gear such as goggles and work gloves.
NOTICE Excessive heat, indicated by discoloration of the knife edge, will lead to microscopic cracks that can cause the knife to break when it is put back into service. Do not use knives that have been exposed to excessive heat from sharpening.
60
Section 4 - Service & Maintenance Procedures General Guidelines To ensure maximum efficiency of the chipping operation the chipper knives must be properly maintained. The time between sharpening or replacement will depend on the type of wood and operating conditions. Indication of dull knives include poor quality, excessive oversize chips and poor feed characteristics. Always maintain proper knife sharpness. It is important to follow these guidelines to ensure efficient chipping: • Use original Morbark LLC. knives with the correct steel composition and hardness. Immediately replace worn knives. • Keep the knife edge sharp and anvil square. Use matched sets. • Maintain the proper clearance between the chipper knife and anvil. • Use the correct hardware to mount the knife to the holder and maintain the correct torque to the bolt. Keep the knife pocket and holder clean and free of debris. Accessing the Chipper Knives 1. Perform the Engine Lockout procedure to prevent inadvertent operation of the machine. 2. Perform the Chipper Hood & Disc Lockout procedure to safely access the knives. 3. See Figure 41, next page. Remove Slot Cover (A) by removing bolts and washers (B). Set parts aside. 4. Proceed to Inspecting the Chipper Knives or Replacing the Chipper Knives, as required.
61
Section 4 - Service & Maintenance Procedures A B
Figure 41 Inspecting the Chipper Knives 1. Perform the Accessing the Chipper Knives procedure. 2. Check that the corners of the knife are square and the edge is sharp. Remove the knife if sharpening or replacement is needed. 3. Check the torque on the knife bolts. Tighten if necessary (see Torque chart). 4. Remove the disc lock pin and rotate the chipper disc to the next knife. Re-insert the disc lock pin. Repeat steps 1 & 2. 5. If there is no need sharpen or replace a knife then close the chipper hood and put the hood locking pin back in place. 6. Proceed to Replacing or Sharpening Chipper Knives procedures, if required. 62
Section 4 - Service & Maintenance Procedures Replacing the Chipper Knives 1. Perform the Accessing the Chipper Knives procedure. 2. See Figure 42. Remove old knife (A) by removing nuts (B) and bolts (C) securing knife and fan (D) to disc. Set all parts aside. 3. Clean debris from the knife and knife holder with a wire brush. 4. Inspect the knife bolts, washers and nuts for wear or damage. 5. Apply a light coat of anti- seize lubricant to the bolts. Install replacement knife in reverse order. Torque bolts to 106 ft-lbs.
A
D B
C
Figure 42 6. Remove the chipper disc lock pin and manually rotate the disc to access the remaining knife, as required. 7. Insert lock pin through base and into disc. 8. Repeat Steps 2 through 5 to install replacement knife. 9. Remove and stow the chipper disc lock pin. 10. Close the chipper hood and stow the hood lock pin back in place after maintaining the chipper knives. 11. Before conducting chipping operation the clearance between the knives and anvil must be set (see Knife Anvil Section). 63
Section 4 - Service & Maintenance Procedures Sharpening the Chipper Knives General Notes: • When sharpening the knife edge use proper grinding techniques (hand file, power belt sander with fine paper or conventional knife grinder with coolant system) to reduce the possibility of excessive heat build up and provide a good cutting edge. • Do not use straight wheel grinding. This method will result in a hollow or concave effect and shorten the life of the knife. • Use a non-petroleum base coolant such as De Santo (orange label) grinding coolant when using a grinding machine. Mix 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. Do not overfeed the grinding machine. 1. Perform the Accessing the Chipper Knives procedure. 2. See Figure 43. Remove the knife (A) by removing nuts (B) and bolts (C) securing knife and fan (D) to disc. Set all parts aside.
A
D B
C
Figure 43
64
Section 4 - Service & Maintenance Procedures 3. See Figure 44. Using one of the grinding methods described in General Notes, grind the angle of the knife edge to 38°. 38°
Figure 44 4. De-burr the edge of the knife using a hand file. 5. NOTE: Apply a light coat of anti- seize lubricant to the bolts. Install knife and tighten bolts to 106 ft-lbs torque. 6. Remove the chipper disc lock pin and manually rotate the disc to access the remaining knife, as required. 7. Insert lock pin through base and into disc. 8. Repeat Steps 2 through 5 to sharpen remaining knife. 9. NOTE: Apply a light coat of anti- seize lubricant to the bolts. Install knife and tighten bolts to 106 ft-lbs torque. 10. Remove and stow the chipper disc lock pin. 11. Close the chipper hood and stow the hood lock pin back in place after maintaining the chipper knives. 12. Before conducting chipping operation the clearance between the knives and anvil must be set (see Knife Anvil Section).
65
Section 4 - Service & Maintenance Procedures Anvil Maintenance
DANGER Failure to lockout the machine (e.g. raise yoke, shut power off) will result in unexpected operation and cause serious injury or death. Always lockout the machine before conducting maintenance (see Safety: Lockout Procedure). A rotating chipper disc can pinch body parts, entangle loose clothing, jewelry and long hair which will result in cuts, mutilation, serious injury or death. Shut down the engine, wait until the chipper disc completely stops rotating and insert the disc lock pin before initiating maintenance.
NOTICE Incorrect clearance between a chipper knife and anvil will result in poor chipping performance, damage to the chipper knives and undue stress on the chipper. Always maintain the proper knife-anvil clearance. General Notes The anvil is located behind the infeed next to the chipper disc. The anvil and chipper disc work together in chipping the brush, therefore it is important the clearance between the anvil and knife are accurate. To ensure maximum efficiency of the chipping operation the anvil must be properly maintained. It is important to follow these guidelines to ensure efficient chipping: • Keep the anvil square • Maintain the proper clearance between the chipper knife and anvil • Inspect, flip or replace anvil when required
66
Section 4 - Service & Maintenance Procedures Accessing the Anvil 1. Perform the Engine Lockout procedure to prevent inadvertent operation of the machine. 2. Perform the Chipper Hood & Disc Lockout procedure. 3. See Figure 45. Remove the yoke stop block (A) by removing nuts, bolts and washers (B). Set parts aside.
B B
A
Figure 45 (Parts Hidden for Clarity)
67
Section 4 - Service & Maintenance Procedures 4. See Figure 46. Position jack (A) on to the jack mount located on the yoke wheel assembly as shown then install jack pin to secure.
A
Figure 46 5. See Figure 47. Using the jack, raise the yoke until the yoke lock pin (A) can be installed through the yoke housing and above the infeed side wall. 6. Install yoke lock pin as shown.
A
Figure 47 (Parts Hidden for Clarity) 68
Section 4 - Service & Maintenance Procedures 7. Lower the jack until the lock pin is resting on the infeed side wall, but DO NOT remove the jack at this time; It will serve as extra protection/ support while doing maintenance 8. Proceed to Inspecting the Anvil, Flipping the Anvil or Replacing the Anvil procedure, as required. Inspecting the Anvil 1. Perform the Accessing the Anvil procedure. 2. See Figure 48. Visually inspect the anvil. If the edge of the anvil is excessively worn or damaged (nicks, chips, etc.) flip or replace, as required.
