5000h Oper Manut - 93146

5000H Maintenance
Manual
Chipper
Serial Number: 2H-282-1455, 2H-284-1483, 2H-287-1494 to 2H-308-1598
93146 English
Copyright © 2008 Peterson Pacific Corp. Document History
All rights reserved. Document Number: 93146
Peterson Pacific Corp. reserves the copyright for this Publication Date: November 2008
manual and the sole right to add, change, summarize,
delete, or otherwise edit and update information con- Reference Documents
tained in this manual, including text, images, tables, The following documents for the 5000H chipper are
translations, formatting, and all forms of information provided to 5000H owners at no added cost.
herein. • The 5000H Operator Safety Manual describes basic
Peterson Pacific Corp. is an Astec Industries Co. safety and operating information.
• The 5000H Maintenance Manual provides step-by-
Trademarks step procedures for many common maintenance
Peterson and the Peterson icon are trademarks of Peter- activities, such as lubrication and replacing com-
son Pacific Corp. Caterpillar and CAT are registered mon wear parts. A maintenance schedule is also
trademarks of Caterpillar, Incorporated. All other prod- included.
ucts or services mentioned in this document are identi-
The 5000H Operator Safety Manual and the 5000H
fied by the trademarks or service marks of their
Maintenance Manual should be kept at the equip-
respective companies or organizations, and Peterson
ment at all times for the use of operators and others
Pacific Corp. disclaims any responsibility for specify-
who are expected to work with or on the 5000H
ing their ownership. Any such marks are used in an edi-
chipper.
torial way, to the benefit of the owner, with no intention
of infringement. • The 5000H Parts Book makes ordering replacement
parts easier and quicker. It is shipped separately
Patents from the machine when it leaves the factory. The
The 5000H is a portable delimber debarker chipper, book is provided by the Peterson Distributor, who is
with critical parts licensed under U.S. patents 5349999 the primary source for replacement parts. The
and RE33840 and Canadian patent 1321528, and other 5000H Parts Book is available on CD-ROM, which
patents pending. in some cases may make it possible to have a copy
of it at the work site.
California Proposition 65 Warning The 5000H Service Manual is recommended for dealers
Diesel engine exhaust and some of its constituents are who expect to do complete service, including removal
known to the State of California to cause cancer, birth and replacement of major parts. It provides in-depth ser-
defects, and other reproductive harm. vicing instructions that include tear-downs with
remove-and-replace procedures for most major parts.
Contacts The book is available for a fee.
Contact your Peterson distributor for current operation, Additional copies and replacement copies of these man-
safety, maintenance, and service information. uals are provided for a fee. Copies of the manuals are
Peterson Pacific Corp also available to regional dealers.
PO Box 40490 Peterson welcomes your comments for improving the
Eugene, Oregon 97404 content, design and usefulness of these documents.
U.S.
Main Office (800) 269-6520
Customer Service (541) 607-1305
Fax (541) 689-0804
www.petersoncorp.com
CONTENTS
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . 5 Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24
The information about this manual describes all the manuals Bark Mover Hazards . . . . . . . . . . . . . . . . . 25
that support the 5000H chipper, the safety notices you need
to follow, the definitions of special terms, and the text of the
Crushing and Pinching Hazards . . . . . . . . 25
limited warranty. Guards and Shields . . . . . . . . . . . . . . . . . . 25
The Manual Set. . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Loader Swing Hazard . . . . . . . . . . . . . . . . 26
Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . .5 Point of Operation . . . . . . . . . . . . . . . . . . . . . 26
Important Messages. . . . . . . . . . . . . . . . . . . . . .5 Feed Roll and Flail Housing Hazards . . . . 26
Removing Jammed Logs. . . . . . . . . . . . . . 26
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . .5
Chipper Disk Hazards . . . . . . . . . . . . . . . . 27
Small Numbers . . . . . . . . . . . . . . . . . . . . . . . . .5
Chip Spout Hazards. . . . . . . . . . . . . . . . . . 28
Units of Weight and Measure . . . . . . . . . . . . . .6
Overs Spout Hazards. . . . . . . . . . . . . . . . . 29
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . .7 Cab Operator Safety . . . . . . . . . . . . . . . . . . . . 29
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Log Loader Hazards . . . . . . . . . . . . . . . . . 29
Entering and Leaving . . . . . . . . . . . . . . . . 30
WORKING SAFELY . . . . . . . . . . . . . . . . . . . . 13
Emergency Exit . . . . . . . . . . . . . . . . . . . . . 30
Safe working conditions require you to avoid machine and
job-site hazards, to practice fire prevention, and to follow safe- Lexan Windows . . . . . . . . . . . . . . . . . . . . 30
ty instructions. Cab Heater Safety . . . . . . . . . . . . . . . . . . . 30
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fire Prevention and Suppression . . . . . . . . . . . . . 30
Safety Topics . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Daily Fire Prevention . . . . . . . . . . . . . . . . . . . 30
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . 13 Before Operation . . . . . . . . . . . . . . . . . . . . 30
Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 During Operation . . . . . . . . . . . . . . . . . . . 30
Responsibility for Safety . . . . . . . . . . . . . . . . . 14 After Operation . . . . . . . . . . . . . . . . . . . . . 31
Use Only for the Designed Purpose . . . . . . . . 14 Sources and Causes of Fires . . . . . . . . . . . . . . 31
Operator Qualifications . . . . . . . . . . . . . . . . . . 14 Fire Suppression Equipment . . . . . . . . . . . . . 32
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . 32
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Water Pump Sprayer . . . . . . . . . . . . . . . . . 32
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency Stop (E-Stop) Buttons . . . . . . . 15 Job Site Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Battery Disconnect Switch . . . . . . . . . . . . . 16 Moving Machinery Hazard. . . . . . . . . . . . . . . 34
Battery Disconnect Lockout/Tagout . . . . . 17 Flying Objects Hazard . . . . . . . . . . . . . . . . . . 34
Stored Energy . . . . . . . . . . . . . . . . . . . . . . . . . 18 Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inertia of the Chipper Disk. . . . . . . . . . . . . 18 Creating a Safe Workplace. . . . . . . . . . . . . . . 35
Falling Objects . . . . . . . . . . . . . . . . . . . . . . 18 Wear Protective Gear . . . . . . . . . . . . . . . . 35
Jams or Blockage . . . . . . . . . . . . . . . . . . . . 24 Avoid Unsafe Conditions . . . . . . . . . . . . . 35
Pressurized Gases and Fluids . . . . . . . . . . . 24 Practice Safe Behaviors. . . . . . . . . . . . . . . 36
Electrical Energy Hazards . . . . . . . . . . . . . 24 Operating and Hazard Zones . . . . . . . . . . . . . 37
93146 5000H CHIPPER MAINTENANCE MANUAL 1

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 1.2.3 Cleaning and Checking the Radiator. . . . . . 77
Safety Decal Illustrations . . . . . . . . . . . . . . . . 43 1.3 Engine Fluids and Filters. . . . . . . . . . . . . . . . . . . 78
Warnings During Maintenance . . . . . . . . . . . 47 1.3.1 Engine Oil and Filters . . . . . . . . . . . . . . . . . 78
1.3.2 Crankcase Breather . . . . . . . . . . . . . . . . . . . 79
SECTION 0000
GENERAL MAINTENANCE . . . . . . . . . . . . . . . 49 1.3.3 Fuel Filters. . . . . . . . . . . . . . . . . . . . . . . . . . 80
A good maintenance program improves awareness of haz- 1.3.3.1 Primary Fuel Filter . . . . . . . . . . . . . . . 80
ards and reduces risk of equipment failure. Regular lubrica- 1.3.3.2 Secondary Fuel Filter . . . . . . . . . . . . . 80
tion is an essential requirement for proper maintenance.
1.3.4 Air Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . 81
0.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 49 1.3.4.1 Air Filter Service Indicator . . . . . . . . . 81
0.1.1 Common Practices . . . . . . . . . . . . . . . . . . . 52 1.3.4.2 Pre-cleaners and Air Filters. . . . . . . . . 81
0.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1.3.4.3 Cleaning the Primary Filter Element . 82
0.2.1 Grease Points . . . . . . . . . . . . . . . . . . . . . . . 53 1.4 V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
0.2.2 Bearing Lubrication . . . . . . . . . . . . . . . . . . 56 1.4.1 Installing Used Belts . . . . . . . . . . . . . . . . . . 83
0.2.2.1 Chipper Bearing Lubrication . . . . . . . 56 1.4.2 Checking Belt Tension . . . . . . . . . . . . . . . . 83
0.2.2.2 Feed and Flail Bearings . . . . . . . . . . . 56 1.4.3 Replacing the Alternator Belt . . . . . . . . . . . 84
0.2.3 Fluids and Filters . . . . . . . . . . . . . . . . . . . . 57 1.4.4 Replacing Chipper Sheave Belts . . . . . . . . . 84
0.2.3.1 Filter Locations . . . . . . . . . . . . . . . . . 59
0.2.3.2 Special Interval . . . . . . . . . . . . . . . . . 60 SECTION 2000
0.2.3.3 Handling Filters Properly. . . . . . . . . . 61 HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . 87
0.2.3.4 Fuel Specifications. . . . . . . . . . . . . . . 61 The 5000H is equipped with two hydraulic systems, one for
the main machine and another for the clutch. Each system
0.2.3.5 Fuel for Cold Weather . . . . . . . . . . . . 61 provides its own tank, pumps, valves, and filters.
0.3 Troubleshooting Chip Production . . . . . . . . . . . 62 2.1 Main Hydraulic System. . . . . . . . . . . . . . . . . . . . 87
0.4 Troubleshooting Machine Operation . . . . . . . . . 66 2.1.1 Checking Hydraulic Oil . . . . . . . . . . . . . . . 87
0.5 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2.1.2 Changing Hydraulic Oil and Filters . . . . . . 89
2.1.2.1 Replacing the Charge Pressure Filters 89
0.6 Maintenance Decals . . . . . . . . . . . . . . . . . . . . . . 70
2.1.2.2 Replacing the Tank Return Filters . . . 90
0.7 Serial Number and VIN . . . . . . . . . . . . . . . . . . . 71
2.2 Clutch Hydraulic System. . . . . . . . . . . . . . . . . . . 93
SECTION 1000 2.2.1 Checking Clutch Oil . . . . . . . . . . . . . . . . . . 93
POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . 73 2.2.2 Changing the Clutch Oil and Filter . . . . . . . 94
Power system maintenance includes checking fluid levels,
changing fluids, and cleaning or replacing filters. V-belts re-
2.3 Oil Coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
quire regular inspection. 2.3.1 Hydraulic Oil Cooler. . . . . . . . . . . . . . . . . . 95
1.1 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . 73 2.3.2 Clutch Oil Cooler . . . . . . . . . . . . . . . . . . . . 96
1.1.1 Engine Sensors . . . . . . . . . . . . . . . . . . . . . . 73 2.4 Hydraulic Pumps and Suction Valves . . . . . . . . . 96
1.1.2 Ether Starting Aid. . . . . . . . . . . . . . . . . . . . 74 2.5 Pump-Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . 98
1.1.3 Hoses and Clamps . . . . . . . . . . . . . . . . . . . 74 2.5.1 Checking the Pump-Drive Gearbox Oil . . . 98
1.1.4 Service Referrals . . . . . . . . . . . . . . . . . . . . 74 2.5.2 Changing the Pump-Drive Gearbox Oil . . . 98
1.2 Coolant Systems . . . . . . . . . . . . . . . . . . . . . . . . . 75 2.6 Drive Motor Gearboxes. . . . . . . . . . . . . . . . . . . . 99
1.2.1 Checking Engine Coolant. . . . . . . . . . . . . . 76 2.6.1 Checking the Drive Motor Gearbox Oil . . 100
1.2.2 Changing Engine Coolant . . . . . . . . . . . . . 76 2.6.2 Changing the Drive Motor Gearbox Oil . . 101

2.7 Hydraulic Manifold Setups . . . . . . . . . . . . . . . .101 SECTION 5000
PROCESSOR SYSTEM . . . . . . . . . . . . . . . . . 123
SECTION 3000 Processor maintenance requires inspecting and replacing the
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . 103 standard and Key Knife systems, adjusting and replacing the
anvil, inspecting and replacing the chipper disk wear plate,
The electrical system consists of batteries and cables, engine
and setting up the chipper and changing chip size.
starter motor, machine controls, alternator, and battery dis-
connect switch. Use precautions when jump starting the en- 5.1 Chipper Knife Systems . . . . . . . . . . . . . . . . . . . 123
gine or welding on the machine.
5.1.1 Key Knife Maintenance . . . . . . . . . . . . . . 124
3.1 Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . .103 5.1.1.1 Replacing Key Knives . . . . . . . . . . . 124
3.1.1 E-Stop Buttons. . . . . . . . . . . . . . . . . . . . . .103 5.1.1.2 Replacing Key Counter Knives . . . . 127
3.1.2 Circuit Breakers . . . . . . . . . . . . . . . . . . . . .103 5.1.2 Standard Knife Maintenance . . . . . . . . . . 130
3.1.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 5.1.3 Knife Extension and the Highest Knife . . 134
3.1.4 Batteries, Cables, and Connections . . . . . .104
5.2 Anvil Maintenance . . . . . . . . . . . . . . . . . . . . . . 136
3.2 Jump Starting the Machine . . . . . . . . . . . . . . . .106 5.2.1 Checking Anvil Wear . . . . . . . . . . . . . . . . 136
3.3 Welding Precautions . . . . . . . . . . . . . . . . . . . . .107 5.2.2 Adjusting Anvil Clearance . . . . . . . . . . . . 137
3.3.1 Grounding Properly . . . . . . . . . . . . . . . . . .108 5.2.3 Rotating and Replacing the Anvil. . . . . . . 139
3.3.2 Bearing Protection . . . . . . . . . . . . . . . . . . .108 5.3 Chipper Disk Wear Plate . . . . . . . . . . . . . . . . . 140
3.3.3 Bearing Failure Examples . . . . . . . . . . . . .108
5.4 Adjusting Chip Size . . . . . . . . . . . . . . . . . . . . . 141
SECTION 4000 5.4.1 Calculating for Setup . . . . . . . . . . . . . . . . 141
FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . 111 5.4.1.1 Example Calculation . . . . . . . . . . . . 142
Maximum wear life and operating efficiency of the feed sys- 5.4.1.2 Formulas for Other Sheaves . . . . . . . 142
tem requires scheduled inspections and adjustments. 5.4.1.3 Standard Knife Setup Data . . . . . . . . 142
4.1 Maintaining the Flails . . . . . . . . . . . . . . . . . . . .111 5.4.1.4 Key Knife Setup Data. . . . . . . . . . . . 143
4.1.1 Flail Drums . . . . . . . . . . . . . . . . . . . . . . . .111 5.4.2 Feed Manifold Setup. . . . . . . . . . . . . . . . . 144
4.1.2 Flail Stands . . . . . . . . . . . . . . . . . . . . . . . .111 5.4.3 Feed Speed Tables . . . . . . . . . . . . . . . . . . 146
4.1.3 Flail Rods. . . . . . . . . . . . . . . . . . . . . . . . . .111 5.4.3.1 Feed Roll RPM Values. . . . . . . . . . . 146
4.1.4 Flail Chains . . . . . . . . . . . . . . . . . . . . . . . .112 5.4.3.2 Feed Speeds, 53 In. Chipper Sheave 148
4.1.4.1 Installing and Replacing Flail Chain .113 5.4.3.3 Feed Speeds, 60 In. Chipper Sheave 150
4.1.4.2 Rearranging Flail Chains. . . . . . . . . .115 5.4.3.4 Feed Speeds, 65 In. Chipper Sheave 152
4.2 Maintaining the UHMW Wear Plates . . . . . . . .116
SECTION 6000
4.2.1 Wear Plates for Flail Housings . . . . . . . . .116 DISCHARGE SYSTEM . . . . . . . . . . . . . . . . . 155
4.2.2 Wear Plates for the Bark Mover . . . . . . . .117 The chip spout requires little maintenance other than daily in-
spection of the spout support cable and lubrication of the
4.3 Clearing Jams. . . . . . . . . . . . . . . . . . . . . . . . . . .118 spout grease points. See “General Maintenance” on page 49
for the maintenance schedule.
4.4 Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . .119
4.4.1 Roll Case and Lower Feed Chains. . . . . . .119 SECTION 7000
4.4.2 Upper Feed and Chipper Feed Chains . . . .121 DISPLAY SCREENS . . . . . . . . . . . . . . . . . . 157
The Peterson Adaptive Control System provides display
screens for tracking maintenance intervals. For a complete
list of display screens, refer to the 5000H Operator Safety
Manual.
7.1 Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.2 Fuel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.3 Feed Speed Setup . . . . . . . . . . . . . . . . . . . . . . . 159
7.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . 160
SECTION 8000
LOG LOADER . . . . . . . . . . . . . . . . . . . . . . 161
Log loader maintenance includes inspection and tightening of
loose fasteners and regular lubrication of moving parts.
8.1 Loader Assembly Items . . . . . . . . . . . . . . . . . . 161

8.2 Loader Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.3 Loader Maintenance Schedule . . . . . . . . . . . . . 162
SECTION 9000
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
The wheels, the accessories, and the optional equipment re-
quire different levels of regular maintenance.
9.1 Wheel Hubs and Tires . . . . . . . . . . . . . . . . . . . 167

9.1.1 Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . 167
9.1.2 Wheel Hub Oil . . . . . . . . . . . . . . . . . . . . . 167
9.1.3 Trailer Wheel Lugs. . . . . . . . . . . . . . . . . . 167
9.2 Accessory Maintenance . . . . . . . . . . . . . . . . . . 169
9.2.1 Guards and Shields. . . . . . . . . . . . . . . . . . 169
9.2.2 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.2.3 Paint Color Numbers . . . . . . . . . . . . . . . . 169
9.2.4 Fire Extinguisher . . . . . . . . . . . . . . . . . . . 169
9.2.5 Air Compressor . . . . . . . . . . . . . . . . . . . . 169
9.2.6 Water Pump Sprayer . . . . . . . . . . . . . . . . 170
9.2.6.1 Water Hose. . . . . . . . . . . . . . . . . . . . 170
9.2.6.2 Tank Freeze Protection . . . . . . . . . . 170
9.2.7 Cab Climate Controls . . . . . . . . . . . . . . . . 170
9.3 Optional Equipment Maintenance . . . . . . . . . . 171
9.3.1 Grapple Saw . . . . . . . . . . . . . . . . . . . . . . . 171
9.3.2 Cold Weather Kits . . . . . . . . . . . . . . . . . . 172
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Page numbers in bold indicate machine controls.
Page numbers in Italic indicate photos and illustrations.

ABOUT THIS MANUAL
The information about this manual describes all the manuals that support the 5000H chipper, the safety notices you
need to follow, the definitions of special terms, and the text of the limited warranty.
The Manual Set 1 CAUTION

This manual is one book in a set that owners and opera- Indicates a potential hazard that, if not avoided,
tors should read and understand. The set consists of the may result in minor or moderate injury.
5000H Parts Book, this 5000H Operator Safety Man-
ual, the 5000H Maintenance Manual, and the 5000H Because alert messages can block the flow of a proce-
Service Manual. dure, shortened alert messages may appear in the step-
by-step task descriptions. For more detailed messages,
This 5000H Maintenance Manual provides owners and see “Working Safely” on page 13.
operators of the Peterson 5000H Chipper with valuable
information for maintaining the machine for a long life
of efficient operation. Important Messages
Please do not remove manuals from the machine. Miss- In addition to the hazard alert messages that refer to pos-
ing manuals can lead to hazards and delays when the sible injury to people, the manual uses the following
manuals are not read or cannot be found by those who type of alert message:
need them.
IMPORTANT: Indicates a situation that, if not
Peterson recommends that you become thoroughly noticed or avoided, may result in equipment or
familiar with these manuals to help ensure safe, effi- property damage. This message type is also used
cient material processing and long machine life. to call attention to opportunities for improving
machine performance or efficiency.
Alert Messages NOTE: Notes are information of minor importance, such as
Throughout this manual and on many decals mounted tips.
on the machine, you will see three types of hazard alert
messages that refer to risks of possible injury to people. Safety Instructions
These messages are shown with the following safety
alert symbols: A copy of the 5000H Operator Safety Manual, which
includes operating instructions, safety instructions, and
transportation procedures, is shipped on board each new
1 DANGER machine.
Many hazards involve systems from cross functional
Indicates an immediate hazard that, if not
avoided, will result in death or serious injury. categories. Be sure to read all the safety information
carefully to avoid hazardous operations and to become
aware of hazards that may arise during maintenance.
1 WARNING
Indicates a potential hazard that, if not avoided, Small Numbers
could result in death or serious injury. In Peterson product manuals, we insert a number, such
as F05555, in small typeface below each graphic to
identify its file name. This number is for editorial use
only.

ABOUT THIS MANUAL
Units of Weight and Measure

In this manual, U.S. customary units of weight and mea-
sure are stated first, followed by their SI (metric) values
in parentheses. For example, 10 lb (4.5 kg).
U.S. customary units are sometimes stated in words,
such as inches and gallons. They also appear as abbre-
viations, such as ft for foot or feet, °F for temperature
degrees Fahrenheit, and in. for inch or inches. Lbs or lb
indicate pounds or pound, and psi indicates pounds per
square inch.
Ft-lb is an abbreviation for “foot-pounds of torque,”
although in some fields the abbreviation lb-ft, for
“pound-feet of torque” is used.
A period (.) after the abbreviation is not included in
most cases, but is retained for the abbreviation of inch
(in.) to avoid confusion with the word “in” of similar
spelling.
Many SI units here have been rounded to avoid incor-
rect precision.
N/A means “not applicable.”

ABOUT THIS MANUAL
Limited Warranty
This warranty is Peterson’s entire and only warranty to This warranty is null and void if other than genuine
the Distributor and Distributor customers on resale with Peterson’s parts are used. Peterson makes no warranties
respect to the Products sold hereunder. This warranty is with respect to trade accessories or component parts not
expressly in lieu of all other warranties, expressed or manufactured by or distributed by Peterson. Those
implied, and any implied warranties of merchantability accessories or components are subject only to such war-
or fitness for a particular purpose are hereby excluded. ranties, if any, as may be made by their respective man-
This is a Limited Warranty, referring only to the prod- ufacturers. Peterson and its customers may expect that
uct, machine, part(s), or unit identified on the original certain operating parts of the product or unit require
sales order and is subject to other limitations established replacement as a result of normal use during the war-
by Peterson’s Warranty Policy and as hereinafter set ranty period. These parts include, but are not limited to:
forth. Peterson is here also referred to by its logo and wear liners, chains, bits or knives, bearings, filters, light
abbreviation Peterson. Only Peterson may assume any bulbs, belts, etc. Replacement of such parts is not
liability pertaining to its products. included within the warranty.
This Peterson product is warranted to be free from Before evaluating a warranty claim Peterson reserves
defects in workmanship and materials under normal use the right to require defective parts be returned for
and conditions for a period of six (6) months, or 1000 inspection with all charges prepaid.
operating hours, or 1000 service meter units, whichever (11/02/07)
occurs first, from the warranty start date. Products sold
as complete machines or operating units have a war-
ranty start date defined by the operating start date. Prod-
ucts sold as parts have a warranty start date defined by
the date of installation of the part. If the machine into
which the replacement part is installed is no longer
within the warranty period, no labor or mileage costs are
reimbursed.
Should any defect in workmanship or materials be
found and reported within the warranty period, Peterson
liability shall be limited to replacement parts and tech-
nician service for replacement, and shall be furnished as
stated in the Warranty Policy.
NOTE: Peterson’s products are not designed for pro-
cessing rocks, metal, or other non-crushables. Process-
ing non-crushables will damage the machine and/or its
parts. Peterson shall not be liable for any damage or per-
sonal injury as a result of rocks, metal, or other non-
crushables going through the machine.
This warranty shall not apply to any Peterson equipment
where the equipment has been subjected to accident or
misuse, or alterations unless Peterson has given prior
written consent. Peterson liability under this warranty is
limited to the repair or replacement of defective parts or
workmanship and in no event shall Peterson be liable
for incidental, consequential or indirect damages of any
kind.

ABOUT THIS MANUAL
Glossary
Table 1: Glossary of Terms for the 5000H
Term or Phrase Meaning
Anvil The stationary metal bar mounted to the chipper housing that supports the very end of
logs as the chipper knife cuts through the log.
Babbitting, Babbitted When referring to chipper knives, this is the process of adding molten babbitt metal to the
back end of a standard knife so that when it is installed it has the desired extension from
the wear plate of the chipper disk. Normally, a worn chipper knife is removed, re-ground
and then babbitted to restore the correct knife length. Babbitt metal is an alloy of tin,
copper, antimony, and lead.
Boom The portion of the loader arm connected to the cab base. Also known as Main Boom.
Chip Plant This term defines all the machine components related directly to debarking delimbing and
chipping. This would include the feed system, flail units, bark movers, chipper and chip
spout.
Chip Spout The long hollow pipe connected to the chipper through which chips are ejected. The
5000H is built with one of two chip spout styles: the top-loading spout and the shorter end-
loading spout.
Chipper Discharge Chute This is the opening on the chipper housing where chips first emerge from the chipping
process. The chip spout is bolted to the chipper discharge chute.
Chipper Hood The portion of the chipper housing that pivots open to expose the chipper disk.
Chock A curved, wedge-shaped block placed against a wheel to prevent movement.
Clutch The clutch engages and disengages the engine drive shaft from the machine drive shaft
that transmits power to the chip plant. See also, Power Take-Off (PTO).
Combustible Liquid Any liquid having a flash point at or above 100° F (37.8° C). For more details, see OSHA
(1910.106,18) or State of Oregon, OAR 437, same paragraph.
Coolant The engine’s liquid coolant consists mostly of water and is sometimes referred to as
“water.” However coolant always contains anti-freeze and additives. Coolant is used to
draw heat from the engine and release it in the radiator.
Coupler Shaft The dampered linkage between the engine and the gearbox drive shaft. It delivers power
from the engine to the cluster of hydraulic pumps connected to the pump-drive gearbox.
Cribbing Beams of wood, for example rail road ties, stacked evenly to form a four-sided column
that solidly supports the machine frame when working under the machine.
Cylinder Body or Base The hollow component of the hydraulic cylinder assembly from which the cylinder rod
extend. Also known as cylinder base.
Cylinder Rod The component of the hydraulic cylinder assembly that extends out of and retracts into the
cylinder body.
Dirt Separator Spout See Overs Spout.

ABOUT THIS MANUAL
Table 1: Glossary of Terms for the 5000H (Continued)

Feed Plate A removable plate built into the side of the chipper that seats firmly next to the anvil. Logs
strike and slide along the feed plate as they approach the anvil and chipper knives.
Feeler Gauge(s) Strips of metal fabricated to precise thicknesses. Feeler gauges of known thicknesses are
used to test the gap between the anvil and the chipper knife. When the required thickness
is achieved a slight sliding resistance is felt between the feeler gauge, knife edge and
anvil.
Fins The blades bolted to the discharge side of the chipper disk. The fins work like fan blades,
helping to blow chips out the chip spout.
Flail The rotating drum with attached chains that strike logs and remove bark and small limbs
from logs. Also known as debarker.
Flail Rod A rod which flail chains are hung onto. Ends of flail chains are insert through holes in flail
drum and strung onto flail rods inside flail drum.
Flail Stand A metal bracket with rubber pad on which upper flail housings come to rest in their lowest
position. Flail stands are adjustable to different heights. Each flail housing has two
adjustable flail stands. Also known as stops or machine stops.
Flammable Liquid Any liquid having a flash point below 100° F (37.8° C), with certain exceptions. Replaces
the term inflammable which is no longer correct.
Flash Point The minimum temperature at which a liquid gives off vapor in sufficient concentration near
the surface to form an ignitable mixture with air.
Float On the 5000H this term applies to the way feed rolls and flail housings are partially
supported by hydraulic cylinders so that they weigh less and can readily rise up and over
logs passing through. On the 5000H the feed rolls and flail housings are never set to
actually float upwards on their own although the system can be set to do this. In the float
setting the feed roll or flail housing should slowly drop down with little force.
Front of Machine The end of the 5000H that is closest to the towing hitch point and the engine.
Glad-hand Couplers The two quick-release connection terminals where the pneumatic brake hoses from the
towing vehicle are connected to the brake system for the 5000H. The glad-hand couplers
are mounted on the front of the machine.
Grapple The claw-shaped parts at the end of the log loader that are used to enclose and grip logs.
Heel Rack The bracket that attaches to the stick portion of the loader arm. It guides or braces the
ends of logs being gripped by the grapple.
Hydraulic Cylinder This term refers to a complete hydraulic component assembly or sub-assembly with all its
moving, stationary, and replaceable parts. Hydraulic cylinders move parts of the machine
such as the flail housings and loader arm. Also known as Actuator.
Hydraulic Lift/Float A customer-chosen option that utilizes hydraulic cylinders to lift and float the upper flail
and feed roll housings. This option is provided on machines to be used in cold climates
where pneumatic cylinders may not function as well.
Joystick A control lever that can be moved in several dimensions causing different machine
actions based on direction of movement.

ABOUT THIS MANUAL

Kills Engine or Kills All The term “kills,” as in “kills the engine” is American slang, meaning to cause to cease
Systems operating or shut down. “Kills all systems” means to shut down all systems. A “kill button”
is a button or switch designed to shut down an engine or system quickly. Also known as
shut down, emergency stop.
Knife Pocket The term knife pocket has two different meanings on the 5000H:
• The chipper disk has three or four large openings called knife pockets that each hold an
entire knife assembly consisting of the knife holders, clamps, counter knives and
knives.
• Each knife holder has knife pockets that the knives fit into.
Landing Gear The two hydraulically operated legs near the front of the 5000H that raise or lower the
front end of the machine. Landing gear are used during hitching/unhitching and when
leveling the machine. See also, Stabilizers, Outriggers.
OSHA Occupational Safety & Health Administration. A US agency that regulates workplace
safety and health conditions. Agency falls under US Department of Labor.
Overs Spout The outlet from the chipper located immediately to the left of the chip spout. Over-sized
objects “overs” are ejected through the overs spout. Also known as dirt separator spout.
Paddle See Fins
PTO Abbreviation for Power Take-Off. This is an additional engine driveshaft that can be used
to provide power to an attachment such as an hydraulic pump.
Pump Drive Gearbox The pump drive gearbox receives power from the drive line and distributes the power to
various hydraulic pumps that provide power to the flails, feed rolls, loader, and cooler
fans.
Roll Case Rolls The series of 5 or 6 chain-driven rollers that move logs from the debarker to the chipper.
Rotate Flail Chain or Rotate in this context means to change the position of the flail chain or anvil so that an
Rotate Anvil unworn portion is exposed for use. Also known as rearrange or flip.
RPM RPM is an abbreviation for revolutions per minute.
Spin-on Filter A filter with a threaded opening which is installed by turning it onto a threaded connection.
Stabilizers The two hydraulically operated legs near the rear of the machine that help support and
stabilize the machine when the log loader is being operated. Stabilizers extend at an
angle out beyond the sides of the machine thus providing added stability. Also known as
outrigger. Stabilizer is not the same as landing gear. See also, Landing Gear.
Stick The outer segment of the loader arm that holds the grapple. The stick is attached to the
boom. See also, boom, also known as stick boom.
Suction Pump Ball Valve Control flow of hydraulic fluid from the hydraulic tank to the pumps and motors. Serious,
Levers permanent pump damage occurs if these valves are not open during machine start up and
operation.
Swing Bearing The large circular bearing that the turret and log loader rotate on. The word swing is
another word for rotation of the cab and log loader.

ABOUT THIS MANUAL

Tachometer A device for measuring the rotational speed of an object. Contains a display which
indicates speed in revolutions per minute (RPM). A photo-tachometer reads RPM by
optically detecting a reflective moving line or spot on a rotating shaft.
Turret The rotating platform on which the cab and loader arm are mounted.
Twig Knockers These are short nubs mounted on the outside edge of the chipper that help move small
twigs and debris out of the chipper. They function primarily as clamps that help secure the
wear plate to the chipper disk. Also known as nubs, wear plate clamps.
UHMW UHMW is what some of the plastic wear plates on the 5000H are made of. UHMW is an
abbreviation for “Ultra High Molecular Weight.” The term describes several types of
dense, wear-resistant plastics used for abrasion or wear-resistant surface protection.
Usually a polypropylene or polyethylene plastic.
Wear Plate This term has two meanings on the 5000H:

• Plastic wear plates made of UHMW are found in the bark mover and flail housings.
These protect the metal housings and provide smooth operation for moving metal
parts.
• The chipper disk, on the knife side, is fully covered by a metal wear plate that slowly
wears down from logs being chipped. When this wear plate wears down, chip quality is
affected because it affects the position of logs in relation to chipper knives.

ABOUT THIS MANUAL

WORKING SAFELY
Safe working conditions require you to avoid machine and job-site hazards, to practice fire prevention, and to follow
safety instructions.
Introduction from the machine, pointing the overs spout in a safe dis-
charge direction, positioning the machine across the
wind, and keeping the machine clean and well main-
This chapter provides complete information about how tained.
to work safely while operating and maintaining the
5000H Chipper. Features and Devices: The primary safety devices
for machine operation are guards, shields, alarms, auto-
Safety Topics matic machine response, hazard warning labels, and an
emergency stop system.
The safety topics cover the following information:
The primary safety devices for machine maintenance
Safety First: Discusses your responsibility for taking are a battery disconnect and lock-out switch; support
safety seriously. stops, pins, and blocks; and secure, slip resistant access.
Machine Safety: Describes the hazards of operating
the machine and identifies safety devices and special
precautions for individual assemblies.
Fire Prevention and Suppression: Describes fire
risks, best practices for fire risk prevention, and fire-
fighting preparations. Covers use of the fire extin-
guisher and the pump sprayer.
Job Site Safety: Discusses the hazards and necessary
precautions for setting up and operating a 5000H chip-
per.
Safety Labels: Displays danger, warning, and cau-
tion decals attached to the machine and lists the warning
messages for performing maintenance.
Safety Summary
Safe operation requires understanding the hazards that
exist, the techniques for avoiding unsafe situations, and
the features and devices of the machine that support
using it safely.
Hazards: When operating the machine, the main haz-
ards arise from movement of machine parts, the possi-
bility of fire, and flying or falling materials. The risk
levels from these hazards are increased by limited visi-
bility and communications around the machine.
Techniques: Important safety techniques for reducing
risk levels involve keeping people at a safe distance

Safety First! Do not attempt to defeat any factory-installed safety
system.
Make safety your first priority. Become familiar with Do not make any field or design modifications to any
this entire manual before attempting to operate the mechanical, electrical, or hydraulic systems without
machine. Before starting the machine, become familiar prior approval in writing from Peterson. Unapproved
with all controls. modifications may void the warranty and increase risks
of safety hazards.
Do not allow anyone to work on the machine who does
not put safety first. Failure to follow safety warnings, The 5000H chipper is a high speed machine. The pri-
messages, and other hazard alert signals could result in mary intended purpose of this machine is to chip trees
serious injury or death. fed into it. It is not intended to chip other products, met-
als, or rocks. Such scrap can cause severe damage to the
Responsibility for Safety machine. This type of damage is not covered by war-
ranty (see “Limited Warranty” on page 7).
Read the safety information carefully to avoid hazard-
ous operating conditions. It is not possible for Peterson
to be aware of all hazardous conditions. It remains the
Operator Qualifications
responsibility of the owner and operator to expect and Those selected to be operators must possess the follow-
avoid unsafe conditions. Safety must be the full-time ing qualities:
responsibility of the owner, operator, and everyone Must Be 18: In the United States, operators of the
working around or on the machine. 5000H must be at least 18 years old. See Code of Fed-
The machine is designed for safe operation. It must eral Regulations: Labor 29: 570.2,a, I.
always be started, operated and serviced by paying Must Be Alert and Sober: Never operate the 5000H
attention to safety procedures. while under the influence of drugs and/or alcohol. Use
Do not permit anyone to operate, service, repair, work of prescription or over-the-counter drugs requires med-
on or around this machine unless they have read and ical advice on whether or not you can safely operate this
understood the safety and operating information. machine.
If you do not already have a complete safety program, Must Not Have Health Restrictions: Do not oper-
including active safety training and on-going, on-site ate the 5000H if you are subject to dizziness, seizures,
safety improvement programs, Peterson strongly rec- or motion disturbance. Operators can experience move-
ommends starting one. ment, jerking, swaying, and vibration when sitting in
the operator’s cab while operating the 5000H.
Use Only for the Designed Must Be Authorized and Trained: 5000H opera-
Purpose
tors must be authorized by the owner of the machine,
and must be trained in all its functions and capabilities
The 5000H must be used to do only the work for which before operating it.
it was designed. Unsafe conditions may occur if the
machine is operated under the following conditions:
• With loads containing material it was not designed
to process
• With accessories, modifications, or attachments not
designed and furnished, or approved, by Peterson
• With modifications that work against its operation
or capacity

Machine Safety These buttons shut off the engine. They lock
when pushed. They must be manually pulled
out again before restarting the engine.
This section describes the hazards of operating the
machine and identifies the safety devices for reducing • Turn the ENGINE switch to OFF on the control
risk of injury. panel. This may take more time to activate, but
it effectively stops the engine and all engine-
Safety Controls driven systems.
Safe use of the machine during normal operation, main-

tenance, and emergencies requires full control of the
engine and energized systems. This section describes
how to use the Emergency Stop buttons and the battery
disconnect switch, including how to lock out and tag
out.
Emergency Stop (E-Stop) Buttons

An Emergency Stop button is the primary means for
rapidly shutting down the entire machine in an emer-
gency.
1 WARNING
Avoid injury or death. The chipper disk continues
to spin for a short period after pushing the E-Stop
button. Do not approach the disk until it stops.
IMPORTANT: Avoid engine damage. Do not use

the E-Stop to routinely shut down the machine.
◆ To shut down in an emergency: F05314
• Do one of the following actions: Figure 1: E-Stop on the Engine Control Panel (JB2)
• Push in the red EMERGENCY STOP button
(Figure 1) on the Engine Control Panel (JB2),
located above the hydraulic tank on the left side
of the machine.
• Push in one of the three additional red EMER-
GENCY STOP buttons:
• On the Spout and Leveling Control Panel
(JB3) (Figure 2).
• From ground level on the main ladder side
of the machine, opposite the chip spout
(Figure 3).
• In the cab (Figure 4).

F06001
Figure 4: E-Stop in the Cab
Battery Disconnect Switch

Use the battery disconnect switch (Figure 5) to turn on
F05938 and off the electrical control system by connecting and
disconnecting the machine batteries. In the locked-out
Figure 2: E-Stop on the Spout and Leveling Panel (JB3)
condition, a hinged, lockable security plate covers the
keyhole (see Figure 6 on page 17).
F05315
F05397
Figure 3: E-Stop Near the Ladder, Forward Left Side Figure 5: Battery Disconnect Switch in the ON Position

Use the battery disconnect switch to turn off the electri-
cal control system under the following conditions:
• When the machine is left unattended
• When the machine is being serviced or repaired
• To prevent starting
With the key-operated battery disconnect switch turned
on, the battery supplies power to the engine control
panel and to the engine starter. With the battery discon-
nect switch turned off, no electrical power is available
from the battery to start the engine.
1 WARNING
When the engine is stopped, and the key is in
OFF position, the system is de-energized, but not
locked out. Do not perform maintenance until the
cover is closed and pad-locked (see “Battery Dis-
connect Lockout/Tagout” on page 17).
F05382
Figure 6: Battery Disconnect Lockout

1 CAUTION
Do not use the battery disconnect switch to
attempt shutdown. Everyone maintaining or servicing the machine must
lock and tag it out. Lockout/tagout procedures must be
• Turning off the battery disconnect switch
followed as written by federal (OSHA in the U.S.), state
while the engine is running can create electri-
(such as OR-OSHA in Oregon, U.S.), provincial, or
cal loads, spikes, and surges that cause
local authorities.
expensive electrical damage to the alternator,
micro-processor, electronic control module Certain maintenance and service activities require that
(ECM), and other sensitive parts. work be done with systems energized or with the engine
• Use the Engine switch for normal shutdown. running. Only authorized mechanics or service techni-
Only when the engine has fully stopped cians are qualified to make a decision not to lock out and
should you then turn off the battery discon- should do so only when necessary.
nect switch.
◆ To lock out or tag out the machine:
Battery Disconnect Lockout/Tagout 1. Turn the ENGINE switch to OFF at the Engine con-
The 5000H is equipped at the factory with a safety lock- trol panel (Figure 7) to stop the engine.
out device for the whole machine (Figure 6). Most shut-
downs require lockout to prevent accidental start-up and
other hazards when a machine is being cleaned, ser-
viced, repaired, or is off shift.

Stored Energy
Some machine systems retain stored energy after the
engine has shut down and the battery disconnect switch
has been locked out. Accidental release of this energy
can cause serious injury or death.
The following sources of stored energy are discussed in
this section:
• Inertia of the chipper disk
• Falling objects
• Jams or blockage
• Pressurized gases and fluids
• Electrical energy
Inertia of the Chipper Disk

The chipper disk continues to rotate after the machine
shuts down because of its large mass and free rotation.
Do not expose any part of your body to the moving disk.
You may suffer an injury, including amputation of fin-
gers, hand, or toes.
F05314 In the same way, the chipper disk drive belts move
Figure 7: Engine Switch at JB2, Engine Control Panel whenever the chipper disk itself is moving. Do not
touch the belts while they are moving. Disk inertia can
grab and trap you into the moving system of sheave,
2. Turn off the battery disconnect switch and remove belts, and chipper disk, which can cause extreme injury.
the key.
In the area of the chipper disk, pay attention to the fol-
3. Close, lock, and tag out the battery disconnect lowing warning label:
switch.
4. Observe the following precautions:
• Keep the battery disconnect switch key and the 1 WARNING
padlock key in a secure location when the Stay away from the spout opening. The exposed
machine is shut down. moving chipper disk can cut and crush.
• When more than one person is working on or
around the machine, use multiple lockout Falling Objects
devices so that each person has their own pad- Any raised or overhead device has stored energy and
lock and key. can fall if its supports fail or are caused to fail. Do not
• Do not disregard lockout procedures. Doing so place yourself under any object that can fall or move by
can be very dangerous. loss of hydraulic pressure or mechanical support.
5000H Support System

Errors during the hitching process can cause the 5000H
to suddenly shift or drop when the its front end is being
raised for hitching to a towing vehicle.

The 5000H can sink when parked on weak, compress-
ible or unstable ground. Hydraulic system leaks or dam-
age related to the landing gear can cause the 5000H to
drop.
Safety Locking Stops and Pins

The following safety pins and locking stops are chained
to the machine near the points where they are used:
• Two safety pins for the upper debarker feed roll
housing
• Two safety pins for each upper flail housing
• Two safety pins for the chipper feed roll housing
• One chipper disk safety pin
• One chipper hood safety pin
1 DANGER
Always use safety pins. The upper feed rolls and
the upper flail housing(s) can cause serious and
fatal crushing injuries if they drop onto someone
working under them. As these housings move up
and down, they can also cause injuries on the
sides where the housing frame slides past the
machine frame.
The location of the safety pin for the chipper feed roll,
the upper flail housing(s) and the upper debarker feed
roll are shown in Figure 8 on page 20 and Figure 9 on
page 21. The chipper disk and chipper hood safety pins
are shown in Figure 13 on page 24.
The safety pins are used to hold the flail housings, feed
roll housings, and the chipper hood in the raised posi-
tion during inspections and maintenance. For the hous-
ings, be sure to use both pins, one on each side of the
machine.
After they are installed, pins can come out if not secured
by the weight of the housing. It is important to lower the
housing onto the pins as soon as the pins are installed.
Each time the housing is raised and lowered back onto
the pins, re-inspect the pins to ensure that they are fully
inserted.

F05898
1 F05321 2 F05334
3 F05324
4 F05322
1. Debarker Feed Roll Housing

2. 1st Upper Flail Housing
3. 2nd Upper Flail Housing
4. Chipper Feed Roll Housing
Figure 8: Safety Pins: Feed and Flail Housings, Right Side

F05331
F05329 F05332b F05333

5 6 F05332a
7 8
5. Chipper Feed Roll Housing

6. 2nd Upper Flail Housing
7. 1st Upper Flail Housing
8. Debarker Feed Roll Housing
Figure 9: Safety Pins: Feed and Flail Housings, Left Side
Securing the Feed Roll and Flail Housings fatal crushing injuries by dropping onto people working
Whenever you work on the machine, use safety locking under them. As they move up and down, they can also
pins to support the feed roll housings and the upper flail cause injuries on the sides where the housing frame
housing(s) in the raised position. The debarker feed roll slides past the machine frame. Notice that the hydraulic
housing and the upper flail housing each require two lifting cylinder is extended when the housing is raised.
safety pins to lock the housing in the raised position.
The debarker feed roll and its housing (Figure 10) and
the upper flail housing (Figure 11) can cause serious or

way to the point where the head of the pin makes
contact with the frame of the 5000H. Then without
delay, complete the next step.
5. Lower the housing onto the pins.
◆ To remove safety pins from the feed roll or

the flail housings:
1. Visually inspect the area under and at the sides of
the housing or roll to be sure no person or tools are
in the hazard zones.
2. Start the engine.
3. Raise the housing.
4. Pull the pins completely out and place them in the
nearby pin holders for storage.
F06005 5. Lower the housing.
Figure 10: Raised Debarker Feed Roll Housing, Right Side
1 WARNING
Crushing hazard. Using the wrong safety pins or
pins not approved and supplied by Peterson
could result in serious injury or death.
1 WARNING
Crushing hazard. Never attempt to remove the
pins from inside or while a person is in the feed
chamber or near the point of operation.
1 WARNING
Never attempt to remove any safety locking pin
from inside or while you are or any other person
F06006
is under the weight it supports.
Figure 11: Raised Upper Flail Housing, Left Side
IMPORTANT: Immediately replace pins that are
bent, damaged, deformed, or do not easily slide
◆ To lock the feed roll and upper flail in and out by hand. Use only Peterson approved
housings in the raised position: safety pins.
1. Make sure logs have passed completely through the
feed system and chipper. ◆ To remove a safety pin that is stuck:
2. Disengage the clutch and allow the chipper disk to 1. From outside the machine, use a slide hammer or
come to a complete stop. other device to pry the pin out.
3. Raise the housing to the highest position. 2. Weld a metal anchor to the pin and pull the pin out.
4. Insert each of the 2 safety pins fully into the holes 3. Contact your Peterson dealer for information about
in the sides of the machine. They must go all the removing stuck pins.

Securing the Chipper Hood
The chipper hood, when fully opened and when the
machine is level, comes to rest at a point where its cen-
ter of gravity stabilizes it and prevents it from swinging
down. Also, the hood hydraulic cylinder helps keep the
hood open.
Do not loosen the hood clamp or bolts that secure the
chipper disk hood until the chipper disk has stopped
rotating and has come to a complete stop.
Do not open the chipper hood when the machine is not
level.
Always insert the hood safety pin immediately after
raising the chipper hood. Keep the pin locked in posi-
tion until the hood is closed.
◆ To open the chipper hood:

1. Make sure the clutch is disengaged and the chipper
disk is not rotating. (The disk sheave and drive belt
must not be rotating.) F05398
2. Shut down and lock out the machine. Figure 12: Chipper Hood Switch
3. Wait until the chipper disk has stopped.
4. Loosen and remove the bolts on the chipper disk
hood. 9. Open the hood fully.
5. Loosen the large bolt on the disk hood clamp. 10. Face the knife side of the chipper and remove the
hood locking pin from its holder.
6. Swing the clamp open.
11. Insert the pin through the 4 aligned holes to secure
7. Restart the engine.
the hood in its fully open position (Figure 13).
8. Turn and hold the CHIPPER HOOD switch
12. Shut down and lock out the machine.
(Figure 12) to the open (up arrow) position.

Pressurized Gases and Fluids
Accidental release or leak of pressurized gases or fluids
1
can cause injury. Some systems may remain pressurized
after the engine has shut down.
Hydraulics: High pressure hydraulic leaks can punc-
ture skin and cause blood poisoning. Do not check for
hydraulic leaks by hand. Use cardboard, heavy paper, or
other objects to detect a leak and its source.
Engine Coolant: The engine radiator coolant reaches
scalding temperatures under pressure. Do not remove
the radiator cap when the engine is hot.
3 2
Electrical Energy Hazards
4
Accidental release of stored electrical energy can cause
4 shock, burns, or fire. The 24-volt system on board the
machine uses industrial-duty batteries with up to 1300
F05399
1. Chipper Hood Locking Pin 3. Chipper Disk Locking Pin
amp-hours cranking capacity when fully charged.
2. Pin Access Cover 4. Pin Holders
Figure 13: Chipper Disk and Chipper Hood Locking Pins 1 WARNING
Avoid physical injury and chemical burns. Explo-
sive hydrogen gas may be present around the
Chip Spout Falling Hazard batteries. Do not allow cigarette smoking, flame,
Do not walk under the chip spout. Should its support or sparks around the battery. Wear safety gog-
system fail, the spout could fall and injure anyone stand- gles and skin covering that is impervious to bat-
ing underneath it. See also, “Chip Spout Hazards” on tery acid when working around the batteries.
page 28. Battery box lids must be clamped down at all
times.
Loader Falling Hazard
Be aware of the following safety concerns when work-
ing around the log loader: 1 WARNING
• A log that falls from the grapple can crush anyone Avoid electric shock from batteries. Improper
underneath it. handling of batteries, wiring and connections
must be prevented. Only those people with
• The loader arm and grapple, if left in the raised appropriate training in the electrical systems for
position, can drop and cause injury. the 5000H are permitted to handle batteries, elec-
• See also, “Log Loader Hazards” on page 29. trical connections, and wiring.
Jams or Blockage Moving Parts

Stray material can sometimes block a feed roll or flail Machine parts that move during operation present dan-
housing, which prevents it from closing and keeps it in gerous conditions to avoid. This section covers the bark
a raised position. Removal of that material could place mover, crushing and pinching hazards, guards and
you at risk of being crushed or pinched if the housing shields, and preventing loader swing. See also “Chipper
were to fall suddenly. See also, “Removing Jammed Disk Hazards” on page 27.
Logs” on page 26.

Bark Mover Hazards • Never attempt to remove any safety locking pin
from inside or while you or any other person is
Hazards associated with the bark mover:
under the weight it supports.
• Anyone near or in the bark mover push zone can be
• Be cautious near the cab. It can rotate suddenly,
seriously injured or killed if the bark mover starts
pushing a person off the machine, leading to a fall
operating.
of 11 feet (3.3 m).
• Moving bark mover components on both sides of
• Never try to remove a jam when the machine is run-
the 5000H can cause injury or death.
ning. Stop the machine completely if material is
Follow these rules to avoid the bark mover hazards: jammed anywhere in the machine. Lock out the bat-
• Perform the machine shutdown and lockout proce- tery disconnect switch before removing the jam.
dures as described in “Battery Disconnect Lockout/ • Do not attempt to manually force jammed materials
Tagout” on page 17 before entering the bark mover into or out of the machine while it is running.
push zone or working in the path of moving compo- • Do not climb into the feed chamber or flail chamber
nents. Follow any lockout/tagout procedures until the engine has been shut down, the battery dis-
required by governmental safety standards. connect switch locked out, and all components have
• Before starting operation, always lower the back come to a complete stop.
guard door of the bark mover to the horizontal posi- • Maintain rigorous safety procedures in operating
tion. This protects anyone in the area behind the the chipper. If proper safety precautions are not
bark mover from the moving plunger. taken, this equipment can cause serious injury or
death.
Crushing and Pinching Hazards
Be alert for the following crush and pinch hazards: Guards and Shields
• Keep clear of all moving parts, such as pulleys, The machine includes the following design features to
chains, sheaves, and belts, while the machine is run- help prevent personal injury. Even while taking advan-
ning. Keep all guards in place during operation. tage of these safety features, continue to use caution
Stay alert. Do not rely on guards to compensate for when working on or near the machine.
mental lapses. • Drive belt guards enclose the drive belts and rotat-
• Keep hands clear of the moving parts on the feed ing shafts.
roll and flail housings while opening or closing the • A welded wire frame keeps hands and fingers away
housings for maintenance (see “Securing the Feed from the engine fan.
Roll and Flail Housings” on page 21).
• Hand holds and handrails are located where opera-
• Keep hands away from the chip spout when operat- tors need support or a grab point when moving from
ing the hydraulic system for folding the spout to its one part of the machine to another.
travel position or for unfolding it to its operating
position. Avoid pinch points. • Do not clean or lubricate any rotating or moving
parts while the engine is running, except as
• Do not place yourself or any part of your body in the instructed elsewhere in this manual.
following positions:
• Do not work on or around any mechanical drive
• Under any pivoting component without first units, or any rotating or moving components, such
installing a locking device as sheaves, chains, or belts when the machine is
• Under the machine unless it is appropriately running.
supported, securely blocked, or cribbed Keep clear of all moving parts such as pulleys while the
• Never remove the safety locking pin while a person machine is running. Keep all guards in place during
is in the chipper or near the point of operation. operation. Stay alert.

Loader Swing Hazard • The feed roll and flail housings can drop and crush
anyone working under them if safety pins are not
Watch out for personnel on the ground and within the
installed on both sides.
swing and pick radius. People should stay back 200 feet
(61 m). • Anyone working to unjam logs near the feed roll
and flail housing can be seriously injured or killed
Watch out for the swing inertia of the grapple. Stopping
if the machine is still operating.
or moving the boom can allow the grapple to swing
beyond the movement of the boom. • When a feed roll or flail housing float is up, a pinch
point exists where the roll rotates up toward the
Anticipate and know the loader swing radius as well as housing upper machine stop.
the swing of the grapple and any object, such as a log,
that it is grasping. Always avoid hitting people, the cab, • Logs being drawn into the feed or flail rolls can
the skidder, or other objects at risk. move with force and injure anyone standing nearby.
See also, “Log Loader Hazards” on page 29. • Anyone who attempts to feed logs or wood into the
feed rolls or flails by hand can be seriously or
fatally injured. Groups of logs or logs with limbs
can drag a person into the feed rolls.
• Logs can be ejected from the feed roll suddenly or
can be backed out of the flail chamber suddenly,
seriously injuring anyone standing in the feed zone.
Removing Jammed Logs
1 WARNING
Crushing or pinching hazard. Never attempt to
manually force jammed logs into the chipper.
Never attempt to manually remove logs from the
chipper when the machine is operating.
Before working in the feed zone, the flail housings, or
under or close to the feed rolls, shut down and lock out
the 5000H and install the safety pins.
F05451 Do not allow anyone to stand in the feed zone when the
Figure 14: Loader Safety 5000H is operating.
When the 5000H is running, use only the grapple to
move logs in the feed zone. Never allow anyone to be in
Point of Operation the feed zone to assist feeding logs or to help unjam
logs.
The point of operation is the area where the 5000H cuts
logs to chips. ◆ To unjam a log from the machine:
Be sure to shut down and lock out the battery disconnect 1. Stop the feed system.
switch for any maintenance or service at or near the 2. Reverse the feed system.
point of operation.
Do the following if the log is still jammed and has
Feed Roll and Flail Housing Hazards to be cut:
The following hazards are associated with the feed roll

and flail housings:

a. Use safety pins to secure the upper feed roll Whenever you perform maintenance on the chipper or
housing and/or the flail housing in the up posi- its drive equipment, such as inspection or changing
tion. knives, observe the following precautions:
b. Shut down and lock out the machine. • Allow the chipper to come to a full stop
c. Cut the log and remove it before restarting the • Turn off the battery disconnect switch
machine.
• Remove the battery disconnect key and locking out
the switch
Chipper Disk Hazards
• Always work with a partner
Maintain rigorous safety procedures in operating the
chipper. If proper safety precautions are not taken, this • Rotate the chipper slowly by hand, voicing warn-
equipment can cause serious injury or death. ings to any others who may be working close to the
chipper
Never operate the chipper or engage the clutch without
checking to be absolutely sure everyone is clear of the • Insert the chipper disk safety locking pin
machine.
Rotating the Chipper Disk Manually
Feed logs only. Do not feed any materials into the
machine other than those for which it was originally
designed to process. 1 WARNING
Do not try to stop the chipper disk. The chipper disk is Crushing, pinching, cutting, amputation hazard.
massive and free-wheeling, allowing it to coast for sev- Injuries to the fingers, hands, and feet can occur
eral minutes after the clutch is disengaged or the engine when working around the chipper disk.
is turned off. Parts of the disk include fins (also called fan blades) and
Wait until the chipper disk stops completely. Even slow knockers (also called twig knockers, nubs, and chipper
disk movement can be hazardous. Look through the twig paddles). When the disk is rotating, they pass close
chipper belt guard (Figure 15) to verify that the disk has to the chipper hood and frame very near where you must
come to a complete stop. stand.
The knives are sharp. And the small spaces between the
rotating disk and the housing can trap, pinch, crush, or
amputate body parts. These injuries can occur even
when the disk is being rotated slowly by hand.
When pushing on the disk, keep hands and fingers away
from sides and close clearance points.
Wear safety shoes with steel toes and keep hands, arms,
and feet away from the chipper housing when manually
rotating the chipper disk. A pinch point is created at foot
level as the disk moves toward the base of the chipper
housing.
◆ To rotate the chipper disk:

F05262
Push one of the knockers or paddles on the disk slowly:
Figure 15: Inspection Point for Chipper Rotation • Rotate the chipper disk backward (in the opposite
direction to knife-edge travel) during maintenance.
Do not turn the disk such that knife edges move
toward the anvil.