INSPECT THIS EDGE
Figure 48 (Parts Hidden for Clarity)
69
Section 4 - Service & Maintenance Procedures Flipping or Replacing the Anvil 1. Perform the Accessing the Anvil procedure. 2. See Figures 49 and 50. Remove bolts and washers (A) securing anvil (B) to the infeed. (NOTE: the two outside bolts go through eye bolts used for adjusting the anvil. The middle bolt is threaded directly to the anvil.)
B
A Figure 49 (Parts Hidden for Clarity)
Figure 50 Anvil Access (Parts Hidden for Clarity) 70
Section 4 - Service & Maintenance Procedures 3. Access the anvil for removal as shown in Figure 50. 4. If using existing anvil, flip over and install using existing hardware. Install hardware finger tight only, then proceed to the Adjusting Anvil Clearance procedure. 5. If replacing the anvil, refer to Steps 1 and 2 and perform in reverse order. Install hardware finger tight only, then proceed to the Adjusting Anvil Clearance procedure. Adjusting Anvil Clearance 1. See Figure 51. Manually rotate the chipper disc until one of the chipper knives are in line with the anvil as shown.
KNIFE
ANVIL
Figure 51 (Parts Hidden for Clarity)
71
Section 4 - Service & Maintenance Procedures 2. See Figure 52. Loosen bolts (A) and nuts (B) enough to allow anvil to be adjusted in or out as required.
A (TYPICAL) B (TYPICAL)
Figure 52 3. Using a feeler gauge manually adjust anvil in or out as required to obtain an even clearance between the anvil and chipper knife of .040” to .090”. 4. Tighten bolts and nuts until finger tight only. 5. Rotate the disc to line up remaining knife with anvil and verify clearance is within specifications. Adjust as necessary. 6. Once clearance between the anvil knives have been verified and are satisfactory, tighten bolts (A) to 106 ft-lbs. then tighten nuts (B) securing adjustment eye bolts. 72
Section 4 - Service & Maintenance Procedures Lubrication Lubrication Points Numerous grease fittings are located on this machine that allow dispensing grease to specific points that require periodic lubrication. Figure 53 shows a typical Zerk grease fitting. Refer to Figures 53 to 55 for locations and Table 3 for description of items to be lubricated. Use a grease gun with an EP2 rated grease. Dispense until grease starts to flow out of fitting to ensure adequate lubrication. ZERK GREASE FITTING (TYPICAL)
Figure 53 Table 3 - Lubrication Points
Callout# 1 2 3 4 5 6 7 8 9 10
Description
Yoke Pivot Pin Discharge Swivel (Underside) Flange Bearing (Chipper Disc Drive Shaft) Control Bar Pivot Pin Discharge Swivel (Underside) Flange Bearing (Chipper Disc Drive Shaft) Cable Linkage Control Bar Pivot Pin Yoke Pivot Pin Jack
73
Section 4 - Service & Maintenance Procedures
2 1
4 3 Figure 54 7 6 5
9 10
Figure 55 74
8
Section 4 - Service & Maintenance Procedures Machine Storage Use the following guidelines when preparing the machine for long-term storage: • Make sure all areas of the machine (engine and exhaust area, infeed, discharge, etc.) are clean and free from debris • Fill fuel tank to at least 3/4 full to avoid condensation buildup in tank and add fuel extender if machine will be stored and not used for more than 6 months • Clean up all fuel and/or hydraulic spills • Perform the Engine Lockout procedure • Store in an enclosed facility if possible to avoid exposure to weather, as well as reduce possibility of theft and/or vandalism • Ensure tires are clean and properly inflated • Make sure infeed tray is closed
Torque Tables Making sure that all the bolts are regularly checked and tightened to the proper torque is critical. Tables 4 to 7 show the proper torque relative to the bolt size and type. When using these tables, keep the following guidelines in mind: • The values in the chart are based on use of clean, dry threads. • Use the next higher torque value when specific torque values are not available. • When replacing a cap screw with a higher grade, use the torque specifications of the new screw. • Do not use the torque values shown in this chart in place of those specified in other sections of the manual. • When oil is used as a lubricant, reduce the torque by 10%. • When using new plated cap screws, reduce the torque by 20%. • Use the Grade 5 torque chart when using cap screws that are threaded into aluminum. These may require reductions in torque of 30% or more and must attain two cap screw diameters of thread engagement. • When using rivet nuts, do not exceed 25 ft-lb of torque.
75
Section 4 - Service & Maintenance Procedures Table 4 - Grade 5 Course Thread Torques
Clamp Load
Plain
Plated
1/4-28 (.250)
Size
2,325
10 ft-lb
87 in-lb
5/16-24 (.3125)
3,675
19 ft-lb
14 ft-lb
3/8-24 (.375)
5,588
35 ft-lb
26 ft-lb
7/16-20 (.4375)
7,575
55 ft-lb
41 ft-lb
1/2-20 (.500)
10,200
85 ft-lb
64 ft-lb
9/16-18 (.5625)
12,975
122 ft-lb
91 ft-lb
5/8-18 (.625)
16,350
170 ft-lb
128 ft-lb
3/4-16 (.750)
23,775
297 ft-lb
223 ft-lb
7/8-14 (.875)
32, 475
474 ft-lb
355 ft-lb
1-12 (1.000)
42, 300
705 ft-lb
529 ft-lb
1-14 (1.000)
32,275
721 ft-lb
541 ft-lb
1 1/8-12 (1.125)
47,475
890 ft-lb
668 ft-lb
1 1/4-12 (1.250)
59,550
1241 ft-lb
930 ft-lb
1 3/8-12 (1.375)
72,975
1672 ft-lb
1254 ft-lb
1 1/2-12 (1.500)
87,750
2194 ft-lb
1645 ft-lb
Plain
Plated
Table 5 - Grade 5 Fine Thread Torques Size Clamp Load 1/4-28 (.250)
2,325
10 ft-lb
87 in-lb
5/16-24 (.3125)
3,675
19 ft-lb
14 ft-lb
3/8-24 (.375)
5,588
35 ft-lb
26 ft-lb
7/16-20 (.4375)
7,575
55 ft-lb
41 ft-lb
1/2-20 (.500)
10,200
85 ft-lb
64 ft-lb
9/16-18 (.5625)
12,975
122 ft-lb
91 ft-lb
5/8-18 (.625)
16,350
170 ft-lb
128 ft-lb
3/4-16 (.750)
23,775
297 ft-lb
223 ft-lb
7/8-14 (.875)
32, 475
474 ft-lb
355 ft-lb
1-12 (1.000)
42, 300
705 ft-lb
529 ft-lb
1-14 (1.000)
32,275
721 ft-lb
541 ft-lb
1 1/8-12 (1.125)
47,475
890 ft-lb
668 ft-lb
1 1/4-12 (1.250)
59,550
1241 ft-lb
930 ft-lb
1 3/8-12 (1.375)
72,975
1672 ft-lb
1254 ft-lb
1 1/2-12 (1.500)
87,750
2194 ft-lb
1645 ft-lb
76
Section 4 - Service & Maintenance Procedures Table 6 - Grade 8 Course Thread Torques Size Clamp Load
Plain
Plated
1/4-20 (.250)
2,850
12 ft-lb
9 ft-lb
5/16-18 (.3125)
4,725
25 ft-lb
18 ft-lb
3/8-16 (.375)
6,975
44 ft-lb
33 ft-lb
7/16-14 (.4375)
9,600
70 ft-lb
52 ft-lb
1/2-13 (.500)
12,750
106 ft-lb
80 ft-lb
9/16-12 (.5625)
16, 350
153 ft-lb
115 ft-lb
5/8-11 (.625)
20, 325
212 ft-lb
159 ft-lb
3/4-10 (.750)
30, 075
376 ft-lb
282 ft-lb
7/8-9 (.875)
41, 550
606 ft-lb
454 ft-lb
1-8 (1.000)
54,525
909 ft-lb
682 ft-lb
1 1/8-7 (1.125)
68,700
1288 ft-lb
966 ft-lb
1 1/4-7 (1.250)
87,225
1817 ft-lb
1363 ft-lb
1 3/8-6 (1.375)
103,950
2382 ft-lb
1787 ft-lb
1 1/2-6 (1.500)
126,450
3161 ft-lb
2371 ft-lb
Table 7 - Grade 8 Fine Thread Torques Size Clamp Load
Plain
Plated
1/4-28 (.250)
3,263
14 ft-lb
10 ft-lb
5/16-24 (.3125)
5,113
27 ft-lb
20 ft-lb
3/8-24 (.375)
7,875
49 ft-lb
37 ft-lb
7/16-20 (.4375)
10,650
78 ft-lb
58 ft-lb
1/2-20 (.500)
14,400
120 ft-lb
90 ft-lb
9/16-18 (.5625)
18,300
172 ft-lb
129 ft-lb
5/8-18 (.625)
23,025
240 ft-lb
180 ft-lb
3/4-16 (.750)
33,600
420 ft-lb
315 ft-lb
7/8-14 (.875)
45,825
668 ft-lb
501 ft-lb
1-12 (1.000)
59,700
995 ft-lb
746 ft-lb
1-14 (1.000)
61,125
1019 ft-lb
764 ft-lb
1 1/8-12 (1.125)
77, 025
1444 ft-lb
1083 ft-lb
1 1/4-12 (1.250)
96,600
2012 ft-lb
1509 ft-lb
1 3/8-12 (1.375)
118,350
2712 ft-lb
2034 ft-lb
1 1/2-12 (1.500)
142,275
3557 ft-lb
2668 ft-lb
77
Section 4 - Service & Maintenance Procedures Troubleshooting Hydraulic The hydraulic pump is critical to the operation of the chipper. Operators should always be alert for possible problems with the pump during operation. Symptoms indicating problems with the pump include: • A noisy pump • Overheating • High discharge pressure • Pump not pumping • Low system pressure • Sluggish start-up Troubleshooting the hydraulic system (see Table 8) involves talking with the operators, understanding the schematics and inspection of the machine. After identifying the problem determine the root causes. It is possible there is more than one cause of the malfunction. Start by creating a list of possible causes. Put the easiest ones to eliminate and do not require dis-assembly or down time first. Systematically test, eliminate or repair possible causes. Initiate corrective action to avoid future maintenance problems and operation downtime. Table 8 - Hydraulic Troubleshooting Symptom
Possible Cause
Corrective Action
Noisy Pump
Air in system
Tighten loose fittings. Replace cracked hoses and damaged parts.
Cavitating pump
Open clogged or restricted intake line or plugged air vent in tank.
Loose/worn parts Replace worn gaskets. Ensure the oil is the proper type and clean.
78
Stuck parts
Dis-assemble pump and clean with solvent and dry thoroughly before reassembling. Do not use hard tools, files or emery cloth on machined surfaces. Replace rusted parts.
Pump/bearing
Disassemble and inspect pump & flange bearing. Repair/replace defective components, as required.
Section 4 - Service & Maintenance Procedures Table 8 - Hydraulic Troubleshooting, cont. Symptom
Possible Cause
Corrective Action
Overheating
Outside tempera- Use oil with higher viscosity index. See ture thickens oil fluid manufacturers recommendations. Low oil
Maintain hydraulic oil level in tank. Keep 3/4 full.
High discharge pressure
Parts misalignment
Check parts for excessive friction. Replace if necessary. Ensure all parts are aligned.
Pump not pumping
Shaft turning in wrong direction
Shut the machine off immediately! Replace existing pump with one that turns in the correct direction.
Intake clogged
Clean tank and maintain oil at 3/4 full.
Air leak in intake
Tighten or replace fittings, hose or damaged parts.
Oil too thick
Drain tank and replace with oil of the proper viscosity.
Relief value setting to low
Block pressure line beyond relief valve and check line pressure with a pressure gauge, adjust relief valve setting so fluid flows to point of use.
Low system pressure
Relief valve stuck Clean dirty relief valve. Check oil for open dirt and deterioration. Change if necessary. Broken, worn or stuck parts
Block pressure line beyond relief valve and check line pressure with a pressure gauge. No pressure buildup and functional relief valve indicate mechanical problems. Inspect pump for worn or broken parts. Replace if necessary.
Valves sticking or Check oil for deterioration (e.g.: dirt, binding sludge, varnishes and lacquers). Change if necessary. Inspect pump parts for misalignment, wear or damage. Replace if necessary. Sluggish start-up
Oil too thick at starting temperature
Run the machine for short period and see if the oil thins out. If not, change the oil to a lighter viscosity. See fluid manufacturers recommendations.
79
Section 4 - Service & Maintenance Procedures Chipper Table 9 - Chipper Troubleshooting Symptom
Possible Cause
Chipper will not feed Dull chipper knives properly Loose belts
Corrective Action
Turn, sharpen or replace knives Check for proper belt tension
Knives ground at incor- Grind knives at 38° rect angle
Chipper bearing running to hot (210° F maximum) Discharge spout plugged
Chipper disc wobbles
Chipper disc will not turn
80
Obstruction in infeed spout
Raise the yoke and insert yoke lock pin. Turn OFF the engine and lock-out the machine. Wait for the chipper disc to come to a complete stop. Carefully remove the obstructing material from the infeed.
Not enough or too much lubrication
Lubricate according to manufacturers recommendations
Disc rpm too high
Do not exceed 2,250 rpm
Obstruction in discharge spout
Lower discharge or if equipped open clean out door and clean out
Chipper disc RPM too low
Always run the chipper at full throttle when chipping
Bearings are loose
Re-Torque bolts
Chipper bearings are worn or damaged
Replace bearings
Knife pockets are plugged with material
Unplug pockets
Obstruction in chipper housing
Turn OFF the engine and lockout the machine. Carefully remove the obstructing material from the chipper housing.