• Keep all body parts away from the chipper disk and 2. Inspect the disk sheave and drive belt to ensure that
the knives when rotating the chipper disk. the disk is not rotating.
3. Open the hood and lock it open with the chipper
Reversing Disk Rotation for Service hood pin. See “To open the chipper hood:” on
page 23.
1 WARNING 4. Loosen the small bolts on the chipper disk locking
pin cover. Swing the cover aside.
Avoid finger injuries or finger loss. Exercise
great care when working around chipper knives 5. Remove the chipper disk pin from its holder.
and disk. While setting knife clearance, rotate the 6. Manually rotate the disk slowly backward until the
disk backward. knife pocket appears.
Measuring the knife clearance is very important to chip When the knocker on the disk appears, a hole on the
quality and chipper performance. Typically, one person edge of the disk will align with the locking hole.
uses a feeler gauge to measure knife-to-anvil clearance 7. Insert the chipper disk safety pin in the hole at the
inside the chipping chamber at the face of the disk while top of the disk (Figure 13 on page 24). The safety
another person, outside the machine, rotates the disk pin drops into the hole in the edge of disk, prevent-
and adjusts bolts to position the anvil. ing the disk from moving.
To avoid injuring the inside worker, it is very important 8. Test the disk to be sure it cannot rotate.
to rotate the disk backward. The person inside, near the
knives, risks getting pinched or cut by the moving knife Chip Spout Hazards
blades as they cross the stationary anvil in a scissor
The following hazards are associated with the chip
action.
spout:
Chipper knives are sharp and, together with the holders,
• Flying objects can be thrown up to 200 feet (60 m)
are very heavy. Mishandling can cause deep cuts and
from the chip spout.
can amputate parts of fingers.
• When the chip spout is being folded for travel or
Wear cut-resistant gloves specifically designed for cut extended for operation, pinch points are created that
protection when handling the knives. Leather gloves or can pinch and crush body parts.
cut-proof gloves such as those made from Kevlar fiber
provide good protection. • Folding or unfolding the spout can bring it into con-
tact with vehicles, electrical wires, or other hazards.
Remove the knives from the knife holders first. Then
remove the knife holders from the knife pockets on the • People can be exposed to the rotating chipper disk
disk. and to flying objects if the chipper disk is still rotat-
ing when the spout is disconnected and folded.
Locking the Chipper Disk • See also, “Chip Spout Falling Hazard” on page 24.
The chipper disk safety locking pin prevents the disk
from turning. The edge of the disk has holes for insert-
ing the locking pin. Install the chipper disk safety lock- 1 WARNING
ing pin each time you service or inspect the chipper Electrocution Hazard. Avoid contacting overhead
disk. power lines. Contacting electric lines with the
chip spout can cause severe injury or death.
IMPORTANT: The chipper disk safety pin must Keep the chip spout at least 10 feet (3 m) from any
be inserted through the hole in the chipper hous- power line or power line support structure.
ing and into the hole in the chipper disk. Treat any wire as live and dangerous. If possible, have
the power line disconnected before you start work. If
◆ To lock the chipper disk from rotating: you know the chip spout has contacted a live wire, try to
1. Make sure the clutch is disengaged. swing it away from wire without downing the wire. If

this is not successful and wires are downed, warn others no objects are being ejected from the overs spout. Then
not to touch any part of the machine and to keep clear of without notice, large, heavy objects may fly outward.
the area. • The operator must be sure the overs spout deflector
is installed. See “Installing the Overs Spout Deflec-
1 WARNING •
tor” on page 77.
The operator must inform chip truck drivers of the
Avoid injury and amputation. When using the overs spout hazard zone and the importance of stay-
Spout Fold controls to extend or fold the chip ing out of hazard zones.
spout, keep people off the 5000H. Small spaces
between the chipper disk and the housing can • Truck drivers must also wear safety hard hats and
pinch, crush or amputate body parts when the full eye protection.
disk is moved during servicing.
During machine operation, do not allow anyone in the Cab Operator Safety
discharge hazard areas, as noted in the hazard zone dia- The loader operator is responsible for his or her per-
grams (see “Operating and Hazard Zones” on page 37). sonal safety and the safety of everyone else in the work
Before folding the spout for travel, disengage the clutch, area.
wait for the disk to stop rotating, and then lock the disk
from moving by inserting the chipper disk safety lock- Log Loader Hazards
ing pin. Whenever the spout is disconnected from the The following potential hazards are associated with log
chipper, the chipper disk safety pin must be installed. loading:
Overs Spout Hazards • Rotating the cab turret and pushing people off the
5000H, causing them to fall 11 feet (3.3 m). See
The overs spout is the short spout next to the chip spout. also, “Loader Swing Hazard” on page 26.
Without the deflector, heavy objects and over-sized
objects are ejected up to 200 feet (60 m) from the chip- • Dropping logs onto people. See also, “Loader Fall-
per through the overs spout. ing Hazard” on page 24.
• Striking people with logs in the grapple.
1 WARNING • Electrocuting people by contacting high voltage

lines with the loader boom, grapple, or logs.
Avoid injury and amputation. Do not insert your • Leaving the loader arm and grapple in the raised
hand into the overs spout while the chipper disk position from where it could fall on people.
is moving.
The overs spout deflector must be installed onto the
overs spout to minimize flying object hazards during 1 WARNING
operation. Crushing hazard. Before leaving the cab, always
lock the loader swing or place the boom in a posi-
tion that prevents it from turning. Otherwise, the
1 WARNING boom could suddenly turn by itself and cause
Chip truck drivers must avoid flying object haz- severe injuries or death to anyone in the operat-
ards from the overs spout. Avoid serious physi- ing range.
cal injury and possible death by staying clear of Disable the loader functions by making sure the Loader
the overs spout hazard zone shown in Figure 22 Functions button is OFF before getting out of the cab or
on page 40. before performing any maintenance, including greas-
Truck drivers and others must stay clear of the overs ing, on or near the loader.
spout hazard zone when operating the chip spout deflect
and chip spout rotate levers. There may be times when

Bring the grapple to rest on the ground (Figure 14 on
page 26) or in a stable position under the following con- Fire Prevention and
ditions:
• Any time you are not using it Suppression
• Before any maintenance
Regular cleaning, inspections, and maintenance are the
• At each shut down primary means of reducing the risk of fire hazard.
Safety is your responsibility.
Entering and Leaving
The preferred method of access to the cab is to climb the Daily Fire Prevention
steps on the sides of the machine, using the handrails for
stability and convenience. Fire prevention starts with the daily practice of ensuring
safe operation before, during, and after running the
The safest normal way to leave is to exit the cab door machine. At least once each day or more often, depend-
onto the landing, then turn and descend the steps while ing on your operation, clean combustible materials from
facing the machine. Use the handrails and hand holds the engine, the exhaust system, bearing housings, and
for a secure three-point descent. other heat sources.
Emergency Exit Before Operation

A second, emergency exit out of the cab roof is pro- Before starting or operating your machine, do the fol-
vided. This exit hatch can be opened from inside or out- lowing:
side without tools. Push the hatch open using about 25
lbs (11 kg) of force. • Read and understand fire safety statements in this
manual.
Do not block or modify the emergency exit hatch in any
• Be sure all items for fire suppression and prevention
way. Regularly check the function of the latches and
are ready for use.
hinges to be sure it can open properly if needed in an
emergency. • Be sure all personnel are trained in the use of fire
prevention and suppression equipment.
Lexan Windows • Inspect the machine and the area for fire hazards.
Thick safety windows are provided to help protect the
operator from harm. To keep maximum visibility, clean During Operation
the windows only with soapy water and a soft cloth, At all times while the machine is being operated, main-
avoiding abrasives and harsh cleaning chemicals. Clean tained, or inspected, do the following:
the windows regularly.
• Watch for hot ignitable materials, smoke or other
If a window becomes damaged, replace it immediately signs of fire.
with a part approved by Peterson.
• Extinguish any fire immediately.
Cab Heater Safety • Repair any oil or fuel leaks immediately.

Always turn off the heater while re-fueling the heater • Repair faulty electrical wiring and battery cables
tank, located near the cab door (see “Cab Heater” on immediately.
page 18). • Clean up any oil or fuel spills immediately.
Keep clothing, flammable material, and heat-sensitive • Do not permit open flames or sparks near ignitable
material at least two (2) inches (6 cm) from the heater. materials.
Regularly check to see that seals are tight and that no • Guard against fire when welding or flame cutting.
exhaust leaks into the cab area. • Do not allow smoking.

After Operation rials are allowed to accumulate on a hot engine or on
exhaust surfaces, a fire can start. Serious fires have
After stopping or shutting down your machine, do the
started this way.
following:
• Inspect the machine and the area for hot ignitable Signs of Fire: Watch at all times for smoke or other
materials or fires. signs of fire, and take immediate action to extinguish a
fire or prevent it from starting.
• Inspect the machine for oil or fuel leaks.
Small Spills: Small spills of oil or fuel raise the risk of
• Move all loose, ignitable materials off and away
fire if an ignition source (such as a spark, flame, or high
from machine.
heat point) suddenly enters that area.
• Prevent open flames or sparks near debris or oil.
Electrical Shorts: Electrical shorts caused by cor-
• Clean debris, dust, and all ignitable materials off the roded or faulty wiring, failed electrical insulation,
engine and hot surfaces. vibration damage to battery cables, terminals and other
• Remove debris from on, under, or around the electrical connectors, and other sources of sparks and
machine. heat must be avoided. Immediately repair faulty electri-
• Replace worn or leaky hydraulic hoses, sleeves, and cal wiring and battery cables.
fuel lines. Welding: Open flame or sparks near wood debris or
• Keep the fire extinguisher, the on-board water tank, oils are an obvious source of ignition. Welding or torch
water trucks, and other fire systems maintained and cutting can be especially hazardous in an environment
near the machine at all times. where woody materials are being reduced to small par-
ticles. Wearing the hood or goggles reduces visibility
Sources and Causes of Fires and the ability to detect a fire.
Smoking: Smoking tobacco in the chipping, wood
Failure to take precautions can lead to material fires
processing area is high risk behavior. Carelessness can
after shutdown. Pay attention to the following condi-
quickly lead to disaster. Peterson recommends a no-
tions:
smoking policy near the chipper machines.
Hot Bearings: Accumulations of wood dust on the
Hydraulic Leaks: Replace worn or leaky hydraulic
surface of bearing housings can act as insulation, raising
hoses, worn or missing hose sleeves, and fuel lines.
the temperature and helping to break down the lubri-
Take notice of pin-hole sized hydraulic or fuel leaks that
cants, eventually contributing to bearing damage.
may spray a fine mist of oil or fuel near a heat source.
Bearing parts may be hotter than they appear. If paint This is a highly flammable condition that operators and
discoloration, or smoke appears, do not touch the parts maintenance personnel must avoid.
until the bearing cools.
Mufflers: Maintain the muffler and exhaust system to
Sources of Heat: Risk of fire is always present when keep sparks from flying out the stack. Regularly inspect
working with heat sources, ignitable fluids, wood, and the muffler and exhaust system for rust spots and leaks.
other organic wastes. Replace as needed to prevent sparks from escaping.
The following ignitable materials are likely to be Training: Train new employees in fire prevention and
present on or near the machine: wood dust, chips and fire emergencies. Re-train more experienced personnel
debris, diesel fuel, gasoline, ether, hydraulic oil, lubri- for fire prevention and emergencies. Get professional
cants, rubber products, and other materials that burn. training on use of the fire extinguisher. Always place
Organic fibers can catch fire, especially when they con- personal safety ahead of the need to extinguish fires.
tact combustible liquids and materials.
Spontaneous Combustion: Wood particles com-
Clean-up: Daily clean-up is required for avoiding bined with oils or greases can burn spontaneously. As
fires and for extending the operating life of individual accumulations increase in depth, the likelihood of spon-
parts. If wood dust, debris, and other combustible mate- taneous combustion increases.

1 WARNING
Fire hazard. Fires can start in combustible mate-
1
rials around the machine many hours after it has 3
been shut down. If the machine is left unattended
2
after shutdown, make certain that it is not near
combustible or flammable materials.
Fire Suppression Equipment 4

Keep Class ABC fire extinguishers (intended for diesel
fuel or wood fires), water trucks, water pump sprayers,
and other fire suppression systems maintained in good
operating condition and near the machine at all times.
Fire Extinguisher 1. Hose Nozzle 3. Water Tank

F05395
The red fire extinguisher (Figure 16) shipped with the 2. Coiled Water Hose 4. Water Pump Starter
machine is mounted on the frame. The extinguisher
must be inspected annually. And it must be hydro-tested Figure 17: Self-contained Water Sprayer System
every 12 years.
Keep the canvas engine cover in place during travel and

when the machine is in storage.
Table 2: Self-contained Water Sprayer Specifications

Item Capacity/ Dimension
Tank capacity 150 gallons (568 liters)
Maximum solid 25 ft (8 m)
stream spray distance
F02935 1-inch diameter spray 50 ft (15.2 m)

hose length
Figure 16: Fire Extinguisher
Minimum full tank 12 minutes
discharge time
Water Pump Sprayer Nozzle Adjusts from solid stream to fog
The self-contained, gasoline-powered, water pump
sprayer (see Figure 17 on page 32) can help prevent The water sprayer can be an effective tool, but is not a
fires and keep the machine clean of dust and debris, substitute for other types of fire prevention equipment
which contribute to machine fires. The frame-mounted or for good fire safety practices. Always be prepared for
tank (Figure 18 on page 33) supplies the water through immediate response to a fire.
a hose and nozzle attached to the water pump. Table 2
• Use this water sprayer to wash debris off the
on page 32 specifies the capacities of the water sprayer
machine and to wet down the area around the
system.
machine.

• Keep the water tank (Figure 18 on page 33) filled at ◆ To shut down the water sprayer:
all times and ready for emergency use when the 1. Twist the spray nozzle to close it.
machine is operating.
2. Reduce the sprayer engine speed to low idle.
• Fire risk levels and hazards change with conditions
3. Turn off the ignition switch.
and job sites. Operators are in the best position to
use the water sprayer most effectively on each job 4. Turn off the fuel supply valve.
site. They are the ones most responsible for job site 5. Re-spool the hose.
fire safety and prevention.
• Use this water sprayer to fight Class A combustible ◆ To prevent tank water from freezing:
material fires. • Add antifreeze to the water in the tank, or take the
• Do not use the water sprayer on Class B flammable system out of service by draining it.
liquid fires or Class C electrical fires. • Consult a local supplier of fire fighting equipment
• Before travel, secure the hose end to prevent it from for anti-freeze.
loosening while transporting the chipper. • If you take the system out of service, drain the tank,
the pump, and then the hose.
F05931
Figure 18: Water Sprayer Tank Fill Cap
◆ To use the water sprayer:

1. Start the pump engine:
a. Turn on the fuel valve.
b. Turn on the ignition switch.
c. For cold starting, close the choke.
d. Open the throttle about 1/3.
e. Pull the starter cord to start the engine.
f. Adjust the choke and set the throttle to full
open.
2. Unspool the hose from the reel.
3. Twist the nozzle to set the spray pattern.

Job Site Safety Flying Objects Hazard
Site conditions vary widely. Your machine may not be
equipped with all devices mentioned. Local or federal 1 DANGER
safety codes and the safety rules of your organization Crushing or pinching hazard. Do not walk or
may add other safety concerns. climb into the log feed zone. Log movement and
One person can start, operate, and stop the 5000H, but flying objects create high risks.
it is good safety practice to have more than one person
at the work site. See “Operating and Hazard Zones” on
page 37. 1 WARNING
Avoid flying objects and whirling knives. If the
Moving Machinery Hazard chipper is operated when the spout is discon-
nected from the chipper assembly, material could
Anyone entering the work area of a 5000H on foot must fly from the chipper and hit anyone nearby. Peo-
realize the following conditions of work sites: ple working near the chipper could accidentally
• Several machines and operators may be at work in come in contact with the moving chipper disk
the same area. knives and be seriously injured.
• Machines working in the area are not likely to travel At any time when the spout is disconnected from the
in predictable paths. chipper discharge opening, or the spout is folded, the
chipper disk safety pin must be installed.
• Visibility is limited by the stacks of material being
processed and the size of the processing machines. Knots and other pieces of wood can sometimes be
thrown as far as 200 feet (60 meters). This could result
• A person may not be able to hear the approach of a in serious injury if it were to strike an unprotected per-
moving machine because several engines may be son. Flying objects are a continuing hazard at any time
running at the same time. material is being processed or the chipper is turning.
Together, these conditions create a potential hazard of
being hit by a moving machine, a hazard that is greater
than one finds in ordinary vehicle traffic. It is very
important to your safety that you follow these rules:
1 CAUTION
Avoid standing near the radiator. At intervals, the
• Do not enter the work area unless you have a spe- fan reverses to blow dust and debris from the
cific purpose. radiator. Wear eye protection.
• Make your presence visible to and acknowledged
by the operators of the various machines in the area. Noise Hazard
• Make no random or unexpected moves. Always wear hearing protection within 50 feet (15 m) of
• Walk, do not run. the machine when it is running.
Sound levels for the engine at 2150 RPM indicate that
hearing protection is required within 7 meters (25 feet).
OSHA (U.S.) has stated that exposure for 8 hours to
noise levels of 90 decibels on the A scale (dBA) is pos-
sible without hearing loss. Exposure of 2 hours at 100
dBA is possible without hearing loss.
At a distance of 15 meters (50 feet) or more from the
operating machine, noise levels are at or below the safe
OSHA (U.S.) 8-hour exposure limit.

Noise levels can vary widely, depending on the type of
material being processed, the rate of processing, the
Creating a Safe Workplace
structures near the 5000H, and the position of the lis- For a safe workplace, wear protective gear, avoid unsafe
tener relative to the noise source. Some directions away conditions, and practice safe behaviors.
from the machine are more quiet than others. Barriers,
such as piled materials and building walls, can absorb or Wear Protective Gear
reflect sounds, which can reduce or increase the noise. People near the 5000H while it is operating must wear
Noise levels drop with greater distance from the sound hard hats, eye protection, and ear protection. Heavy-
source, eventually reaching safe levels. soled shoes with toe protection and a high visibility vest
or other enhanced visibility clothing, and other safety
This decibel data can only approximate the noise condi-
equipment are recommended and may be required by
tions at your operating site. To be safe, always encour-
local codes.
age people to use ear plugs when working near the
5000H.
Avoid Unsafe Conditions
Protection against excessive noise requires taking
A safe workplace requires meeting the following condi-
sound level measurements of each site where the 5000H
tions:
is operated.
Training: Do not operate this machine unless you have
been trained in its safe use.
Crowding: Do not stand or walk near the loader when
it is loading the 5000H with logs.
Cleanliness: Use of high pressure air to clean the
machine of debris or for other maintenance activities
can be hazardous. Wear eye protection. Debris or small
objects can be blown with enough force to injure or
blind. Use only reduced pressure nozzles or other means
of keeping air pressures at or below 30 psi (2.1 bar).
This pressure is recommended by OSHA (in the U.S.)
as the maximum safe air pressure to use for cleaning
dust and debris from the machine.
Ventilation: Engine exhaust contains products of
combustion that are harmful to health. The engine uses
available oxygen, replacing it with toxic gasses. Always
start and operate the engine in a well-ventilated area. In
enclosed areas, vent engine exhaust outside. Ensure that
airborne concentrations of exhaust emissions do not
exceed current health standards.
Motor Oil: Used and hot motor oil vapors can be haz-
ardous. Inhaling vapors or swallowing oil can be dan-
gerous. Avoid prolonged contact with used motor oil.
Lifting: Avoid heavy lifting to prevent back injury and
muscle strains. Avoid twisting or over-reaching, espe-
cially when lifting or carrying heavy weights. When
work requires heavy lifting, get help or use mechanical
assistance.

Practice Safe Behaviors
A safe workplace requires practicing the following
behaviors:
First aid: Keep a well-stocked, accessible first aid kit
on site.
Inspect properly: Consider transporting the machine
to a shop or enclosed area for periodic inspection.
Double up: Although one person can start and stop
the 5000H, a good safety practice is to have more than
one person at a work site.
Instruct personnel: The owner and operator must
make sure that support personnel, observers, or others
needing to enter the operating area or work site are
aware of potential hazards and are properly trained in
safe approaches to it. Admit only authorized personnel
to the operating zone.
Communicate visually: Anyone needing to enter
the work area while the 5000H is operating must make
eye contact or other confirmed communication with the
operator, signaling their intent to approach. They should
approach only when it is safe to do so.
Stand back: Before starting the machine, inspect the
area for people and potential hazards. Make sure every-
one is well away from the operating area before starting
the diesel engine. Allow only trained personnel in haz-
ard zones. To estimate safe distances, see “Operating
and Hazard Zones” on page 37.
Shout warnings: Before starting up, follow the rec-
ommended warning procedures of your site. Typically,
shout a loud warning, and then wait and listen for 10
seconds before starting the machine.
Stay alert: After the 5000H is running at the required
speed, it can be left to run under the supervision of the
loader operator who feeds material to it. Other trained
support personnel may need to be in the operating area.
Everyone must remain alert and actively avoid hazards.
Sound the horn: Use the horn as needed to alert oth-
ers and to communicate. The Horn buttons allow the
operator, chip van driver, or others to signal to anyone
in the area that important safety-related events are about
to occur, such as starting up the engine or moving a
component. Horn buttons are mounted in the cab, at the
Spout and Leveling Control Panel (JB3), and at the
Engine Control Panel (JB2).

Operating and Hazard Zones
Figure 19 through Figure 25 show areas, or zones, Peterson assumes the 5000H is located within an
where material processing takes place and where haz- access-restricted zone where gates, fences, or other
ards are or may be present. The following zones are physical barriers prevent unauthorized people from
intended as general guidelines for reducing risks and entering.
improving productivity while using the 5000H: The operator must be made aware of and must commu-
• Hands-on Control Stations nicate approval for anyone entering an area.
• Log Handling and Loader Swing Zone Like most large wood processing machines, the 5000H
• Flying Materials Hazard Zone (200 ft or 60 m) is a powerful and potentially lethal machine if not oper-
ated safely. Effective safety devices have been incorpo-
• Log Loading Zone
rated into the machine, and safe operating procedures
• Falling Material Hazard Zone and Loader Access are provided.
Zone
Become familiar with machine components and con-
• Truck Access Zone trols, including unguarded moving machine compo-
The owner or operator must make sure that support per- nents, such as the loader and boom. See Figure 19 and
sonnel, observers, or others needing to enter the operat- Figure 21.
ing area or work site are properly trained in safe The owner or operator must fully understand the poten-
approaches to it and are aware of potential hazards. tial hazards and protective measures. The owner or
Admit only authorized people to the operating zone. operator must anticipate and avoid unsafe conditions in
Chip trucks and heavy equipment for moving logs pose all the various locations where the machine may be
serious hazards. Constant vigilance, site-safety training, operating.
and brightly-colored vests and hard hats are strongly
recommended.
4
2 5
3
1 6
F05383
1 3 5
1. Landing Gear 4. Flail Housing
2. Discharge Spout 5. Outriggers (Stabilizers)
3. Bark Mover 6. Log Loader Feeding Logs
Figure 19: Unguarded Moving Machine Components

1 2
F05384
1. Hot Engine Surfaces

2. Hearing Protection Zone
Figure 20: Area 1: High Noise and Hot Surfaces Zones
Area 1: Hands-on Control Stations Normal operating conditions include unexpected rever-
Be especially alert to hazards near the ladders, walk- sal in movement of the feed rolls or flails. By operator
way, engine, and control panel locations. The operator command, the feed rolls or flails may reverse at any
enters these areas (Figure 20) to start the engine, unfold time during normal operation. Material may spill out
the chip spout, check gauges, engage the clutch, check during reversal.
lubricant levels, and perform other functions. Hot engine, exhaust, and turbocharger surfaces can
Before starting the machine, inspect the area for people cause severe burns. Those same heat sources can cause
and potential hazards. dangerous and expensive fires if flammable dust and
wood debris are allowed to accumulate there.
Just before starting the machine, sound the horn and
shout two verbal warnings at least 10 seconds apart:
“Starting Up!” Then count 10 seconds.
“Starting Up!”
Moving the feed roll housing or the flail housing creates
pinch points. Objects can fly out from the feed rolls, the
flails, and the chip spout. High noise levels occur in this
zone. Hot engine surfaces can cause serious, permanent
burns.
Only trained, authorized personnel should be here dur-
ing machine operation, and they must stay on the
machine walkway.

2
1 F05833
1. Loader Swing Zone

2. Log Handling Zone
Figure 21: Area 2: Log Handling and Loader Swing Zones
Area 2: Log Handling and Loader Swing Zones

Do not stand near the machine when the engine is run-
ning. If you need to be closer than 200 ft (60 m), remain
at least 50 ft (15 m) from the machine (Figure 21) unless
authorized by the operator for closer approach. Hearing
protection is needed at all times. Do not stand nearby to
watch the machine operate.
Noise levels, moving parts hazards, and machine activ-
ity, including loaders and trucks entering and leaving,
all combine in this area to make it a zone that requires
special alertness to safety hazards by the operator and
anyone else.
Only qualified and authorized people should enter this
zone. No one should enter the area without specific per-
mission of the machine operator.

2
F05386
3
1. Chip Discharge
2. Overs Discharge
3. Radiator Purges
Figure 22: Area 3: Flying Materials Hazard Zones
Area 3: Flying Material Hazard Zones The operator must inform chip truck drivers of the overs
Flying material hazard. Authorized personnel only. Be spout hazard zone and the importance of staying out of
aware of the hazard zones whenever the 5000H is oper- hazard zones.
ating, including any time the chipper is turning. Truck drivers must also wear safety hard hats, hearing
Within this area are the following three smaller zones protection, and full eye protection.
(Figure 22):
Chip Discharge: The chip spout shoots chips into a
truck or pile (200 ft or 60 m).
Overs Discharge: This area is where thrown wood
chunks, knots, and other objects in the feed can land.
Radiator Purges: The radiator fan reverses the air
flow regularly to blow debris out of the radiator cooling
fins. Protect your eyes in this zone.
This area approximates the output stacking area for the
discharged chips or loading zone for chip trucks. Fre-
quently, loaders or other vehicles enter and exit this area
to move the stack of chips. To reduce risk of being hit
by flying material, anyone not operating machinery
should avoid this area while the equipment is running.

1 2
1 2
F05387
1. Bark Removal
2. Tree Delivery
Figure 23: Area 4: Skidder Machine Traffic Zones
Area 4: Log Loading Zones

Trucks drop and arrange logs in this area (Figure 23).
The log loader lifts logs, arranges logs, and feeds logs
into the feed opening. Logs may become unstable and
suddenly shift or roll.
Do not allow anyone in this area during machine opera-
tion.

2
F05831
1. Flying and Falling Chip Discharge

2. Overs Discharge
3. Skidder Operations and Log Loading
Figure 24: Area 5: Falling Material and Loader Zones
Area 5: Falling Material Hazard Zone and Loader Many areas in a storage yard may contain piles of raw
Access Zone logs awaiting processing. Also, piles of chips may
This is the area where the skidder operator is most obstruct views and can interfere with communications.
active in bringing logs to feed the machine. A possibil- Use care and vigilance at all times to avoid accidents.
ity of flying objects also exists in this area. Any autho-
rized person needing to enter this area (Figure 24) while
the machine is operating should make positive contact
with the operator before entering.
Be alert and react to any person or machine entering this
area. Before start-up, check this area to be sure every-
one is at a safe distance.
Peterson recommends that operators take appropriate
measures to restrict access to this area. Unauthorized
people should never be allowed to enter this area.

1
F05388
1. Chip Van
2. Transporter
Figure 25: Area 6: Truck Traffic Zones
Area 6: Truck Access Zones

Dangerous truck traffic exists in this area (Figure 25).
Safety Labels
Pedestrians need to use caution in traffic paths. Hazard alert, instruction, and safety decals are attached
to the 5000H for your safety. Decals remind operators
and other workers not to expose themselves to risks of
crushing, pinching, or trapping caused by rotating, mov-
ing, or unguarded parts and other hazards. Some decals
also serve as reminders to lock out the power source.
Other labels and decals attached to the 5000H describe
recommended operating or maintenance activities and
other useful information. A complete list of decals,
labels, and legend plates is available in your 5000H
Parts Book. If the decals have been removed or become
unreadable, call your Peterson distributor for replace-
ments.
Safety Decal Illustrations
58068
Figure 26: Warning: Crushing or Pinching Hazard

WARNING
Moving chipper disk can cut or crush.
If chipper disk is turning or coasting

· do not loosen or open hood.
· do not loosen or open spout.
Close and tighten hood and spout before

starting chipper.
72402-
58070-10 72402
Figure 27: Warning: Wear Protective Equipment Figure 30: Warning: Moving Chipper Disk
Avoid injury or death from moving parts or flying objects.

Insert the chipper disk safety pin.
Insert the safety pin if the hood
or spout are opened.
Keep the pin inserted until the

hood and spout are closed.
USE EXTREME CAUTION if

the pin is removed while the
63467-10 chipper is open. The chipper
disk can cut or pinch severely.
Figure 28: Warning: Fluids Under Pressure DO NOT RUN an open
chipper. 72409- 72409
Figure 31: Warning: Use Chipper Disk Safety Pin
WARNING
Chipper hood can fall causing
serious physical injuries.
Raise hood fully. Keep away from
Insert locking pin through all 4 (four) spout opening.
locking holes.
Attach lockout device to hold pin
in place.
67806-
67806 Exposed moving
Figure 29: Warning: Chipper Hood chipper disk can
cut or crush. 72649- 72649
Figure 32: Warning: Keep Away from Opening

Keep hands and
feet clear
Exposed moving
chipper disk can
cut or crush. 72678-
72678
73333-10
Figure 33: Warning: Keep Clear of Chipper Disk Figure 37: Warning: Safety Pin
WARNING
Avoid serious injury or death
from moving machinery or
flying material.
Close cover when operating.