Disc bearings have seized up
Check chipper bearings and lubricate or replace
Section 4 - Service & Maintenance Procedures Tachometer Setup & Operation A tachometer located on the engine tracks job time, engine RPM, total machine time and has two service timers that count down from manually set times to indicate when service is required. Tachometer Description Function Select Button
Display Screen Functions
Tach Functions Press the SELECT button to scroll through, and access, the following functions: TOT - Displays the total machine time (up to 19,999 hrs) and cannot be reset. JOB - Displays hours of machine operation since reset. To reset, press the SELECT button until JOB appears in display and hold down until RESET appears in display then release the SELECT button. The screen will reset to 00:00. SVC - Displays hours of operation left until next service is required. The time will count down to zero and can be set in 5 hour increments from 0 - 50 by doing the following: To Reset: Press the SELECT button until MAX is displayed. Push and hold the SELECT button once more until RESET appears then release. The display will change to read 25:00 (default value)
81
Section 4 - Service & Maintenance Procedures To Program: Proceed as when resetting the timer. However, continue to hold the SELECT button until SET appears and then push and release until the value you want is displayed. NOTE: While the SET is displayed the SVC time can be stepped forward until the desired service interval is achieved. The display will reset to Total Hours in 30 seconds. SVC2 - Displays hours of operation left until next service is required. The time will count down to zero and can be set in 10 hour increments from 0 250 by doing the following: To Reset: Press the SELECT button until SVC is displayed. Push and hold the SELECT button once more until RESET appears then release. The display will change to read 50:00 (default value) To Program: Proceed as when resetting the timer. However, continue to hold the SELECT button until SET appears and then push and release until the value you want is displayed. NOTE: While the SET is displayed the SVC time can be stepped forward until the desired service interval is achieved. The display will reset to Total Hours in 30 seconds. MAX - Displays the maximum RPM since the timer was reset. To Reset: Press the SELECT button until JOB is displayed. Push and hold the SELECT button once more until RESET appears then release. The display will change to read 0000. Battery Information The tachometer utilizes a battery and has a life expectancy of approximately 5 years.
82
Section 5 - Parts Breakdown Major Assemblies
7 8 4
3 6
8 1 5 2
Item
Qty
Part #
Title
1*
1
40628-901
Cable Assy,Switch,Hood
2
1
40061-809
Frame Assy,Trl
3
1
40039-809
Infeed Assy.
4*
1
40031-809
Engine Kit,Kohler 25 Hp Efi
5*
1
40022-809
Tank Assy,Fuel
6*
1
40020-809
Tank Assy,Hyd
7*
1
40011-809
Discharge Assy
8*
1
40006-809
Base Assy
9*
1
39234-210
Holder,Manual
83
Section 5 - Parts Breakdown Frame Assembly 40060-809 12
8
27
7
1 1
28 33
2
21
35
5 1
19
23
18
34
9
11 30
37 31
29
26 36 32
22
18
34
24 34
3
37
4
23 13
33 22
14
Item
Qty
Part #
Title
1
1
40063-809
Frame Assy,Trl,Wldmnt
2
1
40062-809
Light Bar Assy,Wldmnt
3
1
30156-809
Fender,Lh
4
1
30155-809
Fender,Rh
5*
1
30109-809
Mat,Battery
6*
1
30016-809
Hold Down,Battery
7
1
29341-944
"Adjustable Coupler 2” 6000Lb"
8
1
29341-902
Jack, 5000Lb, Side Wind
9
1
29316-377
Tail Lamp, Led Combo Driver Side
10*
1
29316-376
Tail Lamp, Led Combo Passenger Side
84
Section 5 - Parts Breakdown Frame Assembly 40060-809 Item
Qty
Part #
Title
11
2
29315-822
Light,Marker,Amber,Ece
12
1
29315-261
Battery
13
2
29312-419
Tire,Rim,Assy,2060D
14
1
29309-506
Torflex Axle, 2200Lb Ez Lube
15*
1
27112-262
Clamp,Metal,Rubber Insulated
16*
10
27112-259
Clamp,Metal,Rubber Insulated
17*
2
26891-005
Grease Zerk
18
2
24721-386
Mcmaster Carr 9600K228
19
1
24721-385
Grommet,Rubber
20*
1
24721-380
Grommet,Rubber
21
4
21733-405
Nut, Stover, 1/4-20
22
6
21733-307
Nut,Nylock,5/8-11
23
12
21733-302
Nut,Nylock,5/16-18
24
4
21733-300
#10-24 Nylock Nut,Zinc
25*
2
21661-125
Bolt,Carriage,5/16-18X1 1/4,Gr5
26
2
21661-124
Bolt,Carriage,5/16-18X1 Gr5
27
2
21625-364
Bolt,5/8-11,Cadium,Gr8
28
4
21625-354
Bolt,5/8-11X1 3/4
29
8
21625-055
Bolt,5/16-18,Uncx1,Gr-8,Cf
30
2
21625-053
Bolt,5/16-18,Uncx3/4,Gr8,Cf
31
4
21459-080
Button Head Cap Screw
32
2
21171-139
"Washer,Lock,5/16”"
33
8
21161-665
"Washer,Flat,5/8”"
34
20
21161-660
"Washer,Flat,5/16”Zinc"
35
2
21161-159
Washer, Flat, 5/8,Gr 8,Zinc
36
2
21161-110
"Washer,Flat,5/16”Zinc,Sae"
37
8
21161-106
#10 Flat Washer,Zinc
85
Section 5 - Parts Breakdown Frame Assembly 40038-809 10