72691 73334-01
73334-01
Figure 34: Warning: Stay Back from Bark Mover Figure 38: Warning: Close Cover When Operating
Stay Back 200 ft (60m)

72763-72766 CAUTION
Figure 35: Stay Back 200 Feet (English)
WELDING CURRENTS CAN
DAMAGE ELECTRONIC PARTS.
BEFORE WELDING, DISCONNECT

ALL CONTROL MODULES.
73336-01
73336-01
Figure 39: Caution: Disconnect Modules Before Welding
73330-10
Figure 36: Warning: Lock Out

73337-10
Figure 40: Safety Pin (Red)

79723-10
Figure 44: Danger! Fire Hazards
SAFETY PIN 73338-01
73338-01
Figure 41: Safety Pin (White)
79725-10
Figure 45: Danger! Exhaust Fire
79724-10
Figure 42: Danger! Fire from Electrical Arcs
79727-10
Figure 46: Danger! Hydraulic Fire
79726-10
Figure 43: Danger! Fire Ready

1 WARNING
Crushing or pinching hazard. Keep clear of all
moving parts such as pulleys and conveyors
while the machine is running. Keep all guards in
place during operation. Do not rely on guards to
protect you from not paying attention.
Figure 47: Danger! Do Not Smoke

79728-10
1 WARNING
Crushing or pinching hazard. Keep hands clear
of the moving parts of the feed roll housing and
Warnings During flail housing. If stray material has blocked normal
movement of a housing, keeping it in its lifted
Maintenance position, removal of that material could allow the
housing to fall unexpectedly.
Make sure that safety is more important than rushing to
get the machine back in operation.
Do not clean or lubricate any rotating or moving parts, 1 WARNING
whether the engine is running or not. Crushing or pinching hazard. Keep hands clear
Do not work on or around any mechanical drive units or of moving parts in the feed roll and flail housings
any rotating or moving parts, such as sheaves, chains, or while closing each housing after maintenance.
belts, when the machine is running.
◆ To enter the machine safely:
Be aware always of the following warnings:
1. Turn off the engine.
2. Turn off the battery disconnect switch and remove
1 WARNING the key.
3. Close, lock, and tag out the battery disconnect
Pinch point. Do not place yourself or any part of
your body under any pivoting component without switch.
first installing a locking device. 4. Tell your supervisor and area workers that you are
entering the machine.
1 WARNING 5. Have someone stand by the machine while you are

inside.
Crushing or pinching hazard. Do not place your-
self or any part of your body under the machine
unless the machine is supported properly.
1 WARNING
Crushing or pinching hazard. A damaged or
missing guard, safety device, or decal can
expose operators to risk of injury or death. Main-
taining these devices is very important. Comply
with your local and state safety codes.

0000
S ECTION 0000
GENERAL MAINTENANCE
A good maintenance program improves awareness of hazards and reduces risk of equipment failure. Regular lubri-
cation is an essential requirement for proper maintenance.
0.1 Maintenance •
•
1000 hours, 20,000 US gallons
Schedule •
•
Yearly, 3000 hours, 60,000 US gallons
Follow the schedule in Table 3 to maintain your chipper Inspection procedures and checklists are available in
in peak operating condition. Because machines operate Chapter 3, “Operating the 5000H” in the 5000H Opera-
in widely varying conditions, Peterson cannot state tor Safety Manual.
exact intervals at which inspections and/or maintenance For engine oil and fuel filter service, see “Special Inter-
should be performed. Always base the interval on calen- val” on page 60.
dar, service hours, or fuel consumption, whichever
occurs first. For example, the following intervals are Log loader maintenance is covered in “Log Loader” on
somewhat equivalent: page 161.
• Daily or each shift
• Weekly, 40 to 60 hours, or 1000 US gallons 1 WARNING
• Monthly, 250 hours, or 5000 US gallons Be sure to lock out the machine before starting
• 500 hours or 10,000 US gallons any maintenance.
Table 3: 5000H Maintenance Schedule
1000 Hours
2000 Hours
5000 Hours
Maintenance Activity Reference
500 Hours
Monthly
Weekly
Yearly
Daily
Air cleaners, CAT engine; change inner elements page 81 X

Air cleaners, CAT engine; check indicators, clean pre- page 81 X
cleaners and outer filters
Air cleaners, CAT engine; clean or change outer filters page 81 X

Air compressor; change compressor air filter page 169 X
Air compressor; change engine oil (first 20 hours of page 169 X X
compressor use, then every 100 hours)
Air compressor; clean or change engine air filter page 169 X

Air compressor; drain water from tank page 169 X

SECTION 0000 GENERAL MAINTENANCE
0000
Table 3: 5000H Maintenance Schedule (Continued)
1000 Hours
2000 Hours
5000 Hours
500 Hours
Monthly
Weekly
Yearly
Daily
Anvil; check wear, clearance, bolt tension page 136 X
Bark mover; check wear plates page 117 X
Batteries, cables, and connections; check page 104 X
Batteries; check electrolyte level page 104 X
Belts; alternator and chipper disk, check and adjust page 83 X X
tension (first 20 to 40 hours, then monthly)
Belt; air compressor, check and adjust tension page 169 X

Chip spout; check support cable page 155 X
Chipper and counter knives; check sharpness and wear page 123 X
Chipper bearings; clean, inspect, repack grease page 56 X
Chipper disk; check wear plate page 140 X
Clutch; change oil and filter (first: 50 hours) page 94 X X
Clutch; change tank breather cap, and HPTO breather page 94 X
Clutch; check oil level in clutch tank page 93 X
Clutch; internal inspection. Contact PT Tech Customer N/A X
Service for instructions.
Clutch; sample and test clutch oil page 93 X

Coolant system; check all tubing connections page 75 X
Coolant system; check coolant level page 76 X
Coolant system; clean/inspect radiators, check fan blades page 77 X
Cooling system; change coolant (2,000 hrs or 2 years) page 76 X
Cooling system; collect and analyze coolant sample See CAT Manual X
Cooling system; replace thermostat See CAT Manual X
Drive chain sprockets; check for wear page 119 X
Drive chains; check and adjust page 119 X
Drive motor gearboxes for flails and feed rolls; change oil page 100 X X
(first, 50 hours)
Drive motor gearboxes for flails and rolls; check oil level page 100 X
Electronic grounding studs; inspect, clean, and tighten See CAT Manual X

0000
1000 Hours
2000 Hours
5000 Hours
500 Hours
Monthly
Weekly
Yearly
Daily
Emergency Stop buttons (E-Stop); test page 103 X
Engine; change oil and filter (125 or 166 or 250 hours; page 78 X
see “Special Interval” on page 60)
Engine; check oil level page 78 X

Engine; check protective devices (alarms and shut-offs) See CAT Manual X
Engine; clean crankcase breather See CAT Manual X
Engine; collect and analyze oil sample See CAT Manual X
Engine; fuel injector control, check/adjust (first: 250 hrs) See CAT Manual X X
Engine; inspect crankshaft vibration damper; See CAT Manual X
Engine; inspect mounts See CAT Manual X
Engine; inspect starter motor, water pump, turbocharger See CAT Manual X
Engine; speed/timing sensors, check/clean/calibrate See CAT Manual X
Engine; valve lash, check/adjust (first: 250 hours) See CAT Manual X X
Engine; valve rotator, check/adjust (first: 250 hours) See CAT Manual X X
Ether starting aid cylinder; replace as needed page 74 X
Feed roll bearings; check upper, lower, chipper, roll case page 56 X
Feed rolls; check speed, adjust feed manifold as needed page 144 X
Fire extinguisher, inspect yearly, hydro-test at 12 years page 169 X
Flail chains; check, rotate, replace as needed page 112 X
Flail drum bearings; check page 56 X
Flail drums and rods; check page 111 X
Flail liners; check and replace as needed page 116 X
Fluid hoses and clamps; inspect and replace as needed page 74 X
Fuel system; change secondary filter (125 or 166 or 250 See CAT Manual X
hours; see “Special Interval” on page 60)
Fuel system; primary filter, drain water separator page 80 X

Fuel system; primary filter, replace element, clean bowl See CAT Manual X

0000
1000 Hours
2000 Hours
5000 Hours
500 Hours
Monthly
Weekly
Yearly
Daily
Hydraulic system; change filters (charge pressure and page 89 X
tank return) and clean magnets
Hydraulic system; change oil in tank (2,000 hrs or 2 page 89 X

years)
Hydraulic system; change tank breather page 90 X

Hydraulic system; charge pressure filters, check page 89 X
indicators on flail and fan pumps
Hydraulic system; check oil level in tank page 87 X

Hydraulic system; sample and test hydraulic oil page 87 X
Hydraulic system; tank filters, check pressure gauge page 90 X
Machine guards; ensure all are in place and secure page 169 X
Machine; clean overall, including the engine page 30 X
Machine; retorque all loose bolts page 68 X
Pump-drive gearbox; change oil (first: 50 hours) page 98 X X
Pump-drive gearbox; check oil level page 98 X
Safety pins; check condition page 19 X
Warning labels; make sure all are clean and intact page 43 X
Water sprayer pump; change engine oil (first 20 hours of page 170 X X
water pump use, then every 100 hours)
Water sprayer pump; check air filter page 170 X

Water sprayer pump; clean air filter page 170 X
Wheel axles; check level of hub oil page 167 X
0.1.1 Common Practices Excellent performance and long machine life require
the following practices:
Learn the routine daily, weekly, and other scheduled
• Proper loading of feed logs
maintenance activities as well as the longer term main-
tenance issues, such as the time to overhaul the engine. • Daily cleaning and safety inspection
The most important daily routine in addition to safe- • Regular, careful lubrication
guarding against personal injury, is cleaning up and pro- • Constant attention to machine performance
tecting the machine against fire hazards. This inspection • Inspection of parts for their state of wear, and
includes cleaning the engine to avoid hot spots. replacement of worn parts as needed

0000
0.2 Lubrication
NOTE: Log loader lubrication is covered in “Log Loader” IMPORTANT: Over greasing and introducing
on page 161. abrasives and contaminants during greasing are
major causes of bearing failure. Make sure that
0.2.1 Grease Points dirt and contaminants are not introduced during
re-lubrication. Add only the required amount of
The machine uses individual grease fittings and central- grease for each bearing.
ized clusters (Figure 48). In Table 4, quantities of
grease are stated for using a hand-powered grease gun. Grease fittings: Use Number 2 lithium-based grease
One “pump” is one full movement of the handle unless noted otherwise.
throughout its designed range. Table 4 describes each grease point. Figure 49 and
Figure 50 illustrate the locations of the grease points.
Figure 51 through Figure 54 illustrate additional details
about individual grease points.
F06067
Figure 48: Grease Fitting Cluster, Typical
Table 4: Grease Points

Item Description/Location Period Quantity Lube
1. Left side, bark mover cylinders, 2 fittings Weekly 2 pumps Grease
2. Left side, cluster below the 1st upper flail Daily 1 pump Grease
3. Left side, cluster on the chipper throat Daily 1 pump Grease
4. Left side, cluster on the stabilizer housing Daily 1 pump Grease
5. Left side, engine access door hinges, 2 fittings Monthly 1 pump Grease
6. Left side, pump-drive gearbox, input flange, 1 fitting (Figure 51) Daily 1 pump Grease
7. Left side, cab door hinges, 2 fittings Monthly 1 pump Grease
8. Right side, bark mover cylinders, 2 fittings Weekly 2 pumps Grease
9. Right side, battery box door hinges, 2 fittings Monthly 1 pump Grease
10. Right side, chip spout hinge, 5 fittings Monthly 1 pump Grease
11. Right side, chip spout rotation coupling, 4 fittings (Figure 54) Weekly 2 pumps Grease
12. Right side, cluster near the chipper throat Daily 1 pump Grease

0000
Table 4: Grease Points (Continued)

Item Description/Location Period Quantity Lube
13. Right side, cluster on the stabilizer housing Daily 1 pump Grease
14. Right side, cluster under the 1st upper flail Daily 1 pump Grease
15. Right side, engine access door hinges, 2 fittings each door Monthly 1 pump Grease
16. Top, cluster near 2nd upper flail housing (Figure 52) Weekly 2 pumps Grease
17. Top, 1st upper flail housing door hinges, 3 fittings Monthly 1 pump Grease
18. Top, optional 2nd upper flail housing door hinges, 3 fittings Monthly 1 pump Grease
19. Front right, engine sled adjusters, 2 screws (Figure 53) Weekly As needed Anti-seize
20. Top, cab roof, emergency exit door hinges Monthly 1 pump Grease
5 18 16 17 7
F05331
6 3 1 1 2 4
Figure 49: Grease Points, Left Side

0000
20 11
15
F05898
13 14 8 8 12 10 19 9
Figure 50: Grease Points, Right Side
F06059 F01439
Figure 51: Pump-Drive Gearbox, Input Flange Fitting Figure 52: Grease Fitting Cluster, Top Near 2nd Flail Housing

0000
ation or smoke appears, do not touch until the

bearing cools.
A bearing that overheats and fails can cause consider-
able damage to its housing and mating surface, such as
the shaft. Overheated bearings can be caused by con-
taminants or abrasives at the bearing surfaces. Excess
grease can add resistance to the movement of bearing
parts, a cause of overheating.
If overheating occurs in any heavy-duty bearing, includ-
ing a shaft bearing, check first for the presence of grease
in each bearing housing. Look for grease at the seals. A
grease spot at the seals shows that the bearing was lubri-
cated, but not whether grease is currently at the bearing
surfaces.
F06012
A dry bearing may never have had adequate grease. A
Figure 53: Engine Sled Adjusting Screw (1 of 2) ruptured seal may allow grease to leak out when it is
warm. If you determine that a bearing has too much
grease, purge the excess grease as described in “Chipper
Bearing Lubrication” on page 56.
0.2.2.1 Chipper Bearing Lubrication

Inspect the chipper bearings. Adjust them if needed and
re-pack with new grease every 800 to 1000 hours. The
procedure for re-packing the chipper bearing is beyond
the scope of this manual. Only trained, qualified person-
nel should service, repack, and adjust the chipper bear-
ings.
IMPORTANT: Avoid heat damage to chipper

bearings. Do not add grease to the chipper bear-
ings periodically. Too much grease in the bear-
F06075 ings increases frictional heat, prevents proper
Figure 54: Spout Rotation Coupling function of the bearings, and leads to premature
failure.
If the chipper bearing is overheating and shows grease
0.2.2 Bearing Lubrication coming through the seals, remove the pipe plug and
allow any extra grease to purge. When it is warm
Inspect bearings for unusual play, or back and forth enough, the grease becomes liquid and can flow through
movement. Also, be alert to overheated bearings. Con- the plug hole. Replace the plug, or fitting, when no more
tact a service specialist for further assistance. Bearings grease comes out.
are precision machine elements. As such, they require
specialized tools and skills to service properly.
0.2.2.2 Feed and Flail Bearings
Inspect these bearings regularly for unusual play and
1 CAUTION overheating. Their lubrication is covered in “Grease
Points” on page 53.
Avoid burns. Bearings may be hot. Bearing parts
may be hotter than they appear. If paint discolor-

0000
0.2.3 Fluids and Filters
Use Table 5 as a guide for servicing fluids and filters. In the table, “OEM manual” refers to the instruction
Filters are located by the table item numbers in booklet from the Original Equipment Manufacturer that
Figure 55 on page 59 and Figure 56 on page 60. was delivered with your machine.
Table 5: Service Schedule for Fluids and Filters

Item Description Interval Quantity or Fluid or Filter Type Reference
Gals/ Liters
1. Air cleaner (CAT Monthly 2 Dry element page 81

engine), change inner
element
2. Air cleaner (CAT Weekly 2 Dry element page 82

engine), change outer
element
3. Air cleaner (CAT Daily 2 Dry element page 82

engine), clean outer
element
4. Air compressor, 250 hrs 1 See OEM manual OEM manual

change compressor air
filter
5. Air compressor, First 20 hrs, then 1.2 qt/ SAE 10W-30 OEM manual
change engine oil every 100 hrs 1.1 liters
6. Air compressor, 300 hrs 1.2 qt/ See OEM manual OEM manual
change pump oil 1.1 liters
7. Air compressor, Weekly 1 See OEM manual OEM manual

clean engine air filter
8. Clutch, change filter First 50 hrs, then 1 Spin-on canister page 94

every 500 hrs
9. Clutch, change HPTO 500 hrs 1 Screw-on (pipe threads) page 94

breather
10. Clutch, change oil 500 hrs 21/ 80 Warm Climate oil: page 94
• Mobilfluid 424
• Caterpillar TDTO (SAE 30 only)
• Shell Donax TD (TD only)
• Vermeer VMX Ultra Gold
Cold Climate Oil (below 15° F):
• Mobilfluid LT
• Caterpillar TDTO (10W only)
• Shell Donax TD Low Vis
11. Clutch, change tank 500 hrs 1 Screw-on (by hand) page 94
breather cap

0000
Table 5: Service Schedule for Fluids and Filters (Continued)

Item Description Interval Quantity or Fluid or Filter Type Reference
Gals/ Liters
12. Cooling system, 3000 hrs 47/ 176 Fleet Charge 50/50 Pre-diluted page 76
change coolant
13. Drive motors gearbox First 50 hrs, then Varies 75W-90 synthetic gear oil page 101
oil, change every 1000 hrs
14. Engine crankcase; 500 hrs 1 Washable element CAT Manual

clean breather
15. Engine oil, change See “Special 2 Spin-on canister page 78

filters Interval” on page 60
16. Engine oil, change oil See “Special 19.5/ 74 CAT DEO or CAT DEO SYN page 78
Interval” on page 60 (including 15W-40. Refer to the CAT engine
filters) manual for cold climate and
alternative oils.
17. Fuel filter (primary), 500 hrs 1 Spin-on canister CAT Manual
replace
18. Fuel filter (secondary), See “Special 1 Spin-on canister CAT Manual
replace Interval” on page 60
19. Fuel tank, including fill As needed 375/ 1420 Diesel fuel page 61
tube dirt trap, refill
20. Hydraulic charge 250 hrs or by Varies: for • Sauer pumps = spin-on page 89
pressure, change indicator radiator fan canister
filters and flail • Rexroth pumps = element
pumps
21. Hydraulic system, 500 hrs 1 Screw-on (by hand) page 89

change breather cap
22. Hydraulic system, 2000 hrs 320/ 1211 • Hydraulic oil, AW46 page 89
change oil Specification per ASTM D
requirements, or equivalent
ISO-VG46
• For very cold weather
operation, AW32 or equivalent
23. Hydraulic tank return, 250 hrs 3 Replaceable element page 90

change filters
24. Pump-drive gearbox, First 50 hrs, then 2 gals/ 75W-90 synthetic gear oil page 98
change oil every 1000 hrs 7.6 liters
25. Water pump, First 20 hrs, then 0.6 qts/ 0.6 SAE 10W-30 OEM manual
change engine oil every 100 hrs liters
26. Water pump, Weekly 1 See OEM manual OEM manual

clean air filter
27. Water tank, refill As needed 143/ 541 Water page 170

0000
0.2.3.1 Filter Locations
Item numbers refer to Table 5 on page 57.
1 2 3 8 7 4 26
F05331
20 15 21
Figure 55: Machine Filters and Breathers, Left Side

0000
23
F05898
19 11 17 18 9 14
Figure 56: Machine Filters and Breathers, Right Side
0.2.3.2 Special Interval of 250 hours. Your interval may be shorter based on
usage.
Peterson recommends using fuel consumption instead
of engine hours to determine the proper interval for per-
◆ To calculate your maintenance interval in
forming the following maintenance:
hours:
• Engine oil, change
1. Determine the fuel consumption rate (in gallons per
• Engine oil filters, change hour) of the 5000H. See “Fuel Usage” on page 158.
• Secondary fuel filter, change 2. Divide the gallons of fuel used by the number of
The rate of fuel consumption appears on the display hours the machine has run during the work week.
screen, as described in “Fuel Usage” on page 158. 3. Locate the fuel consumption rate in Table 6 to
This consumption approach considers the varying determine your duty cycle and the maintenance
demands on engines and the differences in usage among interval in hours.
machines. The Caterpillar manual described an average
fuel rate of 20 gallons per hour to determine an interval

0000
engine power in cold weather, check the fuel type and
Table 6: Engine Maintenance Interval consider using one or more of the following options:
Duty Cycle Light Medium Heavy • Fuel heater
• Fuel line insulation
Fuel Consumption Rate 20 30 40+
(U.S. gallons per hour) • Engine oil pan heater
• Starting aid
Maintenance Interval 250 166 125
• Engine coolant heater
(hours)
0.2.3.3 Handling Filters Properly

Filter locations are shown in Figure 55 on page 59 and
Figure 56 on page 60.
◆ To handle filters properly:

• Shut down and lock out the machine.
• Place a catch basin under each filter during replace-
ment.
• Replace the seals and gaskets in filter assemblies
whenever the filters are replaced.
• Be sure all filter mating surfaces, seals, and gaskets
are clean before re-assembling the filters.
• Recycle oils and coolants in a safe and legal way.
IMPORTANT: Avoid machine damage and haz-

ardous fluid leaks. When installing filters, make
sure all related gaskets and O-rings are clean,
undamaged, and functional. Serious leaks and
machine damage can result from O-rings, gas-
kets, or seals in filter assemblies that are miss-
ing, degraded, or damaged.
0.2.3.4 Fuel Specifications

The diesel fuel tank contains 375 U.S. gallons (1420
liters) when measured 1 inch from the top.
In North America, fuels that are identified as Number
1-D or Number 2-D provide rated engine performance
and full component life. For other locations, the Cater-
pillar engine manuals provide a complete fuel specifica-
tion.
0.2.3.5 Fuel for Cold Weather

Number 1 fuels are best suited for cold weather opera-
tion. The engine manuals provide specific guidelines on
fuel use in cold weather. Before troubleshooting for low

0000
0.3 Troubleshooting Chip Production

Use the guidelines in Table 7 to resolve chip production
issues.
Table 7: Chip-Making Guidelines

Issue Possible Cause Corrective Action
Bark on the sides of log after Logs too close to the flail drum. Raise height of flail stands so that only
leaving the debarker ends of flail chains strike logs. See flail
stands in “Flail Stands” on page 111.
Flail chains not striking the sides of logs. Load fewer logs. Stagger loads of logs.
Logs too close to machine walls where Load logs away from sides of machine.
the chains cannot debark them.
Too many logs loaded, or logs are Load fewer logs. Do not let logs pile on
stacked on top of each other. top of each other when loading.
Incomplete debarking Flail chains worn or missing in places. • Inspect and install new chain if links or
Chain links have broken off. chains are missing.
• Make sure flail chain is correct type.
Too many logs loaded, or logs are Load fewer logs. Do not let logs pile on
stacked on top of each other. top of each other when loading.
Insufficient debarker capacity. Retrofit machine with a second upper flail

if it is not so equipped.
Small logs are loaded with large logs, Group logs by similar size.
and the flail housing rides too high for the
chains to reach smaller logs.
Flail housing float setting is too high. Flail Adjust flail housing float pressure
chains not striking logs. (contact Peterson Customer Support).
Wet frozen wood does not debark well. • Increase flail speed.
• Decrease feed speed and chipper
RPM so that logs spend more time in
debarker.
• Consult with your Peterson Distributor.
Logs fuzzy on the surface when Logs subjected to excessive debarking. Reduce flail speed (RPM).
leaving the debarker
Slivers or strings Excessive knife and anvil clearance. Reduce anvil clearance.
Poor quality wood. Wood has too many Sort out bad wood before loading into
short pieces that hit the chipper at an chipper.
angle. Or, logs have too many limbs that
hit the chipper at the wrong angle.
Worn feed plate. Replace feed plate.

0000
Table 7: Chip-Making Guidelines (Continued)
Excessive cards Chipper disk turning too slowly. Raise chipper disk RPM.
Needs more aggressive counter knife. • On standard knife systems, increase

the length of the counterknife so that it
is closer to the edge of the chipper
knife.
• On Key Knife systems, increase the
counter knife angle. Contact your
Peterson distributor for assistance.
Feed speed is too fast. Reduce feed speed.
Over-thick chips Anvil-knife clearance is too great. Reduce anvil clearance.
Excessive knife extension or knife Reduce knife extension.

length.
Counter knife extension is too great. Reduce counter knife extension.
Feed speed is too fast. Reduce feed speed.
Chips too long Knife extension is incorrect. Check the knife extension and ensure
that it is correct for the required chip size.
See Table 13 on page 143 and Table 15
on page 143.
Wrong grind angle on the knife. Inspect and correct the knife grind angle
as needed. Change the knife angle about
1/2° at a time.
Worn wear plate on chipper disk. Repair or replace the wear plate. See
“Chipper Disk Wear Plate” on page 140.
Chips too short Knife setting incorrect. Check the knife extension and ensure
that it is correct for the required chip size.
Feed speed is too slow. Increase the feed roll RPM (Feed
Speed).
Too many narrow, or pin, chips; Excessive chipper disk speed. Reduce disk speed and feed speed.
chips are correct length, but too
narrow Excessive counter grind (back grind) on Use knives with less back grind.
the chipper knives.
Very worn counter knives. Replace worn counter knives.
Debarker fuzzes the logs. Reduce flail speed.
Standard knives are cracking or Knife has been ground back too many Do not use knives that have been ground
breaking apart in service times. Knife width is too small to back to less than 3.5 inches (8.9 cm) in
withstand chipping loads. width. See “Standard Knife Maintenance”
on page 130.
Knife clamps are too loose. Retorque knife clamp bolts.

0000

Too many pins and fines Cold, frozen chips can shatter when they Use care in aiming the spout so that
strike the walls of the chip truck. chips land without striking hard objects.
Knives are dull. Install sharp knives.
Chipper disk speed too fast. Lower the chipper disk speed.
Poor chip quality When the knife system was assembled, Clean and de-burr all mating metal
burrs or surface contamination caused surfaces when assembling the knife
the knife to be improperly positioned and system.
secured.
Fractured or damaged edges on Worn anvil. Rotate or replace the anvil.

the chips
Dull knives. Install sharp knives.
Too many fines; chips are too Log feed speed is slightly slow. Increase feed speeds slightly (about
short and too narrow 5%). Feed speed must be set so that
logs crowd or force themselves into the
knives very slightly, but not enough to
press on the chipper disk, which create
friction and power loss.
For standard knife systems: Counter Shorten the counter knife.

knife is set too close to knife for the
hardness of the wood. Wood quickly
wears and rounds the counter knife.
Wood may force a gap between the
counter knife and knife.
Anvil-knife clearance is too great. Reduce anvil clearance.
Excessive counter grind or back grind on Reduce or eliminate back grind on

the chipper knives. chipper knives.
Very worn counter knives. If needed, replace the counter knives.
Worn knife holder. Inspect and replace the holder, if

needed.
Excessive wear on the chip slot. Inspect slot surfaces and repair or
replace the chipper disk. See the chip
slot in Figure 159 on page 130.
Knives dull rapidly Knives striking the anvil. Check and adjust all anvil clearances.
Frozen or dry wood. Apply back grind to the knives.
Wire edge left on the chipper knife after Flat-hone the chipper knives slightly after
grinding. each grinding.
Anvil-knife clearance is too great. Reduce anvil clearance.
Knife steel is too soft. Use the correct knife type for chipping.

0000
Heat checks in the knife Knife grind angle is too small and weak. Replace the knife.
In hot weather, metal weakens, cracks
and breaks off. (Heat checks have one
straight edge.)
Wood packing between the • Counter knife worn. • Replace knife pocket components.
knife and the counterknife • Counter knife too long. • Clean knife pockets thoroughly before
• Worn knife clamps. installing knife components.
• Incorrect torque on clamp bolts.
• Pocket not properly cleaned when
knives were installed.
Chipper feeding poorly, or the Chipper knives ground at wrong angle. Check and adjust the knife angle.
chipper not pulling wood toward
the knives Frozen or extremely hard wood. Change the angle of back grind on the
knife.

0000
0.4 Troubleshooting Machine Operation

See the guidelines in Table 8 to resolve machine opera-
tion issues.
Table 8: Machine Troubleshooting Guidelines

Trouble/Problem Possible Causes Solutions/Remedies
Engine overheating. Radiator fins clogged. Clean the radiator fins as described in “Cleaning and
Checking the Radiator” on page 77.
Radiator fan not working properly. Troubleshoot the following systems for failure: fan
pump, fan motor, fan control electronics.
Coolant level is low. Check the coolant level and more if needed.
Coolant system malfunctioning. Check the coolant lines, pumps, and connections.
Engine oil level is low. Check the oil level and add more if needed
Vibration from flail Some chain segments are not Inspect the flail drums and ensure that all the chains
housings. installed on the flail drum or some are installed as described in “Installing and
chains are the wrong type. Replacing Flail Chain” on page 113.
Chain links or entire segments Replace any missing chains. Inspect the chain rod
have worn thin and broken off. and replace if it is worn thin.
During installation, a chain was Replace any missing chains.

not hooked by the flail rod.
Flail rod broken. Replace the flail rod and maintain it as described in
“Flail Rods” on page 111.
Engine does not start after Fuel filters are empty. Add fuel to the fuel filters when refilling the fuel tank.
running out of fuel and See fuel filters in “Fuel Filters” on page 80.
adding fuel to tank.
Flail or feed roll housing Machine is not level from side to Level the machine by adjusting the stabilizers and
gets stuck against the wall side. the landing gear as described in the 5000H Operator
as the housing moves up. Safety Manual.
Belts slip and smoke after Rubber debris on the sheave or Remove any rubber debris and contamination from
being replaced. the pulley allows slipping. sheave surfaces without scratching the metal.
Low power, poor engine Wrong fuel for cold conditions. Use No. 1 fuel.
performance in cold
weather. Fuel is too cold for good Consider installing a fuel heater, fuel line insulation,
combustion. oil pan heaters, coolant heater. Consult with a
Caterpillar engine specialist.

0000
Table 8: Machine Troubleshooting Guidelines (Continued)
Trouble/Problem Possible Causes Solutions/Remedies
Chip spout gets plugged • Engine RPM is too low, Keep the engine speed above 1750 RPM.
with chips. causing the chipper disk to go
too slowly to blow chips out the
spout.
• Chipper spout is rusty inside. Clean the inside surfaces of the spout.
• Sticky sap on the inside of the
spout.
• Paddle to belly band clearance Add material to the ends of the paddles.
is too high.
• Spout not bolted in place. Install fasteners between the spout and the chipper.

0000
0.5 Torque Values

Table 9 and Table 10 provide torques for grade 8 cap During regular maintenance inspections, retighten all
screws, bolts, and standard hex nuts (NC/NF threads). loose nut and bolts to their specified torque.
Table 9: Torque Value Chart, National Fine (NF) Thread

Torque Values for National Fine (NF)
Grade 8 Cap Screws, Bolts, and Standard Hex Nuts
Nominal Thread “As Received” Lubricated w/ Loctite #242 Loctite #271 High Loctite #277 High Crimp-style
Diameter Dry Threads Permatex #133 Medium Strength - Strength - Red Strength - Red Locking Nutse,f
in. (mm)a ft-lbb (Nm) Anti-Seize Blue ft-lbb (Nm) ft-lbb (Nm) ft-lbb (Nm)
ft-lbb (Nm) ft-lbb (Nm)
1/4 (6.4) 14.0 or 168 in-lb 9.0 or 108 in-lbs 11.5 or 138 in-lb 15.5 or 185 in-lb N/A c 6.0 or 72 in-lb (8.1)
(19.0) (12.2) (15.6) (21.0)
5/16 (7.9) 27.0 or 324 in-lb 17.0 or 204 in-lb 22.0 or 264 in-lb 29.5 or 356 in-lb N/A c 12.0 or 144 in-lb
(36.6) (23.0) (29.8) (40.0) (16.3)
(66.4) (40.7) (53.6) (73.7) (29.8)
7/16 (11.1) 78.0 (105.8) 47.0 or 564 in-lb 62.5 (84.7) 86.0 (116.6) N/A c 35.0 or 420 in-lb
(63.7) (47.5)
1/2 (12.7) 120.0 (162.7) 72.0 (97.6) 96.0 (130.2) 132 (179.0) N/A c 53.0 or 636 in-lb
(71.9)
9/16 (14.3) 171.0 (231.8) 102.0 (138.3) 136.5 (185.1) 188.0 (254.9) N/A c 77.0 (104.4)
5/8 (15.9) 240.0 (325.4) 144.0 (195.2) 192.0 (260.3) 264.0 (357.9) N/A c 106.0 (143.7)
3/4 (19.1) 420.0 (569.4) 252.0 (341.7) 336.0 (455.6) 462.0 (626.4) 462.0 (626.4) 188.0 (254.9)
7/8 (22.2) 668.0(905.7)d 400.0 (542.3) N/A c 735.0(996.5)d 735.0(996.5)d 303.0 (410.8)
1 (25.4) 995.0(1349)d 597.0 (809.4) N/A c 1095.0 (1489)d 1095 (1489)d 455.0 (616.9)
1-1/8 (28.6) 1444 (1958)d 866.0 (1174)d N/A c N/A c 1588 (2153)d 644.0 (873.1)d
1-1/4 (31.8) 2012 (2728)d 1207 (1636)d N/A c N/A c 2213 (3000)d 908.0 (1231)d
1-3/8 (34.9) 2712 (3677)d 1627 (2206)d N/A c N/A c 2983 (4044)d 1190 (1613)d
1-1/2 (38.1) 3557 (4823)d 2134 (2893)d N/A c N/A c 3913 (5305)d 1580 (2142)d
a b c d
Nominal diameters are referenced from ANSI B18. Use Foot-pounds (ft-lb) except where noted as N/A = Not Use one or more
approximate dimension in millimeters for identification only. inch-pounds (in-lb). Installation with an inch- Applicable torque multipliers
No exactly equivalent metric fasteners are available. Using pound wrench is recommended for the to achieve
2.54 mm per inch, an example of this rough conversion of 5/ fasteners where in-lb is indicated. specified torque
16 inch is: multiply 2.54 by 5; then divide by 16, yielding value.
7.9375. Then round to 7.9.
e Caution! Do not use Loctite with f Caution! Do not use an air ratchet to assemble or disassemble Refer to Peterson process specification
crimp-style locking nuts under any crimp-style locking nuts. Friction-induced heat destroys the nut no. 53500, sheet 3 of 3, Revision A,
circumstance. lubricant coating. 082995
All stated torque values are based on use of through-hardened flat washers under All stated torque values are calculated at 75% of proof load
the bolt head and nut, or only the bolt head in tapped and chamfered hole rating, providing a design safety factor.
applications. This provides a uniform, hard, smooth bearing surface.

0000
Table 10: Torque Value Chart, National Coarse (NC) Thread
Torque Values for National Coarse (NC)
Grade 8 Cap Screws, Bolts, and Standard Hex Nuts

Nominal Thread “As Received” Lubricated w/ Loctite #242 Loctite #271 High Loctite #277 High Crimp-style Locking
Diameter Dry Threads Permatex #133 Medium Strength - Strength - Red Strength - Red Nutse,f
in. (mm)a ft-lbb (Nm) Anti-Seize Blue ft-lbb (Nm) ft-lbb (Nm) ft-lbb (Nm)
ft-lbb (Nm) ft-lbb (Nm)
1/4 (6.4) 12.0 or 144 in-lb 7.0 or 84 in-lb 9.5 or 114 in-lb 13.0 or 158 in-lb N/A c 6.0 or 72 in-lb (8.1)
(16.3) (9.5) (12.9) (17.6)
(33.9) (20.3) (27.1) (37.3) (16.3)
(59.7) (35.3) (47.5) (65.8) (29.8)
7/16 (11.1) 70.0 (94.9) 42.0 or 504 in-lb 56.0 or 672 in-lb 77.0 (104.4) N/A c 35.0 or 420 in-lb
(56.9) (75.9) (47.5)
1/2 (12.7) 107.0 (145.7) 64.0 (86.8) 85.5 (115.9) 117.5 (159.3) N/A c 53.0 or 636 in-lb
(71.9)
9/16 (14.3) 154.0 (208.8) 92.0 (124.7) 123.0 (166.8) 169.5 (229.8) N/A c 77.0 (104.4)
5/8 (15.9) 212.0 (287.4) 127.0 (172.2) 169.5 (229.8) 233.0 (315.9) N/A c 106.0 (143.7)
3/4 (19.1) 376.0 (509.8) 226.0 (306.4) 301.0 (408.1) 414.0 (561.3) 414.0 (561.3) 188.0 (254.9)
7/8 (22.2) 606.0 (821.6)d 364.0 (493.5) N/A c 667.0 (904.3)d 667.0 (904.3)d 303.0 (410.8)
1 (25.4) 909.0 (1232)d 545.0 (738.9) N/A c 1000 (1356)d 1000 (1356)d 455.0 (616.9)
1-1/8 (28.6) 1288 (1746)d 773.0 (1048)d N/A c N/A c 1417(1921)d 644.0(873.1)d
1-1/4 (31.8) 1817 (2464)d 1090 (1478)d N/A c N/A c 1999(2710)d 908.0 (1231)d
1-3/8 (34.9) 2382 (3230)d 1430 (1939)d N/A c N/A c 2620(3552)d 1190 (1613)d
1-1/2 (38.1) 3161 (4286)d 1897 (2572)d N/A c N/A c 3477(4714)d 1580 (2142)d
a b c d Use one or more

Nominal diameters are referenced from ANSI B18. Use Foot-pounds (ft-lb) except where noted N/A = Not
approximate dimension in millimeters for identification only. No as inch-pounds (in-lb). Installation with Applicable torque multipliers to
exactly equivalent metric fasteners are available. Using 2.54 an inch-pound wrench is recommended achieve specified
mm per inch, an example of this rough conversion of 5/16 inch for the fasteners where in-lb is indicated. torque value.
is: multiply 2.54 by 5; then divide by 16, yielding 7.9375. Then
round to 7.9.
e Caution! Do not use Loctite with fCaution! Do not use an air ratchet to assemble or disassemble Refer to Peterson process specification
crimp-style locking nuts under any crimp-style locking nuts. Friction-induced heat destroys the nut no. 53500, sheet 3 of 3, Revision A,
circumstance. lubricant coating. 082995
All stated torque values are based on use of through-hardened flat washers under All stated torque values are calculated at 75% of proof load
the bolt head and nut, or only the bolt head in tapped and chamfered hole rating, providing a design safety factor.
applications. This provides a uniform, hard, smooth bearing surface.

0000
0.6 Maintenance Decals

Machine decals provide guidance during maintenance
procedures.
79729-
79729
Figure 60: Grease Point Indicator
73331-10
Figure 57: Diesel Fuel Only
73332-10
Figure 58: Hydraulic Oil, Check Daily
73335-10
Figure 59: Lubricate All Bearings

0000
0.7 Serial Number and VIN
The serial number of the machine is needed for gather- To the right of the serial number plate is the U.S. federal
ing accurate information from a schematic or a parts VIN label (Figure 63), which provides tire inflation
book, or for seeking technical support from your dealer pressures.
or from Peterson. The serial number is engraved on the
serial number plate, which is mounted on the left front
of the frame. Figure 61 shows the location of the serial
number plate, and Figure 62 shows its appearance.
F06034
Figure 63: Federal Vendor Information Notice (VIN)
F06033
Figure 61: Serial Number Plate Location
F05907
Figure 62: Serial Number Plate

0000

S ECTION 1000
POWER SYSTEM
1000
Power system maintenance includes checking fluid levels, changing fluids, and cleaning or replacing filters. V-belts
require regular inspection.
1.1 Engine Service 5
The 5000H is powered by an electronically controlled,

27-liter, Caterpillar C27 engine. The CAT C32 engine
is available as an option. The same maintenance instruc-
tions apply to both engines.
For engine maintenance, parts, service, troubleshooting,
and warranty issues, contact your local Caterpillar
engine representative.
1 WARNING 6
Engine exhaust contains products of combus-

tion that are harmful to health. Always start and
operate the engine in a well-ventilated area.
4
1.1.1 Engine Sensors 3 2
1
F06206
The engine includes sensors for coolant level and tem-
1. Fuel temperature sensor 4. Coolant temperature sensor
perature, oil pressure, fuel temperature, and input and 2. Output speed magnetic 5. Coolant level sensor
output speeds. See Figure 64 and Figure 65. pickup 6. Fuel pressure sensor
3. Oil pressure sensor
Figure 64: Engine Sensor Locations, Left Side

SECTION 1000 POWER SYSTEM
1000
F05923
Figure 66: Ether Starting Aid Canister
1 1.1.3 Hoses and Clamps

F06207
1. Fuel pressure sensor
Replace hoses that are cracked or soft. Tighten any
2. Input speed magnetic pickup loose clamps.
Check for the following conditions:
Figure 65: Engine Sensor Locations, Right Side
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
1.1.2 Ether Starting Aid • Exposed wire that is used for adding strength
An ether injection system is installed as an engine start- • Outer covering that is ballooning locally
ing aid in cold weather. The engine electronic control • Flexible part of the hose that is kinked or crushed
unit (ECU) controls automatically the timing and
amount of ether injection. The only operating require- • Armor that is embedded in the outer covering
ment of the user is to replace an empty canister • Charge air cooler tube with clamps over the tube
(Figure 66). beads.
When the canister is empty, the engine becomes hard to For additional details about replacing hoses, refer to the
start in cold weather. No other indication is apparent. CAT Operation and Maintenance Manual.
◆ To check and replace the ether canister: 1.1.4 Service Referrals

1. Locate the canister on the right front side of the For the following serviceable items and activities, refer
engine. to the CAT Operation and Maintenance Manual that
2. Turn the wing nut to loosen the canister clamp. was shipped with your machine.
3. Lift the canister from the mounting hardware. • Aftercooler core—clean and test
4. Shake the canister to feel whether it is empty. • Alternator belt—inspect/adjust/replace
5. Replace an empty canister with a new one. • Cooling system water temperature regulator—
6. Re-clamp the new canister. replace

• Cooling system—obtain and inspect coolant sam-

ple 1.2 Coolant Systems
• Crankshaft vibration damper—inspect The hydraulic oil cooler and the engine cooling radiator
1000
• Electronic unit injector—inspect/adjust are mounted side by side, with the hydraulic oil cooler
• Electronics grounding stud—inspect/clean/tighten on the right side of the machine (Figure 67). The clutch
oil cooler is mounted behind the hydraulic radiator
• Engine crankcase breather—clean screen.
• Engine mounts—inspect
• Engine oil sample—obtain
• Engine protective devices—check
• Engine speed/timing sensors—check/clean/cali-
brate
• Engine valve lash—inspect/adjust
• Engine valve rotators—inspect
• Fuel system—change primary filter
• Fuel system—change secondary filter
• Hoses and clamps—inspect/replace
• Starting motor—inspect
• Turbocharger—inspect
• Water pump—inspect
F06081
Figure 67: Engine and Hydraulic Radiator
The charge air cooler is positioned in front of the

engine. The pump-drive gearbox cooler is mounted
behind the charge air cooler.
The fan shared by the engine and hydraulic radiators is
driven by a hydraulic motor that pulls or pushes air,
according to a timed cycle. The fan pulls air through the
radiators during normal operation. The fan sometimes
reverses to help purge debris from the radiator screen.
For additional information, see “Oil Coolers” on
page 95.
◆ To inspect the coolant systems:

Check for the following conditions and clean, repair, or
replace them as needed:
• Debris blockage of air flow.
• Air, coolant, and hydraulic oil leaks at fittings, tank
seams, and hose connections.

• Condition of hoses and ducts for wear, bulging, 2. Remove the fill cap on the top of the radiator.
damage, and proper clamping. 3. Fill the radiator with Fleet Charge 50-50 Pre-diluted
until the coolant level is within 1/2 in. (13 mm) of
1.2.1 Checking Engine the bottom of the fill pipe (Figure 69).
1000
Coolant
1
2
1 WARNING 3
Hot liquid and steam. Avoid serious burns.
◆ To check the coolant level:

FM dwg
1. Stop the engine. Allow it to cool to a safe handling
temperature, under 100o F (38o C).
1. Radiator Cap
2. Ensure that the radiator and pressurized cooling 2. Gasket
system is cold (about air temperature). 3. Fill Pipe
3. View the sight gauge near the top of the coolant Figure 69: Radiator Fill Level
surge tank (Figure 68):
• Coolant visible in the sight gauge indicates the
proper level. 4. Inspect the gasket on the fill cap for damage and
• If you cannot see coolant in the sight gauge, fill replace the cap if the gasket is damaged or worn to
the tank before starting up. the point where it cannot maintain a seal.
5. Install the fill cap onto the radiator fill spout.
NOTE: If the coolant level drops below the sensor, the
6. Run the engine for 1 to 5 minutes.
engine can start, but it will shut down a few seconds
later. 7. Recheck the coolant level on the sight gauge.
1.2.2 Changing Engine

Coolant
1 WARNING
Hot liquid and steam. Avoid serious burns.
◆ To change the engine coolant:

1. Shut down the machine. Allow the engine/radiator
to cool to a safe handling temperature, under 100o F
(38o C).
F06004
2. Attach a hose to the petcock at the bottom of the
radiator.
Figure 68: Radiator Surge Tank and Sight Glass
3. Place the other end of the hose in a clean used-cool-
ant container suitable for anti-freeze (about 50 gal/
◆ To refill the radiator with coolant: 200 liters).
1. Make sure the radiator is cool.

4. Open the radiator fill cap enough to allow air to pass keep the coolant and engine within proper operating
through. temperature range. Also check the fan blades for dam-
5. Open the petcock valve (Figure 70) at the base of age.
the radiator to drain the coolant. Each month or every 200-250 operating hours, clean the
1000
radiator with low pressure water, sprayed from the
engine side, to remove small sticks or other debris that
may have lodged in the radiator fins. Be careful to use
only low pressure to prevent damage to the fins. The
fins are soft metal and are easily bent.
IMPORTANT: Avoid engine overheating. The

engine can overheat and shut down automati-
cally when the radiator does not cool enough.
◆ To clean the radiator fins manually:

1. Allow the engine to cool by running it at low idle
for at least five (5) minutes.
2. Shut down and lock out the machine to prevent
F06032 injury from moving fan blades.
Figure 70: Radiator Drain Valve 3. Spray the fins with water at less than 30 psi (2 bar).
If water is not available, use compressed air at no
more than 30 psi (2 bar).
Do not let the container overflow.
6. Close the petcock and remove the hose after the
radiator has been drained.
1 WARNING
Avoid eye injury and physical harm. Avoid body
7. Refill the radiator with a proper coolant recom-
injury. Wear goggles and do not use pressures
mended by Caterpillar. Fill until the coolant level
over 30 psi (2 bar) when using compressed air to
rises to about 1/2 inch (13 mm) below the bottom of
clean. The engine must be shut down and locked
the fill pipe (see Figure 69). out when manually cleaning the radiator.
8. Inspect the gasket on the fill cap for damage and
replace the cap if the gasket is damaged or unable to
maintain a seal.
9. Install the fill cap onto the radiator fill spout.
1.2.3 Cleaning and Checking

the Radiator
When you clean the engine and hydraulic radiator, it is
a good time to also clean the charge air cooler and the
pump-drive gearbox oil cooler.
Dirt, dust, and wood debris on radiator fins can cause
the engine, or other cooled systems, to overheat. The
automatic fan purge feature, which reverses the radiator
fan every 30 minutes for about 15 seconds, blows off
dust and debris. Check the grille as often as needed to

1.3 Engine Fluids

and Filters
1000
Change the filters at intervals appropriate to your oper-

ating conditions or at minimums recommended in the
5000H Maintenance Schedule (see “Maintenance
Schedule” on page 49).
1.3.1 Engine Oil and Filters

Refer to the following references for changing the oil
and filters:
• Refer to the CAT Operation and Maintenance Man- F06026
ual provided with your machine for the procedure Figure 71: Engine Oil Filters
to change the oil and filters (Figure 71) and to iden-
tify the correct filters.
• For determining timed oil change intervals instead
of the recommended interval based on quantity of
fuel used, see “Special Interval” on page 60.
• For the correct oil to use, see “Service Schedule for
Fluids and Filters” on page 57.
• For the location of the oil drain valve for engine oil,
see Figure 72. The valve is located near the lower
front of the engine.
• For resetting the Engine Oil Change Timer, press
and hold F2 on the Maintenance Schedule of the
control panel display (see “Maintenance Schedule”
on page 160).
F06028
Figure 72: Engine Oil Drain Valve
◆ To check the engine oil level:

1. Open the engine access door and locate the dipstick
on the hydraulic tank side of the engine near the
starter (Figure 73).

1000
F06027
F06003
Figure 75: Engine Oil Fill Tube
Figure 73: Engine Oil Dipstick Location
4. Use proper safety precautions to start the engine.

2. With the engine stopped, read the dipstick 5. Ensure oil pressure reaches an acceptable level.
(Figure 74). Keep the oil level within the cross-
6. Check for oil leaks.
hatched region next to the Full mark.
7. Return the machine to operation if the oil pressure
reaches its limits and no leaks are found.
L F LOW IDLE
1.3.2 Crankcase Breather

L F ENGINE STOPPED The crankcase breather (Figure 76) contains a washable
F05902 element that requires service every 500 hours.
Figure 74: Engine Oil Dipstick, Both Sides
3. Add oil, if needed, through the engine oil fill tube

(Figure 75).
F05711
Figure 76: Crankcase Breather

1.3.3 Fuel Filters ◆ To drain water from the fuel filter:

1. Drain the water into a suitable container by turning
The fuel system includes primary and secondary fuel
the stopcock at the bottom counterclockwise (to the
filters. The fuel tank fill tube includes a built-in dirt trap.
left).
1000
The trap requires cleaning whenever dirt is visible in it.

2. Close the stopcock securely when the water layer is
Replace the engine fuel filters as described in the CAT drained and fuel begins to drain out.
Operation and Maintenance Manual provided with
your machine. Whenever a fuel filter is replaced, it is IMPORTANT: Keep air out of the fuel system.
necessary to prime the fuel system. The water separator is under suction during nor-
mal engine operation. Keep the drain valve
1.3.3.1 Primary Fuel Filter securely tight to help prevent air from entering
The primary fuel filter (Figure 77) is a single canister. the fuel system.
Low fuel pressure, below about 23 psi (1.6 bar), is often
an indication of blocked fuel filters. 1.3.3.2 Secondary Fuel Filter
Each time you replace the filter canister, also clean the The secondary fuel filter (Figure 78) is a spin-on filter
fuel filter bowl. Use a non-flammable degreasing sol- attached to the primer pump handle. This filter can be
vent that is not harmful to plastics. Blow the bowl clean replaced using a standard filter wrench.
with compressed air at no more than 30 psi (2 bar), and
then re-install it.
F05928
F05929
Figure 78: Secondary Fuel Filter with Primer Pump
Figure 77: Water Separator, Below the Primary Fuel Filter
Fuel Primer Pump: Fuel lines might not contain fuel

Water/Fuel Separator: The fuel/water separator after the fuel filter has been replaced or when the engine
(Figure 77) is a transparent plastic container on the bot- has run out of fuel. In those cases, you will need to
tom of the primary fuel filter. Water settles to the bot- prime the fuel lines.
tom of the container and can be seen as a separate layer
beneath the fuel layer. Check for and drain the water ◆ To prime the fuel lines:
daily. 1. Locate the fuel primer pump at the rear of the
engine (Figure 78).

2. Unscrew the priming handle by turning it counter-

clockwise until it turns freely and can be pumped.
3. Extend and retract the handle several times. Pump
until you feel resistance from the fuel pressure. It
1000
may take 20 to 70 strokes of the pump handle.
4. Return the handle to the retracted position and turn
it clockwise to tighten.
For more priming information, refer to the CAT Opera-
tion and Maintenance Manual provided with your
machine.
1.3.4 Air Cleaners

Refer to the CAT Operation and Maintenance Manual
for additional guidelines on cleaning or replacing the air F05918
filters. Figure 79: Air Filter Service Indicator Location
IMPORTANT: Avoid engine damage. If the air fil-

ter becomes plugged, air can split the filter mate- .
rial, allowing unfiltered air to enter the engine. 1
Dirty air can increase engine wear. Follow CAT
guidelines for maintaining air filters and for test-
ing the air filter service indicator.
2
1.3.4.1 Air Filter Service Indicator

Locate the air filter service indicator behind each of the
two air filter canisters (Figure 79). As filters fill with
dust, the piston moves toward the red zone. Clean or 3
replace the filter when the yellow piston on the air filter F01262
service indicator enters the red zone (Figure 80).
When you clean or replace the filters, reset the indicator 1. Red Zone: Change Filter (or 2. Yellow Piston Indicator
with the engine running by pressing the reset button on clean primary filter) 3. Reset Button
the bottom once or twice. If the indicator does not reset,
repair or replace it. Figure 80: Air Filter Service Indicator
1.3.4.2 Pre-cleaners and Air Filters

The engine air duct consists of two pre-cleaners, which
separate heavy particles, and two filter canisters
(Figure 81). Be sure to clean out the pre-cleaners regu-
larly.

month or sooner as indicated by the service indicator for

the inner filter only (Figure 83).
1000
1 2
F05919
1. Air Pre-cleaners 2. Air Filter Canisters
Figure 81: Air Pre-cleaner and Filter Canister

F05782
Figure 83: Secondary Air Filter, Service Indicator

Each filter canister contains an outer primary air filter
(Figure 82) and an inner secondary, or safety, air filter.
The outer primary filter can be cleaned and re-used A colored dot in the window of the inner indicator is
daily when handled with care. Replace the outer pri- either green or red. Replace the inner filter when the
mary filter once a week. tiny dot turns red. To reset the indicator when changing
the inner filter, locate the pinhole and suck on that end
of the indicator.
1.3.4.3 Cleaning the Primary Filter

Element
You may use low-pressure compressed air to clean the
primary air filter (Figure 84).
F06029
Figure 82: Primary Air Filter, Partially Removed

F04509
Do not clean or re-use the inner secondary filter. Figure 84: Primary Air Filter, Cleaning
Remove and replace the inner secondary filter once a

Use filtered, dry air with a maximum pressure of 30 psi

(2 bar). Always blow the air from the inside of the filter 1.4 V-Belts
out to force dirt particles toward the dirty side.
The 5000H uses V-belts for driving the chipper disk and
When the primary air cleaner element has been cleaned,
1000
for running the engine alternator.
check for rips or tears in the filter material.
The best belt tension for all belts is the lowest possible
This cleaning method can be used a maximum of 5 tension at which the belt does not slip under peak load.
times per filter life.
When inspecting belts, check for cracks, frayed edges,
NOTE: The threaded shaft that supports the filters is not cen- and glazed contact surfaces. Replace belts that show
tered in the canister. When replacing the cover on the filter such wear.
canister, rotate the cover so that it fits and seals properly.
1.4.1 Installing Used Belts

It is important to distinguish in all cases between appro-
priate tensions for new and for used belts.
A new belt is one that has never been mounted,
stretched, or run and is in perfect condition as manufac-
tured. Because a new belt stretches after installation, it
is necessary to monitor the belt tension after installation
and re-tighten as needed to prevent slippage.
A used belt has been mounted, been tensioned and
stretched and is still in good condition. When re-install-
ing used belts, the tensions must be less than what is rec-
ommended for new belts. Overtightening a used belt is
very likely to overload bearings and sheaves, resulting
in damage or premature wear.
1.4.2 Checking Belt Tension

During installation of belts and when performing regu-
lar inspections, most belts can be tensioned using a
quick check method.
1 WARNING
Crushing or pinching hazard. Accidental starts or
even partial sheave rotation while adjusting V-
belts can cause serious crushing, pinching injury
or death. Shut down and lock out the machine
before servicing the drive system. Make sure all
equipment has come to a complete stop.
◆ To check belt tension during installation or

inspection:
2. Make sure the belt has come to a full stop.

3. Install the belt and tighten the tensioning bolt(s)

until slack is eliminated in the top run of the belt.
1.4.3 Replacing the Alternator
4. Open the belt access door on the top of the belt Belt
guard.
1000
When replacing the alternator belt, use only belts sup-

5. Push down on the belt with one fist, as diagrammed plied by Peterson. These belts are specified for very
in Figure 85. Tension is approximately correct high load requirements.
when deflection equals the thickness of the belt.
Approximate tensions are contained in Table 11. ◆ To replace the alternator belt:
1. Loosen the alternator adjusting rod until the belt can
be removed from the pulleys.
2. Remove the old belt.
3. Install the new belt and tighten it as described in
“Checking Belt Tension” on page 83.
FM dwg 1.4.4 Replacing Chipper

Figure 85: Drive-Belts and V-Belts Tensioning
Sheave Belts
Always replace the belts as a pair. Never reuse an old
6. After installing belts, listen to and watch new belts belt paired with a new belt.
carefully for slipping or signs of overheating during
machine operation. Re-tighten if slipping occurs.
Table 11: Quick-Check Belt Deflections

1 WARNING
Crushing or pinching hazard. Accidental starts or
Belt Type Deflection by Hand even partial sheave rotation while adjusting V-
Force, 100 lbs. (45 kg) belts can cause serious crushing, pinching injury
or death. Shut down and lock out the machine
Chipper Sheave Belts 1 in. (2.5 cm) before servicing the drive system. Make sure all
equipment has come to a complete stop.
Alternator Belt 1/2 in. (1.3 cm)
◆ To remove and replace the two chipper disk
IMPORTANT: Do not over-tighten the alternator belts:
belt. Excess tension can easily damage the bear-
ings.
2. Remove the 9 bolts that secure the center panel of
the belt guard, and remove the panel (Figure 86).
1 WARNING
Pinch points. Avoid severe physical injury. All
belt drives and pulleys must be guarded to pre-
vent access to moving belts, sheaves, and pul-
leys.

7. Loosen the 4 engine sled hold-down bolts

(Figure 88).
1000
F06013
1 2
Figure 86: Chipper Disk Belt Guard, 9 Bolts
3. Remove the following bolts that secure the end

F06012
enclosure of the belt guard:
1. Hold-down Bolt (1 of 4)
• 4 bolts underneath. 2. Jack Bolt (1 of 2)
• 4 bolts on the back side.
Figure 88: Engine Sled Hold-Down and Jack Bolts
• 2 bolts on top.
4. Remove the belt guard support bar (Figure 87).
8. Turn the 2 jack bolts (Figure 88) to slide the engine
sled toward the chipper disk until enough slack is in
the belts to remove them.
9. Remove the two belts.
10. Be sure the grooves of the sheaves are in good con-
dition.
11. Clean the grooves of both sheaves.
Remove oil, rubber residue, and other contamina-
tion from sheaves before installing new belts.
IMPORTANT: Overheated belts may leave rub-

ber residue on the sheaves. Rubber residue
prevents proper contact between new belts
and sheaves, resulting in belt slippage.
Increasing belt tension to prevent slippage,
when the real cause is dirt, damages the
sheaves and bearings and causes the belts to
wear out faster.
F06014
12. Place the new drive belts over the sheaves and into
Figure 87: Belt Guard Support Bar the correct grooves.
13. Adjust the engine sled jack bolts to tighten the belts.
5. Remove the top section of the belt guard. 14. Tighten the belts until they begin to settle into the
6. Remove the rear portion of the belt guard. grooves of the sheaves.