NA
19 5
11
5
3
20
46 30
6
9 36 32 41 48 12
43
4 48 32 44
17
27 5
25 45
37 46
31
26
28
5 32
48 45
18 15
40
27
39 13
47
1
2
38
23 24
35 16 41 24 14
8
44
7 33 31 44
29
31
43 22 21
Item
Qty
Part #
Title
1
1
40059-809
Fender Assy,Lh,Wldmnt,Aussie
2
1
40058-809
Fender Assy,Rh,Wldmnt,Aussie
3
1
40057-809
Mount,Jack,Wldmnt
4
1
40056-809
Light Bar Assy,Aussie,Wldmnt
5
1
40055-809
Frame Assy,Trl,Wldmnt
6
2
32519-901
Chain, Safety, 8Mm X 18 Links
7
2
30159-809
7Ga Astm A1011/B X 1 1/4 X 10 5/8
8
2
30158-809
3/8 Masticated Rubber
9
1
30109-809
1/2 Masticated Rubber
10
1
30016-809
11Ga A1011 X 1 X 9
11
1
29341-902
Jack, 5000Lb, Side Wind
12
2
29316-313
"4” Grommet"
13
1
29315-951
Led, License Lamp
14
2
29315-855
Reflector,White,Adr
15
2
29315-854
Reflector,Red,Adr
86
6
Section 5 - Parts Breakdown Frame Assembly 40038-809 Item
Qty
Part #
Title
16
2
29315-822
Light,Marker,Amber,Ece
17
2
29315-821
Light,Marker,Red,Ece
18
2
29315-803
Stop, Turn, Tail Light, Led, Adr
19
1
29315-261
Battery 600 Cca Mt-24F
20
1
29314-013
Overrun Coupling,Knott,1100-2000Kg
21
2
29314-010
Wheel Assy,Knott,195/50R13
22
1
29314-001
Axle Assy,Knott,1050Kg
23
1
27112-262
Rbc 1
24
2
24721-386
Grommet - Rubber
25
1
24721-385
Grommet - Rubber
26
1
24721-380
Grommet - Rubber
27
2
24713-505
8Mm Grade S
28
1
21733-512
M16 X 2.0 Nut,Nylock,Zinc
29
1
21733-305
Nut,Lock,1/2-13
30
1
21733-303
Nut,Lock,3/8-16
31
10
21733-302
Nut,Nylock5/16-18
32
5
21733-300
#10-24 Nylock Nut,Zinc
33
6
21661-125
Bolt,Carriage,5/16-18 X 1 1/4 Gr5
34*
1
21661-124
Bolt,Carriage,5/16-18 X 1 Gr5
35
1
21625-777
Bolt, M16-2.O X 120Mm
36
3
21625-255
Bolt, 1/2-13 X 1 1/2
37
1
21625-106
Bolt,3/8-16Uncx1 1/4,Gr8,Hh
38
5
21625-055
Bolt,5/16-18,Uncx1,Gr-8,Cf
39
1
21625-053
Bolt,5/16-18,Uncx3/4,Gr8,Cf
40
1
21511-122
#10-24 X 5/8 Philister Head Screw/Zinc
41
6
21459-080
Bhcs, #10-24 X 7/8,Zinc
42*
1
21171-139
Washer, Lock, 5/16
43
4
21161-663
1/2 Washer
44
11
21161-660
Washer, Flat, Zinc 5/16
45
2
21161-159
Washer, Flat, 5/8,Gr 8,Zinc
46
2
21161-155
"Washer, 3/8” , Sae, Flat, Zn"
47
1
21161-110
"Washer,Flat,5/16”Zinc,Sae"
48
10
21161-106
#10 Flat Washer,Zinc
87
Section 5 - Parts Breakdown Infeed Assembly 40038 - 60-809
28
16
24
19 25
2
5
10
24 9
17 21
10 25 10
3 20
7
23 11
23
27
15 26
20 14
88
13
12
22 22 18
12 26
19
25 4
10 6
10
22
1
Section 5 - Parts Breakdown Infeed Assembly 40038 - 60-809 Item
Qty
Part #
Title
1
1
40045-809
Tray Assy,Wldmnt
2
1
30103-809
Pin,Lock,Yoke
3
1
30093-809
Anvil,Infeed
4
1
30079-809
Support,Infeed
5
1
30056-809
Plate,Infeed,Yoke
6
1
27112-251
Hose Clamp
7
1
25978-169
Hose Barb Tee,3/16,Brass
8
1
24721-389
Rubber Grommet
9
6
21733-303
Nut,Lock,3/8-16
10
3
21733-302
Nut,Nylock,5/16-18
11
1
21733-301
Nut,Nylock,1/4-20
12
2
21731-068
Nut,1/2-13
13
1
21711-065
Bolt,1/2-13 X3 1/2,Lg,Swing,Zinc
14
1
21625-255
Bolt,1/2-13,Unc X 1 1/2
15
1
21625-253
Bolt,1/2-13X1
16
1
21625-106
Bolt,3/8-16Uncx1 1/4,Gr8,Hh
17
1
21625-103
Bolt,3/8-16X3/4,Gr-8,Cf
18
1
21625-056
Bolt,Hh,5/16-18Uncx1 1/4G8
19
2
21625-055
Bolt,5/16-18,Uncx1,Gr-8,Cf
20
2
21171-143
Washer,Lock,Single Coil,1/2
21
1
21171-140
Washer,Lock,3/8
22
3
21161-660
Washer,Flat,5/16,Zinc
23
2
21161-157
Washer, 1/2,Sae,Flat,Zinc
24
2
21161-155
Washer, 3/8,Flat,Zinc
25
3
21161-154
Washer,Flat,Gr8,5/16,Zinc
26
2
21161-113
Washer,Flat,1/2
27
1
21161-109
Washer,Flat,1/4,Zinc
28
2
24717-270
Spring Latch
89
Section 5 - Parts Breakdown Infeed Control Bar Assembly 40038 - 60-809
13 20 19
12
1
11
5 6 14
7
21
17 2
3
4
18 15
8
19
22
9
3
6 19
16
19 10
90
Section 5 - Parts Breakdown Infeed Control Bar Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
1
1
40044-809
Bracket Stop,Assy,Wldmnt
2
1
40043-809
Linkage Assy,Cable
3
1
40042-809
Bracket Assy,Wldmnt
4
1
40041-809
Bar,Control,Assy,Wldmnt
5
1
30115-809
Rod,Pivot,Linkage
6
4
26891-005
Grease Zerk
7
1
24735-222
Cable Assy
8
1
24735-221
Clevis,1/4-28
9
1
23126-704
Bearing,Bronze Sleeve
10*
2
21733-303
Nut,Lock,3/8-16
11*
1
21733-301
Nut,Nylock,1/4-20
12
2
21731-066
Nut,Grade 8,3/8-16
13
2
21625-107
Bolt,3/8-16X1 1/2
14
2
21625-106
Bolt,3/8-16Uncx1 1/4,Gr8,Hh
15
2
21625-105
Bolt,3/8-16X1
16
2
21452-504
5/8 X 1 Socket Head Shoulder Screw
17
1
21452-502
Bolt,Shoulder,Hex Socket,1/4-20 X5/8
18
3
21171-140
Washer,Lock,3/8
19
6
21161-661
Washer,Flat,3/8
20
1
21161-659
Washer,Flat,M5
21
2
21161-067
5/8 Flat Washer Sae
22*
2
12971-270
G30 3/8 Chain Link
91
Section 5 - Parts Breakdown Infeed Tower Tree Assembly 40038 - 60 - 809
7
16 18
6
9 10 18 14
4 15
15
17
17
17 13
8 11
17
92
13
Section 5 - Parts Breakdown Infeed Tower Tree Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
1*
2
40050-809
Reset Box,Assy,Wldmnt
2*
1
30139-809
Gusset,Tower,Strobe Light
3*
1