15. Ensure the belts are not caught or binding as tension

increases. To do this, rotate the sheave one revolu-
tion by hand, if possible. If not, pull or push on both
the upper and lower runs of the belts to keep them
1000
even.
16. Continue tightening the belts until the top run is
approximately flat, but the lower run still has a little
slack. Then stop.
17. Ensure the belts are properly seated and aligned.
Continue to tighten the belts until they become taut.
IMPORTANT: Do not over-tighten. Over-tighten-

ing V-belts can easily damage the belts, the
bearings, and other components at the rotat-
ing shafts.
18. Re-install the belt guard components.
19. Follow normal procedures for starting up and run-
ning the machine.
20. Listen to and watch the new belts carefully for slip-
ping or signs of overheating.
21. Check belt tension again after 1/2 hour, 4 hours, and
24 hours.
Variables such as hydraulic power requirements,
local air temperature, and sheave wear can affect
belt tension.

S ECTION 2000
HYDRAULIC SYSTEMS
The 5000H is equipped with two hydraulic systems, one for the main machine and another for the clutch. Each sys-
tem provides its own tank, pumps, valves, and filters.
2.1 Main Hydraulic 2.1.1 Checking Hydraulic Oil
2000
The sight gauge (Figure 90) is on the side of the hydrau-
System lic tank.
The pumps for the hydraulic system power the hydrau-

lic cylinders and motors. The hydraulic tank in the front
center of the machine provides the reservoir of oil
(Figure 89).
2 1
F05926
1. Hydraulic Level Sight Gauge 2. Hydraulic Oil Temperature

Gauge
Figure 90: Hydraulic Oil Level and Temperature Gauge

F06020
1. Breather Cap
2. Filter Pressure Gauge Ensure the hydraulic oil tank level is about 2 in. (5 cm)
Figure 89: Hydraulic Oil Tank, View from Left below the top of the sight glass tube when the machine
is cool before startup (Figure 90).
The thermometer at the bottom of the gauge shows oil
temperature. The normal range of operating tempera-
tures is from 120° to 180° F (49° to 82° C). If the oil
reaches 190° F (88° C), shut down the machine imme-
diately and troubleshoot the problem.
A good practice is to sample and test the hydraulic oil
on a regular basis (see Table 3 on page 49). Consider
purchasing a sample bottle and collection kit for this

SECTION 2000 HYDRAULIC SYSTEMS
purpose. Send the samples to an accredited fluid analy- c. Stop adding oil when the level on the sight
sis laboratory in your local area. gauge is about 2 inches below the top of the
sight glass tube.
IMPORTANT: Avoid machine damage. Do not 3. Re-install the breather cap and the fill plug.
fill the hydraulic tank to the top. Oil expands
when heated and can damage the hydraulic sys-
tem. Do not let the tank level drop below half full.
Doing so can damage the pumps and the hydrau-
lic components permanently.
2000
1 CAUTION
Avoid burns and eye injury from hot oil spray. The
hydraulic tank is under pressure. When loosening the
fill cap or the breather element, hot oil may spray out.
◆ To add hydraulic oil for the main system:

1. Unscrew the hydraulic tank fill plug (Figure 91).
F06019
Figure 91: Hydraulic Tank Fill Cap
2. Add recommended hydraulic oil (as described in

Table 5 on page 57) through the tank fill opening to
bring the level up to the lower acceptable level on
the gauge (Figure 90).
For faster filling, use a low-pressure pump that does
not exceed a fluid pressure of 20 psi (1.3 bar).
a. Remove the breather cap for allowing air to
escape.
b. Seal the gap between the nozzle and the tank-
fill opening.

2.1.2 Changing Hydraulic Oil 12. Reset the Hydraulic Oil Change Timer on the dis-
play screen: press and hold F4 on the Maintenance
and Filters Schedule screen
This topic provides instructions for changing hydraulic

oil and filters.
2.1.2.1 Replacing the Charge
Pressure Filters
◆ To change the hydraulic oil: Charge pressure filters clean the hydraulic oil before it
1. Shut down and lock out the machine. enters the hydraulic system for each flail motor and the
engine radiator fan motor. Each pump for these hydrau-
2000
2. Get a container(s) capable of holding 320 gallons
(1211 liters) of hydraulic oil. lic motors has one charge pressure filter.
3. Locate the drain fitting and ball valve on the bottom Replace the filters when indicated in Table 5 on page 57
of the hydraulic tank (Figure 92). Make sure the or sooner if the indicator on the top of the filter holder
ball valve lever is in the closed position, at a right (Figure 93) moves out of the green zone. Not all pump
angle to the pipe. filters have an indicator.
F05941
Figure 93: Hydraulic Fan Pump Filter with Indicator

F06074
Figure 92: Hydraulic Tank Drain Valve, Closed
◆ To replace the charge pressure filters:

4. Remove the cap or plug, if present, from the drain
fitting and connect the drain hose to the fitting.
2. Locate the hydraulic pumps for the flails and the
5. Insert the other end of the hose into the used oil con-
engine radiator fan (Figure 110 on page 97).
tainer.
3. Remove the filter and replace it.
6. Remove the hydraulic tank breather cap to allow air
to enter the tank as oil drains. • For Rexroth pumps, replace the internal filter
element.
7. Open the ball valve and drain the oil from the tank.
8. Close the ball valve after the tank is empty. • For Sauer pumps, replace the entire spin-on
canister.
9. Remove the hose.
10. Re-install the cap on the drain fitting to help prevent
accidental loss of hydraulic oil.
11. Fill the tank with oil (Table 5 on page 57).

2.1.2.2 Replacing the Tank Return ◆ To replace the hydraulic tank return filters:
Filters 1. Be sure the engine is shut down and locked out and
that oil temperature is under 100° F (38° C).
Inspect and replace as indicated in Table 5 on page 57
and when the hydraulic tank pressure gauge (Figure 94) 2. Release hydraulic tank pressure:
reads 15 psi (1 bar or 100 kPa) or greater. a. Wear goggles.
b. Slowly turn the fill cap (Figure 95) until you
IMPORTANT: Avoid machine damage. When hear the release of air.
pressure reaches 22 psi (1.5 bar or 152 kPa),
If the cap is too tight, turn it with a wrench on
unfiltered oil bypasses the filters and flow into
2000
the bottom nut fitting.

pumps and motors causing serious, permanent
damage. c. Pause. Do not open any further, and do not open
the oil fill cap or remove the tank covers until
all pressure is released.
3. Replace and install the new hydraulic tank breather
cap, if required. See “Maintenance Schedule” on
page 49 for the replacement interval.
4. Remove the three hydraulic tank filter covers
(Figure 95).
F05933
Figure 94: Hydraulic Oil Tank Filter Pressure Gauge
The hydraulic tank is pressurized and has an upper F06019
return chamber and a lower reservoir. Hydraulic oil Figure 95: Hydraulic Tank Filter Covers (3) and Fill Plug
returning from motors and pumps empties into the
return chamber and then drains through the hydraulic
tank filters into the reservoir. From the reservoir, fil- 5. Pull out the filter assembly (Figure 96) and lay it on
tered oil is drawn for use in pumps, motors, and actuator a clean work surface to drain.
cylinders.
1 CAUTION
Avoid burns and eye injury from hot oil spray.
The hydraulic tank is under pressure. When loos-
ening the fill cap or the breather element, hot oil
may spray out.

8. Remove the old filter from the holder and discard it.
9. Inspect and replace the filter O-ring and housing
gasket if needed (Figure 98).
2000
F01204
Figure 98: Filter Assembly Gasket and O-Ring, Removal
10. Apply a non-flammable de-greasing solvent to the

F01193 magnet and blow off metal particles with com-
Figure 96: Filter Assembly, Removal from the Tank pressed air at no more than 30 psi (2 bar or 200
kPa). Keep the magnet surface free of any particles
(Figure 99).
6. Place the hydraulic tank cover(s) over the tank
opening(s) to prevent contamination.
7. Loosen the nut on the bottom of the filter assembly,
and then remove the nut, the nut retainer, and the
spring assembly from the bottom (Figure 97).
F01203
Figure 99: Filter Magnet, Blowing Clean
11. Place the center rod of the filter holder into the open
end of the new filter. Install the bottom spring and
nut onto the end of the rod that protrudes through
F01205 the bottom of the filter.
Figure 97: Filter Bottom, Turning the Nut 12. Manually tighten the bottom nut fully until firm
resistance is felt (see Figure 97).

IMPORTANT: Avoid machine damage. If the nut Major hydraulic system components can be
on the spring retainer assembly is not tight, damaged.
contaminated oil may bypass the filter and 17. Install and tighten the hydraulic tank fill plug.
damage the pumps.
18. After starting the engine, when the hydraulic sys-
13. Install the filter assembly. Be sure the top and bot- tems is running and the hydraulic oil temperature
tom springs are installed correctly. reaches 100° F (38° C), inspect the hydraulic tank
14. Inspect and replace the tank cover O-ring that seals covers for leaks. Operate a hydraulic feature, such
each of the 3 covers if needed (Figure 100). as the loader, for several minutes and inspect for
leaks again. To correct leaks, shut down the engine,
2000
check the O-rings and gaskets, make sure all sealing

surfaces are clean, and ensure that the tank covers
are correctly secured with the required fasteners.
F01195
Figure 100: Filter Tank Cover, Replacing the O-Ring
15. Install the bolts that hold the tank cover(s) in place
and torque them to 35 ft-lbs (47 Nm). Tighten the
bolts evenly in stages, moving from a bolt on one
side of the cover to a bolt on the opposite side, and
then across to another, so that all portions of the
cover are evenly tightened.
16. Check the hydraulic tank sight gauge and, if
needed, add oil through the hydraulic tank fill open-
ing to bring the level up to about 2 in. (5 cm) below
the top of the sight glass tube.
Do not add more than 10 gallons (38 liters) at a time
since that is the capacity of the filter chamber. Wait
for oil to flow through the filters into the main tank
below before adding more.
For faster filling, a compressed air pump can be
used. You must first remove the breather/filter ele-
ment and seal the opening around the pump nozzle
where it enters the return filter chamber.
IMPORTANT: Avoid hydraulic system damage

and malfunction. Filling the hydraulic tank to
the top can cause leakage and harmful sys-
tem pressure when the machine warms up.

2.2 Clutch Hydraulic

System
The clutch uses an independent hydraulic system and oil
tank (Figure 101). On a daily basis, make sure the fill/
breather cap on the clutch oil tank is clear of debris.
Also, check the sight gauge at the tank to be sure the
2000
system contains enough oil.
F06018
Figure 102: Clutch Oil Filter
1
2.2.1 Checking Clutch Oil
The hydraulic clutch requires clean oil of the proper
2 type and quantity, operating within ranges of specified
pressure and temperature. See Table 5 on page 57.
Good practice is to sample and test the clutch oil on a
regular basis (see Table 3 on page 49). Consider pur-
F05921
chasing a sample bottle and collection kit for this pur-
1. Breather, Fill Cap
pose. Send the samples to an accredited fluid analysis
2. Sight Gauge
laboratory in your local area.
Figure 101: Clutch Oil Tank
◆ To check the clutch oil level in the tank:
1. Shut down the machine and let the clutch oil cool.
The clutch oil filter is located on the right front corner
of the engine enclosure (Figure 102). 2. Check the oil level sight gauge (Figure 103) at the
clutch oil tank (Figure 101). Make sure the oil level
is near the high level mark on the sight gauge. The
maximum temperature should not exceed 180° F.
3. Add recommended clutch oil (see “Fluids and Fil-
ters” on page 57) as needed through the tank fill
opening (Figure 101) to bring the level up to the
acceptable level on the gauge.

1
2000
2 F06016
Figure 104: Clutch Tank Drain
4. Remove the tank fill/breather cap to allow air to

F05910
enter tank as the oil drains.
1. High-Level Mark
5. Remove the drain plug and drain the oil from the
2. Low-Level Mark tank.
6. Re-install the drain plug after the tank is empty.
Figure 103: Clutch Oil Sight Gauge
7. Fill the tank with the proper type of clutch oil (see
Table 5 on page 57).
2.2.2 Changing the Clutch Oil ◆ To replace the clutch oil filter and
breathers:
and Filter 1. Shut down and lock out the machine.
Each time the oil is changed, also replace the filter ele- 2. Remove and replace the clutch tank fill/breather cap
ment, the tank fill/breather cap, and the breather on top with a new one.
of the HPTO clutch housing.
◆ To change the clutch oil:

IMPORTANT: Avoid pump damage. Do not use
any tape sealants or thread compounds.
1. Shut down and lock out the machine. 3. Remove and replace the spin-on filter (Figure 102
2. Obtain container(s) capable of holding 21 gallons on page 93). Tighten by hand only. Do not use a fil-
(80 liters) of oil. ter wrench.
3. Locate the drain plug on the bottom of the clutch oil 4. Remove and replace the breather on top of the
tank (Figure 104). HPTO clutch housing (Figure 105). The breather is
attached by pipe threads.

2.3 Oil Coolers

The hydraulic oil cooler is mounted on the right side of
the engine radiator. The clutch oil cooler is mounted
inside the front radiator screen. The two oil coolers
share the fan with the engine radiator (Figure 106).
2.3.1 Hydraulic Oil Cooler
2000
Normal operating temperature of the hydraulic oil is
150° to 180° F (66° to 82° C). If hydraulic oil tempera-
ture reaches 190° F (88° C) or above, shut down and
determine the cause before continuing to run the
machine.
F06017
Figure 105: Clutch HPTO Breather
F06015
Figure 106: Engine, Hydraulic, and Clutch Oil Fan
You can help prevent overheating by providing regular

maintenance checks and cleaning, appropriate filter and
hydraulic oil changes, and alertness to unusual condi-
tions.
Overheating may have the following causes:
• Outside air temperature is the first consideration.
The 5000H can operate successfully in deserts
where afternoon temperatures reach 120° F (50° C)

for several hours. In those conditions, watch the

hydraulic oil temperature gauge closely. 2.4 Hydraulic Pumps
and Suction Valves
• Reduced oil volume in the tank caused by system
leaks. Keep hydraulic oil at the proper level at all
times.
• Improper setting of relief valves. Figure 108 and Figure 109 identify the suction valves
for each of the hydraulic pumps. Table 12 and
• Restricted filters and/or breathers. If the filters or Figure 110 identify the hydraulic pumps and their loca-
breathers are often blocked, shorten the interval for tions in reference to the engine.
checking and changing them.
2000
• Malfunction of the hydraulic oil cooler system.

5
2.3.2 Clutch Oil Cooler
2 6 7
Figure 107 shows the clutch oil cooler mounted on the 1
radiator screen. It swings out with the screen when the 3
screen is opened for maintenance. 4
If the clutch oil temperature rises above a set point, the
Peterson control system disengages the clutch and low-
ers the engine speed to idle.
8
F06269
1. Loader 5. 2nd Upper Flail (Optional)
2. Radiator Fan 6. Feed/Float
3. Lower Flail 7. 1st Upper Flail
4. Charge Air Cooler Fan 8. Feed Makeup
Figure 108: Suction Valves, Front Left
F06270
Figure 107: Clutch Oil Cooler
F06031
Figure 109: Suction Valve, Bark Mover

Table 12: Hydraulic Pump Descriptions

# Pump Description
1
1. Bark Mover Pump Activates the bark mover, 2
landing gears, stabilizer, spout
rotation and deflection, spout 12
stowage, and the chipper hood.
2. Hydraulic Clutch Lubricates, engages, and
2000
Pump disengages the wet clutch.
3. Gear Oil Pump Circulates pump-drive gearbox

oil to the cooler.
4. Hydraulic Fan Powers the engine and

Pump hydraulic radiator fan. 13
5. Charge Air Cooler Powers the charge air cooler

Fan Pump (CAC) fan.
6. Upper Flail #2 Powers the upper flail #2 motor.

Pump
7. Lower Flail Pump Powers the lower flail motor.
8. Loader Pump Activates all of the loader

functions, including turret
rotation and tilt, and the air
conditioning motor.
3 14 5
9. Feed Make Up Provides any needed hydraulic
Pump flow to supplement the feed and
4 6
float pumps.
10. Feed and Float Tandem pumps that lift the feed 15
Pump(s) and flail housings and control
their float function.
7 9 11
11. Upper Flail #1 Powers the upper flail #1 motor.
Pump 10
8
F05939
1. Bark Mover Pump 8. Loader Pump

2. Hydraulic Clutch Pump 9. Feed Make Up Pump
3. Gear Oil Pump 10. Feed & Float Pump(s)
4. Hydraulic Fan Pump 11. Upper Flail #1 Pump
5. Charge Air Cooler Fan 12. Hydraulic Clutch
Pump 13. Engine
6. Upper Flail #2 Pump 14. Coupler
7. Lower Flail Pump 15. Pump Drive Gearbox
Figure 110: Hydraulic Pumps, Top View Diagram

2.5 Pump-Drive 6. Reconnect the hose to the gearbox oil cooler.
Gearbox 3
The pump-drive gearbox is located front of the engine
below the charge air cooler.
2.5.1 Checking the Pump-

2000
Drive Gearbox Oil 2

Check the gear oil level by removing the plug located on 1
the front of the box in the center line of the pump drives.
◆ To check the oil level in the pump-drive

gearbox:
1. Shut down and lock out the machine. F05942
2. Remove the oil-level plug on the front of the gear- 1. Drain Plug 3. Elbow connector to the oil
box (Figure 112). 2. Oil level plug cooler
3. Disconnect the hose to the gearbox oil cooler Figure 112: Pump-Drive Gearbox
(Figure 111) where it attaches to the gearbox elbow
connector (Figure 112).
2.5.2 Changing the Pump-

Drive Gearbox Oil
◆ To change the oil in the pump-drive
gearbox:
2. Place a container directly under drain plug
(Figure 112) for capturing 2 gallons (8 liters) of
used oil.
3. Disconnect the hose to the gearbox oil cooler
(Figure 111) where it attaches to the gearbox elbow
connector (Figure 112).
F05940 4. Remove the drain plug from the bottom of gearbox
Figure 111: Gearbox Oil Cooler and drain the oil into the container.
5. Re-install the bottom drain plug after the pump-
drive gearbox has drained.
4. Add synthetic 75W-90 gear oil through the add/fill
6. Add 2 gallons (7.6 liters) of 75W-90 synthetic gear
opening (the elbow connector) on the top of the
oil through the elbow connector.
gearbox until oil flows out of the level check hole.
7. Check the oil level.
5. Install the level check plug and then add 1 extra
quart (.95 liter). 8. Reconnect the hose to the gearbox oil cooler.

2.6 Drive Motor 1
Gearboxes
The following hydraulic drive motors transfer power
through a gearbox:
• Debarker lower feed roll
• Debarker upper feed roll
2000
• Case roll
• Chipper feed roll
2
• Lower flail 3
• 1st upper flail F06088
1. Oil Fill Plug 3. Oil Drain Plug
• 2nd upper flail (optional) 2. Oil Level Inspection Plug
For all of the feed rolls, power from the gearboxes is
Figure 114: Upper Feed and Chipper Feed Gearboxes
then transferred to the rolls through sprockets and
chains. For chain maintenance, see “Drive Chains” on
page 119.
Because the gearboxes vary in shape, the location of the
ports for inspecting, filling, and draining the gear oil
varies also. For details, see Figure 113, Figure 114,
Figure 115, and Figure 116.
1
1
F06090
1. Oil Fill and Breather
2
Figure 115: Flail Gearbox Fill Port
F06087
1. Oil Fill Plug 3. Oil Drain Plug
2. Oil Level Inspection Plug
Figure 113: Lower Feed and Case Roll Gearboxes

1
2000
F06091
1. Oil Level Inspection Plug
2. Oil Drain Plug
Figure 116: Flail Gearbox Inspection and Drain Plugs

F06089
2.6.1 Checking the Drive Figure 117: Access Bolts to the Upper Feed Motor and Chain
Motor Gearbox Oil 4. Access the chipper feed gearbox only, from the
This inspection applies to all drive motor gearboxes for right side of the machine, below the water tank.
the flails and the various feed rolls. See Figure 113, Remove the 4 bolts that secure the chain guard that
Figure 114, Figure 115, and Figure 116. covers the motor and chain.
5. For all gearboxes, unscrew the oil-level inspection
◆ To check the oil level in drive motor plug from the gear case.
gearboxes:
6. Check to see that oil is at the level of the plug.
1. Make sure the machine is level.
7. Add additional oil as required.
a. Unscrew the fill-port plug from the gearbox.
3. Access the upper feed gearbox only from the right
b. Fill with 75W-90 synthetic gear oil until the oil
side of the machine, above the feed area. Remove
overflows the inspection port. Add oil as speci-
the 6 bolts that secure the plate that covers the
fied in “Fluids and Filters” on page 57.
motor and chain (Figure 117).
c. Replace the fill plug.
8. Replace the inspection plug.
9. Replace the cover plates over the upper feed gear-
box and the chipper feed gearbox.
10. Clean any spilled oil from the machine.

2.6.2 Changing the Drive 2.7 Hydraulic

Motor Gearbox Oil
This maintenance activity applies to all drive motor Manifold Setups
gearboxes for the flails and various feed rolls. See
Manifold valve setups and adjustments are configured
Figure 113, Figure 114, Figure 115, and Figure 116.
at the factory and reset whenever related parts are
◆ To change the oil in the drive motor repaired or replaced. With the following exception,
gearboxes: hydraulic valves do not require periodic adjustment.
2000
1. Make sure the machine is level. The exception is the feed manifold. Because chip size
depends partially on the speed at which logs encounter
2. Shut down and lock out the machine. the chipper disk, this maintenance manual provides
3. Access the upper feed gearbox only from the right instructions for adjusting the feed speed. See “Feed
side of the machine, above the feed area. Remove Manifold Setup” on page 144.
the 6 bolts that secure the plate that covers the
motor and chain (Figure 117 on page 100).
4. Access the chipper feed gearbox only, from the
right side of the machine, below the water tank.
Remove the 4 bolts that secure the chain guard that
covers the motor and chain.
5. For any gearbox, place a pan or other container
under the gearbox to catch the oil.
6. Open the fill-port plug.
7. Open the drain plug to drain the oil.
8. Close the drain plug when oil stops draining.
9. Open the oil-level inspection plug.
10. Add oil into the case until it is at the level of the
inspection plug, and then screw in the inspection
plug. Use oil as specified in “Fluids and Filters” on
page 57.
11. Close the fill plug.
12. Replace the cover plates over the upper feed gear-
box and the chipper feed gearbox.
13. Dispose of the used oil properly.
14. Clean any spilled oil from the machine.

2000

S ECTION 3000
ELECTRICAL SYSTEM
The electrical system consists of batteries and cables, engine starter motor, machine controls, alternator, and battery
disconnect switch. Use precautions when jump starting the engine or welding on the machine.
3.1 Electrical Parts 2. Press CONTROL POWER on the engine control

panel (JB2) to energize the system.
Electrical system maintenance is limited to servicing 3. Press the EMERGENCY STOP (E-Stop) button on
the batteries and cable connections, resetting the circuit the engine control panel.
breakers, and replacing fuses in the control panel. 4. Verify that the electrical system turns off.
3000
Engine electrical components are covered in the CAT 5. Pull out the E-Stop button.
Engine Manual. The control system is covered in the 6. Press CONTROL POWER to re-energize the system.
5000H Service Manual.
7. Repeat testing for the other E-Stop buttons:
3.1.1 E-Stop Buttons • In the cab

• Near the forward left-side ladder
The four large red Emergency Stop (E-Stop) buttons
require regular testing. For their locations, see “Emer- • On the spout and leveling control panel (JB3)
gency Stop (E-Stop) Buttons” on page 15.
3.1.2 Circuit Breakers
◆ To test the Emergency Stop buttons:
The main circuit breaker panel is located in the cab
1. Turn the battery disconnect switch to the ON posi- above and behind the operator (Figure 119).
tion (Figure 118).
F06007
Figure 119: Circuit Breaker Panel in the Cab
The circuit breakers protect the various electrically

powered items from drawing too much current.
Three additional circuit breakers are located in control
F05315 box JB1 under the engine air cleaners (Figure 120).
Figure 118: Battery Disconnect Switch in the ON Position When a circuit breaker trips, its control lever changes
position.

SECTION 3000 ELECTRICAL SYSTEM
7. Turn on the battery disconnect switch.

8. Check for proper operation.
9. If the problem still exists, contact Peterson Cus-
tomer Service.
3.1.4 Batteries, Cables, and

1
Connections
The batteries energize the control panel, and they power
2
the engine starter motor. The batteries are located next
to the engine in the battery box (Figure 121).
F06008
1. Circuit Breakers
2. Fuses
3000
Figure 120: Control Box JB1
◆ To reset a circuit breaker:

1. Turn off the battery disconnect switch.
2. Use a Phillips screwdriver to open control box JB1.
3. Switch on the tripped circuit breaker control lever
back to the ON position.
4. Close the control box.
5. Turn on the battery disconnect switch. F05920
6. Check for proper operation. Figure 121: Battery Box

7. If the circuit breaker trips again, contact Peterson
Customer Service.
◆ To clean, inspect, and service the batteries:
3.1.3 Fuses 1. Shut down and lock out the machine.
Separate electrical circuits in the control system are pro-
tected by fuses. If an electrical system or device no
longer operates, check for a blown fuse in JB1.
1 WARNING
Avoid serious physical injury and chemical
◆ To check and replace a fuse: burns. Explosive hydrogen gas may be
present around batteries. Do not allow ciga-
1. Turn off the battery disconnect switch. rette smoking, flames, or sparks around bat-
2. Use a Phillips screwdriver to open control box JB1. teries. Wear eye protection, such as safety
3. Locate the fuses under the circuit breakers goggles, and skin covering that is impervious
(Figure 120). to battery acid when working around the bat-
teries.
4. Pull the suspected bad fuse straight out and inspect
it.
5. Re-install the fuse if it appears OK or replace it with
a new fuse.
6. Close the control box.

1 WARNING 1 3 4
5
Avoid electric shock and possible death. The
24-volt battery system can generate up to
1300 amps when fully charged. The battery
disconnect switch cover must be closed and
locked when servicing the batteries and bat-
tery cables. Do not allow contact between
positive (+) and negative (-) terminals or
cables.
2. Open the battery box. 9
3. Remove debris on and around the batteries. Use

compressed air for good results. Avoid injury: limit
air pressure to less than 30 psi (2 bar).
3000
4. Visually inspect the batteries, terminals, and cables
for corrosion.
5. Make sure battery cables are securely attached to 6 7
battery posts. Tighten connectors if they are loose.
6. Replace corroded cables, or if corrosion is minimal, 2
clean as follows:
a. Remove cables from the batteries and clean
them with a wire brush or terminal cleaning
tool.
b. Install felt washers on terminal posts.
c. Connect cables securely to the battery posts.
8
d. Apply spray-on battery sealant or coating to the
battery cable connections to prevent corrosion.
Use only sealants specifically designed for bat-
tery connections.
F06062
7. Check the electrolyte level inside each battery cell
1. Battery 1 6. Starter 2
by removing individual caps. Adjust the electrolyte 2. Battery 2 7. Solenoid 2
level as necessary by adding distilled water until the 3. Battery Disconnect Switch 8. Power Distribution Box
level reaches full, as indicated by the battery manu- 4. Starter 1 (JB1)
facturer. 5. Solenoid 1 9. Ground Straps
8. Check connections between the batteries, the
Figure 122: Battery Cable Routing
machine ground, and the battery disconnect switch.
Tighten them as needed to ensure a good electrical
path.
9. Inspect cables for wear throughout their routing
path (Figure 122), and correct any problems such as
damaged or missing insulation or poor electrical
connections.

3.2 Jump Starting before attaching the jump start cables. Ensure that
the main battery disconnect switch is in the OFF
position before attaching the jump start cables to the
the Machine engine being started.
◆ To jump-start an engine from an external

source:
1 WARNING 1. Connect one positive (+) end of the jump start cable
Explosion Hazard. Prevent sparks near batteries. to the positive (+) terminal of the discharged bat-
Sparks near some batteries could cause vapors tery.
to explode. Do not allow jump start cable connec-
2. Connect the other positive (+) end of the jump start
tors to contact each other or the engine.
cable to the positive (+) terminal of the electrical
source.
1 WARNING 3. Connect one negative (-) end of the jump start cable
3000
to the negative (-) terminal of the electrical source.

Avoid physical injury and chemical burns. Explo-
Connect the other negative (-) end of the jump start
sive hydrogen gas may be present around the
cable to the engine block or to the chassis ground of
batteries. Do not allow cigarette smoking, flame
the machine with the discharged battery.
or sparks around batteries. Wear safety goggles
and skin covering that is impervious to battery 4. Turn on the battery disconnect switch.
acid when working around batteries. 5. Start the engine.
6. Immediately after the stalled engine is started, dis-
IMPORTANT: Avoid damage to the electrical connect the jump start cables in reverse order.
system. Use a battery source with the same volt-
age as the electric starting motor. Use only equal
voltage for jump starting. The use of higher volt-
age will damage the electrical system.
After a jump start, the alternator may not be able to fully
recharge batteries that are severely discharged. The bat-
teries may need to be charged to the proper voltage with
a battery charger. Contact your Caterpillar service rep-
resentative for battery testing and charging procedures.
Follow these rules when jump starting:
• Do not reverse the battery cables. Doing so can
damage the alternator.
• Attach the ground cables last and remove them first.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the neg-
ative (-) jump start cable should be connected last
from the external power source to the negative (-)
terminal of the starting motor. If the starting motor
is not equipped with a negative (-) terminal, connect
the jump start cable to the engine block.
• Before using an external electrical source to start
the engine, turn the Engine control switch to the
OFF position. Turn all electrical accessories off

3.3 Welding • Control box JB8, for machines with serial num-
ber 309 and up. JB8 is located underneath the
roll case.
Precautions • Turret harness at the side of the machine below
the cab (Figure 124).
Peterson recommends that only experienced, qualified For all connectors, simply twist the securing ring
welders be allowed to weld on the machine. Serious and then pull the connector loose.
damage can occur to the machine from improper or
careless welding. Electrical damage can occur to the
ECM, the control panel, and the bearings. Welding
sparks and cutting torch flames can cause equipment
fires. Welding is especially hazardous when typical
combustible or flammable materials are present.
1 WARNING
3000
Do not tamper with the electronic system or the
engine wiring. Avoid personal injury or death
and/or engine damage.
IMPORTANT: Avoid damage to voltage-sensi-

tive systems. Before welding, disconnect all elec-
trical connectors from all control panel boxes F06058
and disconnect the engine ECM connectors. Figure 123: Control Panel Electrical Connectors
Doing this protects the clutch control unit, the
control panel modules, and other sensitive com-
ponents.
◆ To weld safely on the machine:

2. Disconnect the negative (-) battery cable at the bat-
tery. See battery diagram (Figure 122 on page 105).
3. Set the battery disconnect switch to OFF, remove
the key, and lock out the switch cover.
4. Disconnect the electrical connectors at the follow-
ing locations:
• Control boxes JB1, JB2, JB3, and JB4 (see
Figure 123 for an example of its connectors):
JB1 is located under the engine air cleaners.
F06057
JB2 is located on top of the hydraulic tank.
Figure 124: Turret Harness Connector
JB3 is located at the right front of the machine.
JB4 is located on the left side at ground level
under the walkway. 5. Disconnect the two connectors from the engine
ECM unit (Figure 125). The connectors are held on
by Allen screws.

3.3.2 Bearing Protection

Controlling the ground path to avoid arcing through the
bearings is critical to preserving their durability. By its
nature, arc welding creates the potential for electrical
arcs anywhere on the machine that electrical current can
flow. Proper grounding controls current flow and pre-
vents accidental arcing at other points, such as across
bearings.
The potential for arcing at bearings is very high. Only a
thin coating of grease insulates the facing metal sur-
faces. Because proper operation requires these surfaces
to be smooth, even a small arc can create metal weak
points, lumps, and pits. A small amount of surface dam-
age can very quickly lead to complete bearing failure.
3000
3.3.3 Bearing Failure

F06025
Figure 125: Engine ECM with Two Connectors

Examples
6. Connect the welder ground cable directly to the In Figure 126, note the microscopic view of the small
member to be welded. Place the ground cable clamp rectangular area on one of the bearing rollers. The trac-
as close as possible to the weld area. ery lines are typical of damage to roller surfaces from
Do not use electrical components, the ECM, or an electrical arcing. Arcing not only causes metal transfer
electronics ground stud for grounding the welder. from race to roller, arcing also weakens and roughens
the rolling surfaces.
7. Protect the machine and engine wiring from weld-
ing debris or splatter. Several rollers from this bearing show similar damage,
indicating repeated arcing and eventual failure. The arcs
8. Use standard welding techniques to weld the mate-
jumped from the bearing housing to the race, then from
rials.
the race to the rollers, possibly grounding through the
9. Reconnect the ECM, cab, and control panel connec- shaft to the bearing housing.
tors when welding is complete.
3.3.1 Grounding Properly

To concentrate arcing where it is required (at the point
where welding is being done), and to avoid arcing else-
where, the key practice is to properly place and solidly
connect the grounding clamp. The clamp and its cable
must be in good condition.
Do not change where you are welding without also
changing where you place the ground. Always move the
ground to the same base metal component. Do not weld
for awhile on one part, then turn and weld on a different
part, unless you also move the ground to the new part.
Check the clamp frequently to make sure it is secure and
that it tightly grips the base metal.

F04911
F04909
3000
Figure 126: Rotor Bearing Damage from Electrical Arcing
In Figure 127, note the damage to the outer bearing

race. This type of metal transfer indicates repeated elec-
trical arcing between the bearing housing and the outer
race.
F04910
Figure 127: Rotor Bearing Damage to the Outer Race

3000

S ECTION 4000
FEED SYSTEM
Maximum wear life and operating efficiency of the feed system requires scheduled inspections and adjustments.
4.1 Maintaining the 4.1.2 Flail Stands

Flail stands are also known as stops or machine stops.
Flails The flail stand is a metal bracket with an attached rubber
pad on which upper flail housings come to rest in their
The flail drums, rods, and chains wear down with use. lowest position (Figure 129). Flail stands are adjustable
They require frequent inspection. As needed, the rods to different heights. Each flail housing has two adjust-
and chains can be rotated to an unworn position before able flail stands, one on each side of the machine.
needing replacement. Flail stands must be set to accom-
modate the installed chain length.
4.1.1 Flail Drums
4000
Inspect the thickness of the drums at the chain hole
openings where chain movement causes the most wear
(Figure 128). Replace flail drums when the thickness
has decreased to 50% of the original thickness or about
3/4 in. (2 cm).
The thickness of an un-worn drum is about 1-1/2 in. (4
cm). Inspect for cracks in the flail drum and replace it if
cracks are seen.
F05334
Figure 129: Flail Stand
4.1.3 Flail Rods

The flail rods support the flail chains within the flail
drum. The rods wear down at points where the flail
chain is attached. When rod wear under the chain link
F01200
exceeds 1/16 inches (1.6 mm) in depth, replace the rod
Figure 128: Inspection Point for Flail Drum Thickness with a new rod or reverse the rod position in the drum
so that the flail chains hang on new un-worn sections of
rod.
Use the flail rod tool (Figure 130) to remove the flail
rod plugs and for pulling flail rods out. It is a combina-

SECTION 4000 FEED SYSTEM
tion tool, with a 1/2 in. square-end wrench at one end for
removing flail rod plugs. The other end is threaded to
screw into a flail rod for extracting it. The handle func-
tions as a slide hammer when inserting and extracting
flail rods. The flail rod tool is provided with the 5000H.
F01767
2
1. 1/2 in. Square-End Wrench F01129
2. Handle/ Slide Hammer

3. Threaded, Extraction End
Figure 131: Flail Chains, Inspection
Figure 130: Flail Rod Tool for Peterson Flail Drums

Some operators prefer to have a staggered schedule
where at each interval, chains on one drum are re-
4000
4.1.4 Flail Chains arranged (rotated) and chains on a second drum are
replaced. Consider the following points as a general
Inspect flail chains at least once per shift. The greatest starting guideline:
wear usually occurs on the last two links. The rate of
• Rearrange (rotate) chains when their thickness
wear depends on wood characteristics, rate of feeding,
drops to 70% of the original chain diameter (about
temperature, and contamination such as sand. See Fig-
0.45 in. or 1.1 cm). To rearrange, the chains, see
ures 131, 132, and 133.
“Rearranging Flail Chains” on page 115.
Monitor chain wear for each new chipping situation.
• Replace the chains when their thickness drops to
Use this experience to establish an inspection, rotation, 50% of the original chain diameter (about 0.32 in.
and replacement schedule that prevents chains from or 0.81 cm).
breaking apart in the debarker.
When inspecting chains, note that the 2nd and
sometimes the 3rd link in from the unattached end
usually show the most wear. Contact your distribu-
tor for further assistance.

• Hammer or mallet
• Leather gloves
• Light source
◆ To remove and install flail chains:
1 WARNING
Avoid serious injury or death from rotating flail
drums. Before entering the machine to remove
F01131
and install flail chains, make sure the machine is
Figure 132: Flail Chains, Thickness Monitoring shut down and locked out as described in “Bat-
tery Disconnect Lockout/Tagout” on page 17.
1. Set up the machine for chain maintenance:
a. Retract the bark mover to allow the maximum
100% 70% 50%
opening for a person to climb into the flail drum
area.
b. When working on the upper flail drums, raise
the flail housing and insert the safety pins as
4000
described in “Safety Locking Stops and Pins”
on page 19.
c. Shut down and lock out the machine before
entering the machine to replace flail chains.
d. Remove all wood from the bark mover areas.
F01017
1. 100% = New e. Make sure any new chains are approved by
2. 70% = Rotate Peterson.
3. 50% = Replace The chains must be the correct length and
Figure 133: Flail Chain, Wear Indications weight and have the correct link count. If some
chains are longer than others or if they are the
wrong type, the flail drum will not turn prop-
4.1.4.1 Installing and Replacing Flail erly, and the debarker may not run properly.
Chain f. Locate the ends of the flail drum shafts:

• Lower Flail: Right side of the machine
Use only flail chains that are approved by Peterson.
(Figure 134 on page 114)
Each chain has 8 links, is about 16 in. (40 cm) long, and
weighs about 5 lbs (2.3 Kg). Thirteen (13) chains are • Upper Flail(s): Left side of the machine
strung onto each of the 6 flail rods, giving a total of 78 (Figure 135 on page 114)
chains per drum. The flail drum may run roughly and
vibrate if different types of chains are used on the same
drum or if chains are missing. Installing flail chains
requires the following resources:
• Two people
• Pry bar
• Flail rod tool

1
2
F06098
Figure 136: Flail Housing Access Cover

F01289
1. Flail Rod Tool
2. Flail Rod Plug
2. Remove the flail chains:
Figure 134: Flail Drum Shaft End, Lower Flail a. Remove the first of 6 flail rod plugs by using
the flail rod tool or a 1/2 in. (13 mm) square-end
wrench drive.
4000
b. Screw the flail rod tool into the end of the flail
rod (Figure 137).
1 2
4
5
3
F01770
1. Oval: Install two chains. 5. Flail rod tool screwed into
2. Circle: Install one chain. the end of the flail rod. Flail
F06097 3. Flail chain suspended by the rod partially extracted from
flail rod. the flail drum.
Figure 135: Flail Drum Shaft End, Upper Flail, Plug Removed 4. Flail rod.
Figure 137: Flail Drum Section with Flail Rod Installation

g. Open the doors on the 1st and 2nd (optional)
upper flail housings to access the flails
(Figure 136). Access to the lower flail is c. Make sure no one is under the flail drum as
through the bark pusher or through the feed chains begin dropping from upper flail drums.
area. d. Remove the flail rod (Figure 138) completely,
allowing all 13 chains to fall free from the flail
drum. Use the slide hammer on the handle of
the flail rod tool to help remove the rod.

a. Position a flail rod in the hole in the end of the

flail drum. Install it up to the beginning of the
first chain hole in the drum.
Move the flail rod slowly while listening for the
person who is hanging the chains to say “Stop.”
b. Insert link(s) of flail chain far enough into the
drum chain holes for the flail rod to pass
2 through the end link(s).
• Install one chain in the drum’s circular
holes.
1 • Install two chains in the drum’s larger,
F01318
oblong holes.
1. Flail Rod Plug c. Insert the rod slowly until it passes through and
2. Flail Rod secures the chain link(s).
Figure 138: Flail Rod Tool, Extracting a Flail Rod d. Slowly move the flail rod to the next hole and
hook the next chain(s) with the rod.
The rod installer can continually insert the rod,
3. Inspect the chains, rods, and wear liners: stopping and starting as requested by the person
a. Make sure the person who is hanging the chains hanging chains.
4000
has enough light to see the drum chain holes e. Fully insert each flail rod, making sure it is
and the flail rods. inserted through all 13 flail chains.
b. For re-hanging partially-worn chains, separate f. Tug firmly on each chain to make sure it is
them by the zone they came from: low wear secured by the flail rod.
area or high wear area. See Figure 139 on During installation, the chains can become
page 116. jammed between the flail rod and the drum
c. Inspect the flail wear liners and replace them as without being hooked onto the flail rod. When
needed. See “Wear Plates for Flail Housings” this occurs and the flails are operated, the flail
on page 116 for instructions. chain flies off and typically damages the chip-
d. Inspect the flail rod for wear and, if needed, per and other machine components.
replace or reverse its position as noted in “Flail 5. Repeat the chain removal and insertion steps for all
Rods” on page 111. six flail rods on each flail drum.
4. Re-hang the chains: To prevent the flail drum from turning while install-
ing new chains, install the chains on every other rod
1 CAUTION first. Then, install the chains on the remaining rods
until all 78 chains are installed on the flail drum.
Avoid serious finger injury. Keep your fingers
6. Apply an anti-seizing compound to the threads on
out of the hazard zones:
the flail rod plugs, replace the flail rod plugs, and
• Do not insert your fingers into the drum tighten them to 35 ft-lbs (47 Nm).
chain holes.
• Do not insert your fingers between a 4.1.4.2 Rearranging Flail Chains
chain link and the side of the hole in the This procedure uses the techniques described in
drum. “Installing and Replacing Flail Chain” on page 113.
• Wear thick leather gloves.

◆ To rearrange, or flip, flail chains:

• Flip the chain: Remove the chains from the flail rod.
4.2 Maintaining the
UHMW Wear Plates
Grasp the previously-free end of the chain and
secure it to the flail drum with the flail rod.
• Reposition the chain: Move the chain from a low
UHMW is the abbreviation for “Ultra High Molecular
wear area to a high wear area or from a high wear
Weight.” The term describes several types of dense,
area to a low wear area (Figure 139).
wear-resistant plastic used to protect metal parts of the
5000H from damage by abrasion and mechanical wear.
1 2 1
These plates wear down and must be replaced before
damage to expensive metal components occurs.
4.2.1 Wear Plates for Flail

Housings
Logs and rotating flail chains strike the sides of the flail
housing. UHMW wear plates (Figure 140) prevent
F01281 damage to the metal sides of the flail housings.
1. Low Wear Area
2. High Wear Area IMPORTANT: After the wear plates on flail hous-
4000
Figure 139: Flail Chain, Areas of Wear ings wear through, permanent damage to the flail
housing occurs in less than four hours. In such
cases, replacement of the flail housing may be
necessary.
• Inspect the flail wear plates every time the flail
chains are rearranged or replaced. Replace the wear
plates when their thickness drops to 50% of the
original thickness, or about 1/2 in.(13 mm).
• When replacing the flail housing wear plates, two
people are needed to remove the fasteners. One per-
son secures the fastener nut inside the machine
while another uses a 3/8-inch Allen wrench to
remove the bolt.
• To replace the upper flail wear liners, raise the flail
housing and insert both safety pins as described in
“To lock the feed roll and upper flail housings in the
raised position:” on page 22.
• For machines with a second upper flail housing,
first remove the access panel on the outside of the
machine to access the wear plate fasteners.

F01330 F05915
Figure 141: UHMW Wear Plate Under the Bark Mover
4000
F01329
1. Safety pin(s) to support the 2. UHMW Wear Plates

flail housing
Figure 140: UHMW Wear Plates In the Flail Housings
4.2.2 Wear Plates for the Bark

Mover
Five UHMW wear plates protect the bark mover com-
ponents from damage. One front strip is secured under F05914
the front edge of the bark plunger (Figure 141). Two Figure 142: UHMW Wear Plates on the Side and Bottom
strips are on each side and the bottom of the plunger
(Figure 142).
Inspect the bark mover wear plates weekly or more
often, depending on operating conditions and rate of
wear. Replace the bark mover wear plates when the
thickness drops to the point where the brass bolts that
secure the wear plates begin to show wear. This occurs
when wear plate thickness decreases to about 50% of
the original, or 1/4 in. (6 mm). New bark mover wear
plates are about 1/2 in. (13 mm) thick.

4.3 Clearing Jams • Switch the 1ST FEED ROLL (debarker) to

LIFT.
Jams can occur in the feed system or in the bark mover. • Switch the 2ND FEED ROLL (chipper) to
LIFT.
d. Repeat Step 1 to reverse the system again.
1 WARNING 3. If the feed system still remains jammed:
Crushing or pinching hazard. Never attempt to a. Shut down and lock out the machine as
manually force jammed logs into the debarker or described in “Battery Disconnect Lockout/
chipper. Never attempt to manually remove logs Tagout” on page 17.
from the debarker or chipper when the machine b. Remove the obstruction manually with the help
is operating. of another person.
1 WARNING 1 WARNING
Hazard from flying objects. Avoid serious physi- Operating combustion engine devices such
cal injury, especially to the eyes and face. Raising as chain saws inside the 5000H can cause
the upper debarker feed roll increases the risk of dangerous or fatal atmospheric hazards.
objects flying out of the machine from the log Fully ventilate the area during the work. See
feed zone. Keep people away from the log feed “Removing Jammed Logs” on page 26.
4000
zone. Do not go to the feed zone to inspect or

clear logs.
◆ To clear a jam in the feed system:

1 WARNING
Crushing, shredding, pinching hazards. Never
1. Reverse the system momentarily, and then switch to inspect inside the bark mover or debarker hous-
forward again: ings unless the flails are stopped, the engine is
a. Momentarily set the FEED SYSTEM OFF/ON/ stopped, and the machine is locked and tagged
REV switch to REV, or press and hold the trig- out as described in “Battery Disconnect Lockout/
ger on the right-hand joystick while the FEED Tagout” on page 17.
SYSTEM is set to ON.
b. Set the FEED SYSTEM to ON. ◆ To clear a jam in the bark mover:
c. Repeat the reverse-forward cycle several times 1. Reverse the log feed system as soon as the bark
if necessary. Limbs may have jammed the feed mover becomes plugged or jammed:
rolls. Visually check for jammed feed rolls or a. Momentarily set the FEED SYSTEM OFF/ON/
drive chains. REV switch to REV, or press and hold the trig-
2. If the feed system remains jammed: ger on the right-hand joystick while the FEED
SYSTEM is set to ON.
NOTE: The first upper flail can work against log movement,
b. Set the FEED SYSTEM to ON.
and therefore it should be shut off and raised when
reversing the feed system to clear the logs. The debarker 2. Rotate the cab so you can see the rear of the bark
feed roll, due to its inward angle of motion, can interfere mover plunger.
with log movement when the feed system is reversed. The 3. Set the BARK MOVER OFF/ON/REV switch to REV
chipper feed roll can dig into and trap a log. long enough for the bark plunger to reverse about 6
a. Switch all flails to OFF. inches. Then switch it to ON so that plunger moves
b. Switch the upper flail housings to LIFT. forward. If the plunger does not resume its normal
cycle, repeat this step several times.
c. Raise the chipper feed roll and upper debarker
feed roll:

4. If the bark plunger remains stalled, check the

hydraulic pressure. It should be approximately
4.4.1 Roll Case and Lower
3000 psi (207 bar or 20,684 kPa). If the pressure is
less than 3000 psi, adjust the relief valve setting to
Feed Chains
3000 psi. Your Peterson distributor can provide The roll case drive chains are powered by the roll case
instructions for this procedure. hydraulic motor and gearbox. From the gearbox, each
case roll is connected to the next in a series of chains
5. If the bark plunger still does not move forward, pro-
and sprockets (Figure 144).
ceed as follows:
a. Set the BARK MOVER OFF/ON/REV switch to The lower feed chain is the same mechanism as the
REV to retract the bark mover plunger to the gearbox chain on the roll case. Adjust its slack in the
back of its normal travel path. Release the same way, by using the jack screw.
switch before the bark mover reaches the end of
◆ To inspect and adjust the roll case drive
its reverse cycle.
chains and sprockets:
b. Set the BARK MOVER switch to OFF.
c. Shut down and lock out the machine as
described in “Battery Disconnect Lockout/ 2. Remove the expanded metal chain guards from the
Tagout” on page 17. right side of the machine (Figure 143).
d. Remove the obstruction manually in the bark 3. Check the chains and sprockets for wear
mover with the help of another person. (Figure 144).
4000
1 WARNING
Operating combustion engine devices such
as chain saws inside the 5000H can cause
dangerous or fatal atmospheric hazards.
Fully ventilate the area during the work. See
“Removing Jammed Logs” on page 26.
4.4 Drive Chains

All feed rolls are powered by hydraulic motors that
F06092
transfer the power through gearboxes and then through
Figure 143: Roll Case Chain Guard
sprockets and chains. For gearbox maintenance, see
“Drive Motor Gearboxes” on page 99.
Proper chain maintenance includes checking the chains
weekly for excessive slack and then adjusting them as
needed. Proper chain tension includes a small amount of
slack. A chain should never be tight.
On a monthly cycle, check the sprockets for cupping
wear on the teeth. Replace worn sprockets as needed.

F06093
1. Jack Screw Adjuster
2. Motor Mount Bolt (1 of 4)
Figure 145: Roll Case Drive Motor Adjuster

4000
◆ To inspect and adjust the lower feed chain

and sprocket:
F06094 1. Shut down and lock out the machine.
Figure 144: Roll Case Chains, Partial Cutaway View 2. Remove the chain guard from below the lower feed
drive motor (Figure 146).
4. Adjust the chains according to their location:

• For the chain from the drive motor to the first
case roll, loosen the 4 motor mounting bolts, 1
and then turn the jack screw to remove most,
but not all, chain slack. Then retighten the
mounting bolts (Figure 145).
• For the other case roll chains, remove a link to
adjust the slack. If necessary, replace a
2
removed link with a half link.
5. Replace the chain guards.
3
F06095
1. Jack Screw Adjuster
3. Chain Guard
Figure 146: Lower Feed Drive Motor and Chain Guard
3. Check the chains and sprockets for wear.

4. Adjust the chain if needed: 3. For the chipper feed drive motor and chain, gain
a. Loosen the 4 motor mounting bolts. access to them on the right side of the machine
below the water tank. Remove the 4 bolts that
b. Turn the jack screw to remove most, but not all,
secure the chain guard that covers the motor and
chain slack.
chain.
c. Re-tighten the mounting bolts (Figure 146).
4. Check the chain and sprocket for wear (Figure 148).
5. Replace the chain guard.
4.4.2 Upper Feed and Chipper

Feed Chains 1
The upper feed roll and the chipper feed roll use the
same type of motor, gearbox, and chain mechanism, but
they are in different locations.
◆ To inspect and adjust the chains and

sprockets for the upper and chipper feeds:
1. Shut down and lock out the machine. 2
3
2. For the upper feed drive motor and chain, gain
access to them on the right side of the machine
4000
above the feed area. Remove the 6 bolts that secure F06096
the chain guard that covers the motor and chain 1. Drive Motor
(Figure 147). 2. Jack Screw Adjuster
Figure 148: Upper Feed Chain and Sprocket
5. Adjust the chain if needed:

a. Loosen the 4 motor mounting bolts.
b. Turn the jack screw to remove most, but not all,
chain slack.
c. Re-tighten the mounting bolts (Figure 148).
6. Replace the chain guard.
F06089
Figure 147: Upper Feed Motor and Chain, Access Bolts

4000

S ECTION 5000
PROCESSOR SYSTEM
Processor maintenance requires inspecting and replacing the standard and Key Knife systems, adjusting and replac-
ing the anvil, inspecting and replacing the chipper disk wear plate, and setting up the chipper and changing chip size.
5.1 Chipper Knife

Systems
This Section describes maintenance for the standard
knife system and the Key Knife BCS and KPS systems.
For information about other Key Knife systems, refer to
Key Knife documents.
For any knife system, proper maintenance is essential
for efficient operation. Dull knives cause poor chip
quality, increased power consumption, and increased
stress on the entire chipper.
The 5000H chipper disk is fitted with either the standard F01376
knife or a Key Knife system. Several versions of Key
Figure 149: Manual Rotation Hazard, Chipper Disk Nub
Knife systems are available.
5000
Key Knife provides specific instructions for using your
Key Knife system. A Key Knife instruction manual is Rotate the chipper disk clockwise to avoid lacer-
provided with new machines. Always follow the knife ations (Figure 150).
manufacturer’s maintenance and safety instructions.
Portions of the Key Knife instructions are incorporated
into this manual for your convenience.
1 WARNING
Avoid pinching, crushing, cutting and finger
amputation hazards. Before working on the knife
system, see “Chipper Disk Hazards” on page 27.
1 WARNING
Avoid serious hand, toe, and foot injuries when F01811
manually rotating the chipper disk. Nubs and fins
Figure 150: Clockwise Rotation for Avoiding Knives
(also known as paddles) on the chipper disk can
trap and pinch or crush body parts when the disk
is manually rotated.
Wear safety shoes with steel toes (Figure 149).

SECTION 5000 PROCESSOR SYSTEM
5.1.1 Key Knife Maintenance 1 2 3 8

Two alternative Key Knife systems are commonly
installed on the 5000H, the BCS system (Figure 151)
and the KPS system (Figure 152). 7 4
Each knife assembly consists of three counter knives 6

8
and two 11.5 in. (23 cm) knives or three 7.66 in. (19.46
cm) knives. Each Key Knife has two usable edges. 5 4
Observe how the “key” on the counter knife fits into a
groove, or keyway, on the back of the knife. 9 9
2
F06802
1. Knife 6. Pin
3
1 10 2. Knife Clamp 7. Counter Knife
4 3. Load Screw 8. Wear Plate
4. Knife Holder 9. Chipper Disk
5. Spring
9
5 Figure 152: Key Knife KPS System
11 7 11 5.1.1.1 Replacing Key Knives

8 IMPORTANT: Do not remove or loosen the knife
holder when replacing Key Knives. The knife
5000
F05859 holder has been precisely shimmed at the fac-

1. Knife Clamp 7. Counter Knife Screw tory. Once the knife holder is loosened or
2. End of Feed Plate 8. Knife Clamp Bolt removed, a time-consuming shimming and mea-
3. Anvil 9. Knife Holder
surement process is necessary to establish uni-
4. Knife 10. Wear Plate
form knife extension for all knives.
5. Counter Knife 11. Chipper Disk
6. Hardened Face Key knives have two cutting edges. When one edge is
Figure 151: Key Knife BCS System worn, rotate to use the other edge. Worn knife edges can
be re-honed on a device available at your Peterson
dealer.
1 WARNING
Avoid serious cuts to the body. Use extreme care
in handling chipper knives. Wear protective
gloves and body gear to prevent cuts.
◆ To prepare BCS and KPS systems for

maintenance:
1. Disengage the clutch.
2. Make sure the chipper disk has stopped rotating.
See “Chipper Disk Hazards” on page 27.