30138-809
Mount,Light,Strobe
4
1
30137-809
Tube,Tower,Light
5*
1
30136-809
Mount,Light,Strobe
6
1
29315-706
Light-Strobe-Led,Amber
7
1
29315-184
Branch Guard,Strobe Light
8
1
27347-887
Electrical Box
9
1
27347-881
Electrical Box, Aussie
10
1
27347-202
Push Button-Twist To Release
11
1
27347-016
Switch
12*
1
22137-107
Stud
13
6
21733-302
Nut,Nylock,5/16-18
14
2
21733-300
#10-24 Nylock Nut,Zinc
15
6
21625-055
Bolt,5/16-18,Uncx1,Gr-8,Cf
16
2
21459-080
Button Head Cap Screw
17
12
21161-154
Washer,Flat,Gr8,5/16
18
4
21161-106
#10 Flat Washer,Zinc
93
Section 5 - Parts Breakdown Bump Bar Assembly 40038 - 60 - 809
11
14
7
13
1 5
8
5
9
1
2 4 2
6 9
2 2
8
2
10
3 13
14
Item
Qty
Part #
Title
1
2
40594-451
Wldmt,Pin,Pivot
2
1
40052-809
Kit,Electrical,Bump Bar
3
1
40046-809
Bump Bar,Wldmnt
4
1
30142-809
Guard,Wire
5
2
26891-005
Grease Zerk
6
1
24741-974
Spring,180° Torsion,Rh
7
1
24741-973
Spring,180° Torsion,Lh
8
2
21735-111
1/4-20 Offset Weld Nut
9
2
21733-301
Nut,Nylock,1/4-20
10
1
21731-066
Nut,Grade 8,3/8-16
11
1
21624-009
Bolt,1/4-20 X2
12
1
21171-140
Washer,Lock,3/8
13
2
21161-314
Washer,Flat,9/16
14
2
21126-016
Cotter Pin,1/8X1
94
12
Section 5 - Parts Breakdown
Yoke Assembly 40038 - 60 - 809 16
9
6 6 2
5 13 15 8
4
8 7 3 1
14
10
12
17
17
11
Item
Qty
Part #
Title
1
1
40048-809
Yoke Assy,Wldmnt
2
1
40028-809
Shaft Assy,Pivot,Yoke
3
1
40019-809
Mount,Feed Wheel,Assy,Wldmnt
4
1
40018-809
Feed Wheel Assy,Wldmnt
5
1
30077-809
Cover, Access,Yoke
6
2
26891-005
Grease Zerk
7
1
26732-324
Motor,Wheel,24.03 In
8
2
26511-610
Union,Adapter
9
1
21733-308
Nut,Nylock,3/4-10
10
1
21733-305
Nut,Nylock,1/2-13
11
1
21625-258
Bolt,1/2-13X2 1/4,Gr8,Zinc Plt
12
1
21625-253
Bolt,1/2-13X1
13
1
21625-101
Bolt,3/8-16X1/2
14
1
21171-143
Washer,Lock,Single Coil,1/2
15
1
21171-140
Washer,Lock,3/8
16
1
21161-160
Washer ,Flat,3/4
17
2
21161-113
Washer,Flat,1/2
95
Section 5 - Parts Breakdown Base Assembly 40038 - 60 - 809 30
34
9
37 10 15
29
4
34 37
15 19
3 2 33
5
36
37 22
17 23
25
27 35
6
38
35 36 26 20 11 36
13
21 18 32
37 14
11
27
33
36
34
30
25
35
Item
Qty
Part #
Title
1*
1
40036-809
PUMP MOUNT ASSY,WLDMNT
2
1
40026-809
COVER ASSY,SLOT,WLDMNT
3
1
40007-809
BASE ASSY,WLDMNT
4
1
39234-210
"HOLDER,MANUAL,PAK,9”x6”
5
1
30176-809
SHIELD,BEARING
6
1
30122-809
GUARD,PUMP
7*
1
30108-809
SPACER,BEARING
8*
1
30103-809
PIN,LOCK,YOKE
9
1
30037-809
SHIELD,BELT
10
1
26891-001
"GREASE ZERK,1/8” NPT"
96
28 37
Section 5 - Parts Breakdown Base Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
11
1
26709-012
PUMP.58IN^3,26003,RZS
12*
1
26552-075
"12” FLEXIBLE HOSE ASSY.-1/4”-4CIT-2MP-12"
13
1
26512-155
FITTING,HYDRAULIC TEE
14
1
26511-617
UNION,ADAPTER,STRAIGHT
15
1
26511-221
1/8 NPT
16
1
24717-270
"1/2” SPRING LATCH,WALLACE FORGE"
17
1
23922-124
"BRG,FLANGE,2”,EXP"
18
1
23922-123
"BRG,FLANGE,2”,NON-EXP"
19
1
21733-308
NUT,NYLOCK,3/4-10
20
13
21733-305
NUT,NYLOCK,1/2-13
21
2
21733-303
NUT,LOCK,3/8-16
22
2
21733-302
NUT,NYLOCK,5/16-18
23
1
21625-418
BOLT,3/4-10,UNCx6 1/2 GR8,CF
24*
1
21625-261
BOLT,1/2-13x3,GR8,ZINC
25
20
21625-255
BOLT,1/2-13,UNC x 1 1/2, GR8
26
2
21625-108
BOLT,3/8-16 x 1 3/4,GR8,CF
27
4
21625-104
BOLT,3/8-16x7/8 GR8,CF
28
2
21625-055
BOLT,5/16-18,UNCx1,GR-8,CF
29
2
21625-053
BOLT,5/16-18,UNCx3/4,GR8,CF
30
7
21625-051
BOLT,5/16-18,UNCx1/2 GR8,CF
31*
1
21451-334
3/8-16x2 1/4 F.H.S.C.S.
32
8
21171-143
"WASHER,LOCK,SINGLE COIL,1/2”"
33
4
21171-140
"WASHER,LOCK,3/8”"
34
9
21171-139
"WASHER,LOCK,5/16”"
35
33
21161-113
WASHER,FLAT,ZINC,1/2
36
8
21161-111
"WASHER,FLAT,3/8”,ZINC"
37
13
21161-110
"WASHER,FLAT,5/16”ZINC,SAE"
38
1
21129-068
PIN W/CHAIN & LOCKING RING
97
Section 5 - Parts Breakdown Disc Assembly 40038 - 60 - 809
6
9
8 3
1 7 5 2 10
Item
Qty
Part #
Title
1
1
40010-809
Disc,Machined
2
2
39233-800
Knife,Single Edge
3
1
36754-700
Cf Sq
4*
2
32189-700
Key
5
1
30108-809
Spacer,Bearing
6
2
30041-809
Blade,Fan,Disc
7
1
30038-809
Shaft,Disc,Boxer X7
8
1
24114-604
B-Loc
9
8
21733-409
Nut,Stover,1/2-13
10
8
21451-366
Bolt,1/2-13,Uncx2 3/4 Fhscs
98
Section 5 - Parts Breakdown Discharge Assembly 40038 - 60 - 809 3
13 15 17 17
4
15
10
10
5
6
8 16 10
14 9
17
11 1
15
12 17
7
17 13
15
17
10 2
Item
Qty
Part #
Title
1
1
40027-809
Handle Assy,Wldmnt
2
1
40024-809
Lock Ring Assy,Wldmnt
3
1
40013-809
Flipper,Assy,Wldmnt
4
1
40012-809
Discharge,Wldmnt
5
1
30051-809
Lock Ring,Discharge
6
1
30047-809
Linkage,Discharge
7
2
26891-005
Grease Zerk
8
2
24731-955
Handle, Rubber
9
1
24731-232
Handle,Grip,Discharge
10
12
21733-303
Nut,Lock,3/8-16
11
1
21625-255
Bolt,1/2-13,Unc X 1 1/2
12
6
21625-107
Bolt,3/8-16X1 1/2
13
4
21625-106
Bolt,3/8-16Uncx1 1/4,Gr8,Hh
14
1
21171-143
Washer,Lock,Single Coil,1/2
15
4
21161-661
Washer,Flat,3/8
16
1
21161-113
Washer,Flat,1/2
17
20
21161-111
Washer,Flat,3/8
10
99
Section 5 - Parts Breakdown Hydraulic Tank Assembly 40038 - 60 - 809
22 6 20
18
16
10
29
5 15 5
12
13
8
24
5 7
17
5
11
9
5
19
5
5
1
13
5 27
2
5
5 5
14 28 25
5 28
26
1
3 22 28 28
100
27 26
4 22
28
Section 5 - Parts Breakdown Hydraulic Tank Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
1
1
40021-809
Tank,Hyd,Assy,Wldmnt
2
1
30087-809
Bracket,Valve
3
1
30086-809
Cover,Tank,Hyd
4
4
29234-733
Rubber Isolator
5
1
26849-401
Filter,Tank Top,Ikron
6
1
26676-203
Valve,Solenoid
7
1
26661-801
4 Position Safety Valve
8
1
26538-419
Coupler,Nipple,Sae#6
9
1
26538-416
Dust Cap
10
1
26513-077
Union,Adaptor
11
1
26512-631
Union,Adaptor
12
1
26512-617
Union,Adaptor
13
2
26512-578
Union,Adaptor
14
1
26511-680
Union,Adaptor
15
1
26511-676
Union,Adaptor
16
1
26511-673
Union,Adaptor
17
1
26511-633
Union,Adaptor
18
1
26511-611
Union,Adaptor
19
1
26511-606
Union,Adaptor
20
1
25845-703
Adaptor
21*
1
25311-104
Plug,1/2 Npt,Mag,Sq-Head
22
8
21733-302
Nut,Nylock,5/16-18
23*
2
21733-154
Nut,Stover Lock,5/16-18
24
1
21625-743
Bolt,M10x1.5x25
25
2
21625-062
Bolt,5/16-18X2 3/4,Gr8,Zinc
26
6
21625-053
Bolt,5/16-18,Uncx3/4,Gr8,Cf
27
6
21171-139
Washer,Lock,5/16
28
16
21161-660
Washer,Flat,5/16,Zinc
29
2
21161-154
Washer,Flat,Gr8,5/16,Zinc
101
Section 5 - Parts Breakdown Fuel Tank Assembly 40038 - 60 - 809
4 1 7 1 9 10 6
3
10 9
8
102
Section 5 - Parts Breakdown Fuel Tank Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
1
1
40023-809
7 Gallon
2*
1
32451-901
Oil/Fuel Tank Cap Assy
3
2
29234-733
Rubber Isolator
4
1
26849-144
Gauge,Oil/Fuel
5*
1
26598-507
Fuel Suction Tube
6
1
26531-111
Hose Barb
7
2
25978-105
Brass Hose Barb
8
1
25311-204
Pipe Plug,1/2
9
4
21733-302
Nut,Nylock,5/16-18
10
4
21161-660
Washer,Flat,5/16,Zinc"
103
Section 5 - Parts Breakdown Engine Assembly 40038 - 60 - 809
3
6
5 10 12 24
8
15
16
25
2 11
9
19
1 22
14 7
23 20 13
104
17
4
1 18
21
Section 5 - Parts Breakdown Engine Assembly 40038 - 60 - 809 Item
Qty
Part #
Title
1
1
40038-803
Assy,Oil Drain Kit
2
1
33335-701
Spacer
3
1
30110-809
Guard,Muffler
4
1
30099-809
Spacer,Clutch
5
1
30095-809
Guard, Engine Assy
6
1
29135-709
Kohler 25 Hp Efi
7
1
24528-205
Clutch,Centrifugal 1800 Rpm
8
1
24226-090
Sheave,3B12.4,Sk
9
1
24180-601
Belt,3/B61
10
1
24133-512
Sk-2 Bushing
11
1
24115-401
Tensioner
12
1
24115-169
Pulley,Idler,5"
13
1
22425-355
Bolt,5/8-18X 2
14
1
21733-305
Nut,Nylock,1/2-13
15
4
21733-155
Nut,Stover,Zinc,3/8-16
16
1
21625-261
Bolt,1/2-13X3,Gr8,Zinc
17
4
21625-108
Bolt,3/8-16 X1 3/4
18
4
21625-103
Bolt,3/8-16X3/4,Gr-8,Cf
19
1
21451-334
3/8-16X2 1/4 F.h.s.c.s.
20
1
21171-265
Washer,Lock,5/8
21
4
21171-140
Washer,Lock,3/8
22
4
21161-661
Washer,Flat,3/8Zinc
23
1
21161-442
Washer,Flat Oversize,5/8,Zinc
24
1
21161-113
Washer,Flat,1/2
25
4
21161-111
Washer,Flat,3/8,Zinc
105
Appendix A - Routine Maintenance Replacement Parts Part#:
Qty:
Description:
29834-724
1
X7 Maintenance Kit (includes all items listed below in this table)
26849-416
1
Filter, Hydraulic Oil
29135-772
1
Filter, Inner Air
29135-838
1
Filter, Fuel
29135-771
1
Filter, Outer Air
29135-234
1
Filter, Engine Oil
18672-040
2 qts
Oil, 10W30
Appendix B - Hydraulic Hose List Part#:
Qty:
26552-075
1
4C2AT-2MP-012
Grease Line
26900-336
2
6C2AT-6JIC-6JIC90-059
Valve To Motor
26265-215
1
8C2AT-8JIC-8JIC90L-022
Pump To Mechanical Valve
26265-214
1
8C2AT-8JIC-8JIC90L-016
Pump To Solenoid Valve
26594-313
1
.75 100R4-12JIC-016
Pump To Tank
106
Description:
Machine Location
5 4 3 2 1 SYM
REF REF REF REF REF QTY
26849-401 26661-801 26676-203 26732-324 26709-012 PART NUMBER
FILTER ASSEMBLY HYDRAULIC SAFETY VALVE SOLENOID VALVE WHEEL MOTOR PUMP DESCRIPTION
B1
A1
HYDRAULIC
P
T
Appendix C - Schematics Hydraulic Schematic 48000-809
107
108
ASSY,HOOD SAFETY SWITCH
HARNESS ASSY,CONTROL MODULE
DESC.
HARNESS ASSY,SOLENOID VALVE
PART #
1
47002-809
2
47003-809
HARNESS ASSY,EXTENSION
HARNESS ASSY,TAILLIGHT
47004-809
47001-809
47006-809
1
1
3
QTY
1
4
WEDGE
RECPT - 2 PIN (DT)
HARNESS ASSY,BATTERY CABLES
1
1
5
27255-703
47007-809
27255-705
ITEM #
1
1
6
1
7*
8*
PART LIST
S C
WHT
WHT
GROUND
R
BAT
WHITE # 10
BLK
RED
(OEM PART)
YEL
YEL/GRN
WHT
BLACK 12 GA. -2-
WHITE 12 GA. -1-
12V STARTER
RED/WHT
2
SPEED SENSOR
5
STARTER SOLENOID
BLK RED
RED
1
HARNESS ASSY,TAIILIGHT
4
3
2
3
4
+ BATTERY
1
4
3
2
BLK
RED WHT GRN
TRUCK OUTLET
GROUND
CONTROL MODULE
1
Electric Schematic 47000-809
BATTERY
+
WHT GRN
BLK
RED
4
3
2
1
C
BAT
S
R
14
(OEM PART)
12V STARTER
AMBER STROBE LIGHT
YEL
MODULE
CONTROL
-
RED/WHT
1
GROUND
WHITE # 10
3
4
3
2
1 BLK RED
RED
5
GROUND
6
RED
RED BLK
STARTER
SOLENOID
WHT
BLK WHT
HARNESS ASSY,TAIILIGHT
SPEED SENSOR
4
YEL/GRN WHT
12
TRUCK OUTLET
2
11
PART #
DESC.
HARNESS ASSY,CONTROL MODULE 47002-809 1
1 ITEM #
QTY
ASSY,HOOD SAFETY SWITCH HARNESS ASSY,TAILLIGHT 47009-809
HARNESS ASSY,SOLENOID VALVE 2
HARNESS ASSY,EXTENSION 1 1
3
47003-809
1
4
RECPT - 2 PIN (DT) 47006-809
27255-703
47013-809
1 1
6 5
WEDGE - 2 PIN (DT)
TINY TACH TT2B SOLENOID VALVE 27255-705 1 7*
BOX ASSY,FEED STOP
HARNESS ASSY,BATTERY CABLES
47010-809 29135-712 26676-203 47007-459
REF
BOX ASSY,BUMP BAR
1
1 REF 9*
ASSY,AMBER STROBE LIGHT HARNESS ASSY,FUNCTION 47011-809
PART LIST 47016-809 47012-809
8*
11
1
12 10*
1 1
14 13*
Electric Schematic 47008-809
109
110
TAIL LAMP,LED COMBO
TAIL LAMP,LED COMBO
TAILLIGHT RECEPTACLE
29316-376
29316-796
PART #
REF
1
QTY
2
1
ITEM #
DESC.
2 1/2" YELLOW MARKER LAMP
29316-377
REF
3
PIGTAIL,STRAIGHT,6"
BUTT SPLICE
29316-378
11
27245-105
2
10
REF
4
29316-380
WIRE,16 GA,BROWN
EYELET,3/8"
14/6 CABLE
5
18141-481
27214-236
18141-335
BUTT SPLICE
6
5
12'-0"
11'-1"
8
7
9
WIRE,16 GA,WHITE
PIGTAIL
27245-106
29316-379
2
3
11
10
CLAMP,WIRE
NUT
12
21733-303
27151-054
18141-322
10
10
14'-5"
NS
QTY
7'-0"
10'-0"
0'-7"
NS
PART LIST
DESC.
ELECTRICAL LOOMING - 1/4"
18763-020
PART #
ELECTRICAL LOOMING - 3/8"
18763-022
BROWN 13"
GROUND
5 4
10
WHITE 8"
BROWN 13"
WHITE 34.5"
8
10
10
WHITE 34.5"
7 FOOT FROM PLUG TO END OF TOUNGE
7
5
WHITE
ELECTRICAL LOOMING - 5/8"
RED BLUE YELLOW GREEN BROWN WHITE
BLUE
GREEN
RED
11
4
9
9
GREEN 21.5" BROWN 21.5"
18763-024
WHITE
YELLOW
BROWN
1
WHITE - GROUND YELLOW - LEFT TURN/STOP BROWN - TAIL/SIDE MARKER/LICENSE RED - NOT USED GREEN - RIGHT TURN/STOP BLUE - NOT USED
YELLOW 25" BROWN 25" WHITE 46.5"
WHITE 46.5" BROWN 25" GREEN 25"
5
5
RED BLK WHT
WHT BLK RED
6
6
GRN BLK WHT
WHT BLK GRN
LEFT TAILLIGHT
RIGHT TAILLIGHT
3
2
Trailer Schematic 47001-809
YELLOW 21.5" BROWN 21.5"
1
5 BLUE
1 YELLOW 6 RED
13
WHITE - GROUND YELLOW - LEFT TURN BROWN - TAIL/SIDE MARKER/LICENSE RED - STOP GREEN - RIGHT TURN/STOP BLUE - BRAKES
3 WHITE 4 GREEN
2 NOT USED
7 BROWN
14
7 FOOT FROM PLUG TO END OF TONGUE
RED BLUE YELLOW GREEN BROWN WHITE
WHITE
BLACK
13"
9
WHITE 8"
BROWN
RED YELLOW WHITE
WHITE GREEN RED
WHITE
10
BROWN
BLACK
13"
15
2
PART #
DESC.
7 PIN ROUND NARVA PLUG
TAIL LAMP,LED 29315-973
29315-803 1
REF QTY
1
2 ITEM #
LED,LICENSE LAMP 29315-951
4" GROMMET
PLUG - 4 PIN (DT)
WEDGE - 4 PIN (DT)
RECPT - 4 PIN (DT)
WEDGE - 4 PIN (DT)
BUTT SPLICE
BUTT SPLICE
CLAMP,WIRE
NUT
REF
29316-313
27255-727
27255-729
27255-728
27255-730
27245-105
27245-106
27151-054
21733-303
LED,SIDEMARKER,RED
LED,SIDMARKER,AMBER 29315-821
EYELET - 3/8"
3
27214-236
RECPT - 2 PIN (DT)
BLACK
29315-822
27255-703
PART LIST
7"
16 18
BLACK
WHITE
GRN/YEL - PIN 1 WHITE - PIN 2 BROWN - PIN 3 RED - PIN 4
WHITE
3
2
2
2
2
10
7
10
10
7
WHITE
REF
5
1 REF
5
21"
WHITE
BLACK GRN/YEL - PIN 1 WHITE - PIN 2 BROWN - PIN 3 RED - PIN 4
7"
4*
6* WEDGE - 2 PIN (DT) PART #
DESC.
PLUG - 2 PIN (DT) 27255-704 27255-705 4
4 QTY
18 17* ITEM #
7
9 8*
10
WIRE,16 GA,WHITE
WEDGE - 2 PIN (DT)
4
11*
WIRE,16 GA,RED WIRE,16 GA,BROWN CABLE - 14/6
7'-0"
20 19*
12*
WIRE,16 GA,YELLOW
14 13
WIRE,16 GA,GREEN
REF
15
ELECTRICAL LOOMING - 5/8"
ELECTRICAL LOOMING - 3/8"
4
16
18141-481
18141-322
11'-6" 10'-10"
21
BROWN
YELLOW - PIN 1 WHITE - PIN 2 BROWN - PIN 3 RED - PIN 4
ELECTRICAL LOOMING - 1/4"
7"
GREEN - PIN 1 WHITE - PIN 2 BROWN - PIN 3 RED - PIN 4
27255-706
18141-323 18141-335
10'-10"
22
23
5'-5"
25 18141-320
18763-024 18141-318
0'-8"
26* 5'-5"
18763-022
10'-10"
27*
24
18763-020
2'-8"
PART LIST
30"
28*
21.5"
21.5"
30"
Trailer Schematic 47009-809
111
BIG POWER IN ALL PLACES
Phone: Morbark®, LLC. Sales - 800-831-0042 8507 S. Winn. Rd., P.O. Box 1000, Parts and Service - 800-255-8839 Winn, Michigan 48896 www.boxerequipment.com www.morbark.com