3. Open the chipper hood as described in the 5000H 7. Loosen any debris around the knife clamp bolts by
Operator Safety Manual. using a clean-out tool and blow it out with com-
pressed air.
1 WARNING A clean-out tool is available for the Key Knife sys-

tem. Contact your Peterson distributor to order one.
Avoid serious physical injury from a falling
The following procedures for rotating or replacing
chipper hood. Be sure the hood safety pin is
knives are separated for BCS and KPS systems.
installed and locked in place (Figure 153).
◆ To rotate or replace BCS Knives:
1. Perform the procedure, “To prepare BCS and KPS
4
systems for maintenance:” on page 124.
2. Use an impact wrench to loosen the knife clamp
bolts about 1/2 inch (13 mm).
3. Pull open the knife clamps and remove each knife
by pulling it up and off the keyway where the
1
counter knife fits into it (Figure 151). It is not nec-
2 essary to remove the knife clamps.
3 4. Clean the knife clamps and the counter knives by
using a wire brush and compressed air. Remove
dirt, pitch, and any foreign matter that may interfere
F01335
with a good fit.
1. Knife Pocket 4. Hood Safety Pin Installed 5. Remove any burrs, high spots or nicks on flat sur-
2. Nub Through All 4 Hinge Tabs. faces, corners, and edges of the knife clamps and
3. Chipper Disk Safety Pin Pin Locked in Place With the counter knives.
Fully Installed Lockout Device.
5000
Use a fine, single-cut mill file. Do not bear down
Figure 153: Chipper Hood Locked in the Raised Position hard on the metal or change the dimensions of the
metal parts. Use light pressure to eliminate irregu-
larities that might affect fit.
4. Shut down and lock out the machine as described in
“Battery Disconnect Lockout/Tagout” on page 17.
5. Insert the chipper disk safety pin (Figure 153) to 1 WARNING
prevent movement of the chipper disk. Follow Avoid serious physical injury and machine
instructions in “To lock the chipper disk from rotat- damage. The knife assemblies must be held
ing:” on page 28. together tightly. The key on the counter knife,
6. Retract the anvil to prevent interference with the the entire surfaces of the Key Knife, and the
new knife edges. Follow steps 1 and 2 on page 137. contacting surfaces of the clamp must be
clean and free of debris when assembled.
1 CAUTION 6. Install the knives in the knife pockets (Figure 154).

a. Begin at the outer edge of the chipper disk and
Avoid eye injury and bodily harm. Wear gog- work toward the center.
gles and do not use pressures exceeding 30
b. Slide the knives toward the outside of the disk
psi (2 bar or 200 kPa) when using compressed
until they rest firmly against the outer knife
air to clean.
stop.
c. Fit the knife grooves onto the counter knife so
that they interlock with the keyway. The ends of

the knives must solidly contact each other with- 3. Remove each knife by pulling it up and off the key-
out leaving gaps. way where the counter knife fits into it. there is no
need to open or remove the knife clamps.
4. Clean the knife clamps and the counter knives by
using a wire brush and compressed air. Remove
dirt, pitch, and any foreign matter that may interfere
with a good fit.
5. Remove any burrs, high spots or nicks on flat sur-
1 faces, corners, and edges of the knife clamps and
counterknives.
Use a fine, single-cut mill file. Do not bear down
hard on the metal or change the dimensions of the
2
metal parts. Use light pressure to eliminate irregu-
larities that might affect fit.
F01773
1. Push key knives to the outer

edge.
2. Leave no gaps between the
knives. 1 WARNING
Avoid serious physical injury and machine
Figure 154: Key Knives Installed Firmly to the Outside Edge damage. The knife assemblies must be held
together tightly. The key on the counter knife,
the entire surfaces of the Key Knife, and the
contacting surfaces of the clamp must be
1 WARNING clean and free of debris when assembled.
6. Install the knives in the knife pockets (Figure 154).
Avoid serious physical injury and machine
damage. Discard knives with excessive dam- a. Begin at the outer edge of the chipper disk and
5000
age or knives that do not fit properly on the work toward the center.
counter knife. The Key Knife must fit securely b. Slide the knives toward the outside of the disk
on the counter knife for safe and proper oper- until they rest firmly against the outer knife
ation. stop.
7. Install the knife clamp and the knife clamp bolts c. Fit the knife grooves onto the counter knife so
with an impact wrench. Tighten the knife clamp that they interlock with the keyway. The ends of
bolts to a torque value of 120 to 150 ft-lb (163 to the knives must solidly contact each other with-
203 Nm). out leaving gaps.
IMPORTANT: If a knife clamp bolt is acciden-

tally tightened over 150 ft-lb (203 Nm), discard
that bolt and use a new one. Over torquing
1 WARNING
Avoid serious physical injury. Avoid machine
may damage bolts and clamps.
damage. Discard knives with excessive dam-
age or knives that do not fit properly on the
◆ To rotate or replace KPS Knives:
counter knife. The Key Knife must fit securely
1. Perform the procedure, “To prepare BCS and KPS on the counter knife for safe and proper oper-
systems for maintenance:” on page 124. ation.
2. Use an impact wrench to loosen the load screws just 7. Close the load screws with an impact wrench.
until they stop. This allows the counter knife to Tighten the load screws to a torque value of 75 to 90
pivot, freeing the knife. Use a torque stick to pre- ft-lb (102 to 122 Nm).
vent damage to the load screws.

IMPORTANT: If a knife clamp bolt is acciden-

tally tightened over 90 ft-lb (122 Nm), discard
that bolt and use a new one. Over torquing
5.1.1.2 Replacing Key Counter

Knives
Replace counter knives when they are worn. Excessive
fines in chips is an indication of counter knife cupping
(Figure 155).
1
2 F05262
Figure 156: Inspection Viewpoint for Chipper Rotation
◆ To replace BCS counter knives:

1. Perform the procedure, “To prepare BCS and KPS
systems for maintenance:” on page 124.
F01363
2. Remove, clean, and prepare the knife assembly
1. A new knife without wear 2. A used, worn knife with
cupping parts:
a. Loosen and remove the knife clamp bolts by
Figure 155: Counter Knife Wear
using an impact wrench. If debris is packed
5000
around the knife clamp bolts, free them with a
clean-out tool, and blow them out with com-
pressed air.
1 WARNING b. Remove the knife clamps and the knives.
Avoid pinching, crushing, cutting, and finger c. Clean out and remove the 3/16 in. Allen screws
amputation hazards. See important warnings in that secure the counter knives.
“Chipper Disk Hazards” on page 27. d. Remove the counter knives.
e. Use a wire brush and air gun to clean all sur-
1 WARNING faces of the knife holder, counter knife pockets,
and knife clamps. Remove dirt, pitch and any
Avoid serious, possibly fatal physical injury. Do foreign matter that may interfere with fit
not loosen the bolts that secure the chipper disk between parts.
hood until the chipper disk has stopped rotating
and has come to a complete stop. 3. Remove any burrs, high spots or nicks on flat sur-
faces, corners and edges of the knife holder, knife
If the disk is still rotating, it can catch the hood and clamps, knife pocket, and the counter knife pocket
throw it. Serious physical injury and death may result. (Figure 157).
Look through the chipper guard (Figure 156) to see if
the chipper disk belt drive and sheave are moving. If
they are not moving, then the chipper disk has stopped
rotating. Use a flashlight when lighting is poor.

6. Install the counter knives:

2 3
a. Insert the counter knives into their pockets.
b. Apply an anti-seizing compound to the clamp
bolt threads.
c. Install, but not tighten the knives with one
1 screw in each end.
d. Install, but not tighten all the counter knife
screws.
e. Ensure that the counter knives are completely
F01399
seated in the pocket before tightening the
1. Knife Holder screws.
2. Knife Clamp Pocket
3. Counter Knife Pocket f. Tighten the Allen screws to 14 ft-lb (19 Nm).
Figure 157: Pockets in the Key Knife System 7. Install the knives:
a. Begin at the outer edge of the chipper disk and
work toward the center for each knife pocket.
Ensure that mating surfaces on the counter knife b. Fit the knives onto the counter knife key so that
and Key Knives are clean and free of any debris or the knives interlock with the counter knives as
high spots that may interfere with precise fit. shown in Figure 151 on page 124.
Use a fine, single cut mill file. Do not bear down c. Place the knives firmly next to each other. The
hard on the metal or change the dimensions of the ends of the knives must contact each other sol-
metal parts. Apply light pressure to eliminate irreg- idly without leaving gaps (Figure 154 on
ularities that would prevent a correct fit of mating page 126).
parts. d. Install the knife clamp and the knife clamp bolts
4. Inspect the face of the knife holder just beneath the by using a 1/2 in. impact wrench.
5000
counter knife (Figure 151 on page 124). The face Tighten the knife clamp bolts to a torque value
has a hardened steel surface that protects the steel of 100 to 120 ft-lb (135 to 163 Nm). Discard
body of the holder and chipper disk. Replace the and do not use any bolts that are accidentally
knife holder when this protective coating has worn tightened over 150 ft-lb (200 Nm).
through. If the face of the knife holder wears back,
the chipper disk can begin to wear, resulting in IMPORTANT: If a knife clamp bolt is acciden-
costly damage to the chipper disk. tally tightened over 150 ft-lb (200 Nm), discard
5. Inspect the knife clamps. Occasionally, foreign that bolt and use a new one. Over torquing
matter can damage the knife clamping surface. If may damage bolts and clamps.
the edge of the knife clamping surface is bent or 8. Adjust the anvil clearance as described in “Check-
damaged, replace the clamp. Worn clamps do not ing Anvil Wear” on page 136.
control the knife adequately, resulting in poor chip
quality. ◆ To replace KPS counter knives:
Key Knife manufactures special clamp bolts for 1. Perform the procedure, “To prepare BCS and KPS
maximum strength and performance. The use of systems for maintenance:” on page 124.
other bolts voids the Key Knife warranty and may 2. Remove, clean, and prepare the knife assembly
cause failure of the clamping system and ejection of parts:
metal parts.
a. Loosen and remove the knife clamp bolts
To prevent clamp bolts from seizing or sticking, (Figure 158) by using an impact wrench. If
apply an anti-seize compound to the clamp bolt debris is packed around the knife clamp bolts,
threads.

free them with a clean-out tool, and blow them has a hardened steel surface that protects the steel
out with compressed air. body of the holder and chipper disk. Replace the
knife holder when this protective coating has worn
through. If the face of the knife holder wears back,
1 2 1
the chipper disk can begin to wear, resulting in
costly damage to the chipper disk.
5. Inspect the knife clamps. Occasionally, foreign
matter can damage the knife clamping surface. If
the edge of the knife clamping surface is bent or
damaged, replace the clamp. Worn clamps do not
3
control the knife adequately, resulting in poor chip
quality.
F06803
1. Knives
Key Knife manufactures special clamp bolts for
2. Knife Clamp Bolts maximum strength and performance. The use of
3. Load Screws other bolts voids the Key Knife warranty and may
cause failure of the clamping system and ejection of
Figure 158: KPS Knife Clamp Bolts and Load Screws metal parts.
To prevent clamp bolts from seizing or sticking,
b. Remove the knife assembly consisting of the apply an anti-seize compound to the clamp bolt
knife clamp, knife, and counter knife. threads.
c. Remove the counter knife from the clamp by 6. Install the counter knife into the knife assembly by
sliding it off of the load screw. Be careful not to sliding it into the load screw. Be careful not to lose
lose the spring and roll pin that are between the the spring and roll pin that are between the clamp
clamp and the counter knife (Figure 152 on and the counter knife.
page 124). 7. Install the knife assembly onto the knife holder,
5000
d. Use a wire brush and air gun to clean all sur- beginning at the outer edge of the chipper disk and
faces of the knife holder, counter knife pockets, working toward the center, for each knife pocket.
and knife clamps. Remove dirt, pitch and any See Figure 154 on page 126. The ends of the knives
foreign matter that may interfere with fit must contact each other solidly without leaving
between parts. gaps.
3. Remove any burrs, high spots or nicks on flat sur- • Install the knife clamp and the knife clamp bolts
faces, corners and edges of the knife holder, knife by using an impact wrench.
clamps, knife pocket, and the counter knife pocket. • Tighten the knife clamp bolts to a torque value
The pockets on the KPS knife system are similar to of 300 to 330 ft-lb (407 to 450 Nm).
those shown in Figure 157 for the BCS system.
Ensure that mating surfaces on the counter knife IMPORTANT: If a knife clamp bolt is acciden-
and Key Knives are clean and free of any debris or tally tightened over 330 ft-lb (450 Nm), discard
high spots that may interfere with precise fit. that bolt and use a new one. Over torquing
Use a fine, single cut mill file. Do not bear down
hard on the metal or change the dimensions of the 8. Adjust the anvil clearance as described in “Check-
metal parts. Apply light pressure to eliminate irreg- ing Anvil Wear” on page 136.
ularities that would prevent a correct fit of mating
parts.
4. Inspect the face of the knife holder just beneath the
counter knife (Figure 152 on page 124). The face

5.1.2 Standard Knife Maintenance

A standard knife assembly consists of the following • 1 knife holder
components (Figure 159 and Figure 160): • 1 counter knife
• 2 standard knives (sometimes a single large knife)
• 2 knife clamps
A
W
8 B
37.5°
5 6
4
3
1
2
7
5000
F05860
A. Gap 2. Knife Holder 6. Wear Plate
B. Extension 3. Counter Knife 7. Chip Slot
W. Knife Width 4. Knife 8. Spout Angle
1. Disk 5. Knife Clamp NOTE: See Table 13 on page 143 for the
Dimensions of A, B, and W
Figure 159: Standard Knife System

◆ To replace standard knives and counter

knives:
1
1. Prepare the machine for maintenance:
a. Disengage the clutch.
b. Make sure the chipper disk has stopped rotat-
2 ing. See “Chipper Disk Hazards” on page 27.
c. Open the chipper hood.
3
4 1 WARNING
Avoid serious physical injury from a fall-
ing chipper hood. Be sure the hood safety
F01344
pin is installed and locked in place
1. Knife Clamp with Studs 3. Counter Knife Screws
2. Standard Knife 4. Counter Knife (Figure 153 on page 125).
d. Shut down and lock out the machine as
Figure 160: Standard Knife, Counter Knife, and Knife Clamp
described in “Battery Disconnect Lockout/
Tagout” on page 17.
IMPORTANT: Re-used knives can crack and e. Manually rotate the chipper disk clockwise to
break apart in the chipper if the knife width, after expose the knife.
grinding, is less than 3.5 in. (8.9 cm) (Figure 161). f. Insert the chipper disk safety pin to prevent
Do not re-use a standard knife, and do not babbitt movement of the chipper disk. Follow instruc-
a standard knife that is worn to a width of less tions in “To lock the chipper disk from rotat-
than 3.5 in. (8.9 cm). ing:” on page 28.
2. Remove the knife assemblies:
5000
1 a. Retract the anvil to prevent interference with
the new knife edges. Follow steps 1 and 2 on
page 137.
b. Hold on to the knife while loosening the knife
3.5 In.
clamp nuts on the rear of the chipper disk
(8.9 cm) (Figure 162). Be sure to wear cut-resistant
gloves.
F01643
1. Babbitted Areas
Figure 161: Knife Minimum Size after Grinding
1 WARNING
Avoid serious lacerations. Use extreme care in
handling chipper knives. Wear protective gloves
and body gear to prevent cuts.

2 3 4
6
F01345
1. Knife Holder 5. Knife Clamp Studs

2. Knife Clamp 6. Knife Clamp Nuts and
3. Knife Washers
F01348 4. Counter Knife
Figure 162: Knife Clamp Nuts, Loosening Figure 164: Standard Knife Components
c. Remove worn knives carefully (Figure 163). 3. Inspect the counter knives for cupping and wear
(Figure 165).
1
2
5000
F01363
1. A new knife without wear 2. A used, worn knife with
cupping
Figure 165: Counter Knife Wear
F01355
If the counter knives are worn, replace them as fol-
Figure 163: Knives, Removal When Worn lows:
a. Remove the counter knife screws and the
d. Remove the knife clamp nuts and the knife counter knives (Figure 160 on page 131).
clamps (Figure 164). Perform this step only if b. Clean and de-burr the knife pocket, the counter
you need access to the counter knives. knife pocket, and other surfaces of the knife
holder that contact the counter knife
(Figure 166). Remove high spots, nicks, and
burrs so that the knife seats properly.

c. Install new counter knives and torque the

screws to 14 ft-lbs (18.9 Nm).
F01366
1. Knife Holder
2. Knife Clamp Pocket
3. Counter Knife Pocket
Figure 166: Pockets in the Standard Knife System
F01351
Figure 168: Standard Knife Clamp, Tightening the Nuts

4. Clean the knife holder, knife, counter knife, and
knife clamp. Remove any debris, burrs, nicks or
high spots from the edges and mating surfaces to 7. Adjust the anvil clearance as described in “Check-
ensure a correct fit of mating parts (Figure 167). Do ing Anvil Wear” on page 136.
not round or bevel the edges.
IMPORTANT: Remove the disk safety pin before
engaging the clutch. Otherwise, severe damage can
5000
result.
F01350 F01353
F01352
Figure 167: Standard Knife, Removal of Defects
5. Install the knife clamps and knives (Figure 164).

6. Install the knife clamp washers and nuts on the back
of the chipper disk. Make sure the chipper disk
safety pin is installed. Tighten the nuts to 600 ft-lbs
(814 Nm) (Figure 168).

5.1.3 Knife Extension and the Make the spots about 2 inches (5 cm) in diameter.
Locate one spot near the outer end of the knife
Highest Knife pocket and the other spot near the inner end of the
knife pocket.
The knife extension is also known as the knife offset
3. Obtain a dial gauge and magnetic stand
(Figure 169). This setting helps determine chip quality.
(Figure 170), with gradations of 0.001 in. and a
By measuring the extension of all the knives, the highest
range of 0 to 1 in. These devices are available
knife can be found. The knife with the highest extension
through industrial equipment suppliers.
determines the anvil setting.
The following procedures apply to both the Key Knife
and the standard knife systems.
1 2
3
4
F01362
5 5 Figure 170: Dial Gauge Mounted on a Magnetic Stand

5000
F05858
1. Anvil 4. Wear Plate
4. Position the dial gauge on the flange of the chipper
2. Clearance 0.023 - 0.025 in. 5. Chipper Disk
(0.58 - 0.63 mm) 6. Chipper Knife
housing, in line with the #1 outer measuring spot
3. Knife Extension (Offset) created in step 2 (Figure 171 and Figure 172)
Figure 169: Anvil Clearance and Knife Extension
1 WARNING
Avoid pinching, crushing, and cutting hazards to
the hands and feet. Avoid finger amputation haz-
ards. See important warnings in “Chipper Disk
Hazards” on page 27.
◆ To measure extension of the knives:

F01255
1. Label each knife pocket on the chipper disk by Figure 171: Knife Extension, Setup for Measuring
using a simple numbering system, such as 1, 2, 3.
2. Sand smooth two measuring spots on the chipper
disk, below each knife pocket on the wear plate.

1 WARNING
Avoid serious injuries to fingers and hands.
Avoid finger amputations. Use great care
when working around the chipper knives and 3
the disk.
1
Rotate the chipper disk backward (clockwise)
during maintenance to reduce the risk of a 2
body part being caught between the knife and
the anvil. Do not turn the disk so that the knife
edges move toward the anvil (Figure 171).
• Before manually rotating the chipper disk,
see “Rotating the Chipper Disk Manually” F01341
on page 27. 1. Dial Gauge
• Keep all body parts away from the chipper 2. Chipper Housing Flange
disk and the knives when rotating the 3. Chipper Knife Edge
chipper disk. Figure 172: Knife Height, Setting the Zero Point
• Rotate the chipper disk very slowly.
• Wear cut-resistant gloves specifically
designed for cut protection. 7. Rotate the chipper disk clockwise until the dial nee-
5. Manually rotate the disk clockwise, and position the dle drops onto the wear plate at a measuring spot
dial needle on the knife edge of knife pocket num- created in step 2. Measure and record this value as
ber #1 (Figure 171). the knife extension for outer knife #1.
6. Using the dial gauge, locate the highest surface of 8. Measure and record the knife extension at the inner
end of knife pocket #1.
5000
the knife edge. Rotate the disk back and forth
slightly while watching the dial needle to find the 9. Follow the previous steps for measuring and record-
highest point (Figure 172). Set this as the zero point ing the knives in the remaining knife pockets.
on the dial. 10. Determine the knife extension for the required chip
characteristics. For guidelines, see “Standard Knife
Setup Data” on page 142 and “Key Knife Setup
Data” on page 143.
If the extension is not within +/-0.004 in. (0.1 mm)
of the required value, it is necessary to adjust the
adapter shims in Key Knife systems or change the
knife babbitt length in standard knife systems. Such
procedures require special equipment and skills that
are beyond the scope of this manual.
11. From the measurements, determine the highest
knife and place a temporary mark next to it on the
chipper disk. For example, if the knives in the num-
ber 2 knife pocket were higher than the knives in the
number 1 and number 3 pockets, the anvil clearance
would be set for the number 2 knives. Use this
information to check and adjust anvil clearance. See
“Checking Anvil Wear” on page 136.

5.2 Anvil roll. It is the space immediately in front of the chip-

per disk.
Maintenance
7. Inspect the edges of the anvil for wear.
The entire feed plate assembly, including the anvil 1 WARNING

insert, is referred to as the anvil (Figure 173 on Avoid serious injuries to fingers and hands.
page 137). The anvil supports the end of the log as the Avoid finger amputations. Use great care
chipper knife cuts into it. A properly positioned anvil when working around the chipper knives and
with unworn surfaces is essential to making quality the disk.
chips. Rotate the chipper disk backward (clockwise)
As the anvil wears down during use, the anvil-to-knife during maintenance to reduce the risk of a
clearance must be readjusted regularly. Eventually, the body part being caught between the knife and
anvil must be replaced. This topic provides instructions the anvil. Do not turn the disk so that the knife
for maintaining the anvil of standard knife and Key edges move toward the anvil (Figure 171).
Knife systems. • Before manually rotating the chipper disk,
see “Rotating the Chipper Disk Manually”
5.2.1 Checking Anvil Wear on page 27.
• Keep all body parts away from the chipper
Anvil clearance should be checked daily and adjusted in disk and the knives when rotating the
the following situations: chipper disk.
• As the anvil wears down • Rotate the chipper disk very slowly.
• After installing knives • Wear cut-resistant gloves specifically
• When rotating the anvil designed for cut protection.
• When replacing the anvil 8. Rotate the disk slowly clockwise by hand until the
5000
highest knife is in position near the anvil.

• When chipper knives strike the anvil
9. Check the anvil clearance at both ends of the anvil:
◆ To check the anvil for wear and clearance: a. Manually rotate the chipper disk clockwise
until the highest point of the knife edge is
1. Raise the chipper feed roll and the upper debarker
directly under the anvil. See Figure 174 on
feed rolls and secure them in the raised position
page 138 for anvil and feed plate orientations.
with safety pins. Follow instructions for installing
safety pins in “Safety Locking Stops and Pins” on b. Use a metal feeler gauge to measure the clear-
page 19. ance between the anvil and the highest point of
the knife.
2. Make sure the chipper disk has stopped rotating as
described in “Chipper Disk Hazards” on page 27. The correct clearance is 0.023 to 0.025 in. (0.58
to 0.63 mm). This is achieved when a 0.025 in.
3. Open the chipper hood.
(0.63 mm) feeler gauge slides with slight resis-
4. Shut down and lock out the machine as described in tance.
5. Make sure an experienced helper is available to
assist you from outside the feed zone before you
5.2.2 Adjusting Anvil
enter the chipper area. Clearance
6. Climb into the 5000H through the log feed opening, Always make anvil adjustments with the machine lev-
between the debarker feed rolls. Or enter through eled on its landing gear and stabilizers. Recheck clear-
the bark pusher. Proceed toward the chipper. The ance after moving the machine.
chipper feed zone is just beyond the chipper feed

The anvil, also known as the anvil insert, is fixed to the To retract the anvil when installing knives, turn the
feed plate (Figure 174 on page 138). Anvil clearance is anvil-retract nuts clockwise until the anvil is away
adjusted by loosening the feed plate bolts to allow from all knife edges.
movement of the feed plate and anvil. Then, turning the 3. Check to see if any knives strike the anvil as you
anvil extend/retract nuts causes the feed plate and anvil manually rotate the disk. Listen and watch for inter-
to slide. ference. If any knives hit, repeat the instructions for
checking and adjusting anvil clearance.
◆ To adjust anvil clearance:
4. After setting the anvil clearance, tighten the 7 feed
1. Loosen slightly the 7 feed plate bolts (Figure 173). plate bolts.
Keep these bolts as snug as possible. If they are too
5. Lock the position of the anvil without moving it:
loose, the anvil adjustment will be incorrect.
• If an anvil-retract nut was the last nut turned to
adjust the anvil position, tighten the anvil-
3 extend nut.
• If an anvil-extend nut was the last nut turned to
adjust the anvil position, tighten the anvil-
retract nut.
2
1 6. Re-check the anvil clearance and re-adjust as
needed for 0.023 to 0.025 in. (0.58 to 0.63 mm).
7. Re-check to see if any knives strike the anvil while
you manually rotate the chipper disk. Listen and
watch for interference. If any knives hit the anvil,
4 repeat the instructions for checking and adjusting
F06801 anvil clearance.
1. Anvil Retraction Nuts 3. Feed Plate Bolts (7)
2. Anvil Extension Nuts 4. Feed Plate
5000
Figure 173: Anvil (hidden) and Feed Plate
2. Use the anvil-extend and anvil-retract nuts to

change the anvil clearance:
• To increase anvil clearance, loosen the anvil
extend nuts and turn the anvil-retract nuts
clockwise.
• To decrease anvil clearance, loosen the anvil-
retract nuts and turn the anvil-extend nuts
clockwise.
• Set the anvil clearance with a feeler gauge to
0.023 to 0.025 in. (0.58 to 0.63 mm) for normal
chip production.
Typically, each end of the anvil is adjusted sepa-
rately, just as the extension of each knife in a knife
pocket is measured separately. The amount of
adjustment on each nut will be different, depending
on the clearance between each end of the anvil and
the knives.

6
2
3 7
4
9
5000
10
F01783
11
12 F01784
1. Anvil-Retract Nut 5. Anvil Positioning Screw (2) 9. Standard Knife

2. Anvil-Extend Nut 6. Feed Plate (Slides for Anvil Adjustment) 10. Anvil Clearance
3. Rear Feed Plate Bolts 7. Anvil Insert 11. Anvil Extend
4. Front Feed Plate Bolts 8. Chipper Disk 12. Anvil Retract
Figure 174: Anvil Orientation for Clearance Adjustment

5.2.3 Rotating and Replacing 11. Re-install the feed plate assembly (Figure 175).
12. Secure the 2 anvil-positioning screws to the feed
the Anvil plate by installing and tightening the 2 anchor bolts.
The anvil has two wear surfaces (Figure 174 on 13. Set the clearance of the anvil, as described in
page 138). When one edge has become worn, rotate the “Checking Anvil Wear” on page 136.
anvil to expose the unused edge. After both surfaces are 14. Correctly install and tighten the 7 feed plate locking
worn, replace the anvil with a new one. bolts.
◆ To rotate or replace the anvil:

1. Shut down and lock out the machine as described in
2. Make sure the chipper disk has stopped rotating as
described in “Chipper Disk Hazards” on page 27.
3. Remove the 4 rear feed-plate locking bolts
(Figure 175).
4. Loosen, but do not remove, the 3 front feed-plate
locking bolts to allow the feed plate to be pulled out.
5. Remove the 2 anvil-positioning screw anchor bolts.
3
4
5000
1 2
F06801
1. Anvil Positioning Screws (2) 3. Rear Feed Plate Locking
2. Anvil Positioning Screw Bolts (4)
Anchor Bolts (2) 4. Front Feed Plate Locking
bolts (3)
Figure 175: Anvil Positioning Screws and Locking Bolts
6. Loosen the anvil-extend and anvil-retract nuts.

7. Use the feed plate handle to pull out the feed plate.
8. Remove the anvil insert from the feed plate.
9. Rotate the anvil position to expose the new, unworn
edge. If both edges have been worn, replace the
anvil with a new one.
10. Install the anvil into the feed plate.

5.3 Chipper Disk 2
Wear Plate 1
A replaceable metal wear plate covers the knife side of

the chipper disk. This wear plate slowly wears down
from the impact and rubbing of logs. The wear plate
consists of four or six pie-shaped sections (Figure 176)
F01657a
that are bolted to the chipper disk and then secured at the
edges by welded-on L-shaped plate clamps called nubs.
2
The wear plate thickness affects the position of logs in
relation to chipper knives. If the plate wears too thin,
poor chip quality results. Indications of a worn wear
plate include long chips and inconsistent chip size.
F01656a
3 4
2
1. 0.050 in. (1.3 mm) Maximum 3. Wear Plate
3 Wear 4. Un-worn Area of Wear Plate
2. Straight Edge
Figure 177: Chipper Disk, Wear Plate Indications
2. Measure the gap in the wear area near the chipper

knife.
5000
1
3. Replace the wear plate if the depth of wear exceeds
0.050 in. (1.3 mm). All wear plate segments of the
4
disk must be replaced at one time.
F05908
1. Fan blade 3. Plate Clamp (Nub)
2. Safety Pin Pocket 4. Wear Plate (1 of 4 or 1 of 6)
Figure 176: Chipper Disk Wear Plate
◆ To inspect the wear plate:

1. Place a straight edge across the wear plate and hold
it firmly against an unworn portion (Figure 177).

5.4 Adjusting Chip 3. Measure the chipper disk RPM as follows (see Note
1 for an alternative methods):
Size
a. Open the small shaft guard (accessed from the
walkway) that covers the end of the chipper
sheave shaft (Figure 178).
The guidelines in this topic are useful for determining
the feed roll speeds to produce a chip of a specific length
and thickness.
Chip length is selected to meet the requirements for
using the chips as a feed stock, such as for pulp and
paper digestion. Chip length relates directly to chip
thickness, the most important chip characteristic during
digestion.
Chip length is affected by the following variables:
• Knife extension (see Figure 180 on page 143 and
Figure 181 on page 144).
• Chipper disk RPM.
• Knife angle and knife relief (not covered in this
manual). F05262
Figure 178: Chipper Sheave, Shaft Guard

• Feed speed. This is set by adjusting the feed roll
RPM. See “Feed Manifold Setup” on page 144.
b. Use a tachometer to measure and note the RPM
5.4.1 Calculating for Setup of the chipper-sheave shaft (Figure 179).
5000
For comparison, general starting values are:
◆ To calculate the required feed roll settings: • 492 RPM for a 53 in. chipper sheave
1. Decide what chip size you want. • 435 RPM for a 60 in. chipper sheave
2. Determine if the knife extension is set properly: • 405 RPM for a 65 in. chipper sheave
a. Measure the extension of the knives. See
c. Close and secure the shaft guard.
“Knife Extension and the Highest Knife” on
page 134.
b. Use the tables on page 143 and page 144 to find
the knife extension that you need.
c. Compare the measured values with the values
in the tables.
d. Adjust the knife extensions as needed.
For a standard knife system, extension is deter-
mined by knife width and is adjusted by grind-
ing or adding babbitt metal (Figure 180 on
page 143). For a Key Knife system, adjust it by
adding or removing shims under the knife hold-
ers (Figure 181 on page 144). These procedures
require special equipment and skills that are
beyond the scope of this manual.

5.4.1.1 Example Calculation

Engine Speed = 2080 RPM
Knife Pockets = 3
Chipper Sheave Diameter = 53 in.
Chip Length = 7/8 in. (0.875 in.)
Engine Sheave Diameter = 12.5 in.
1. Knife Extension:
From Table 13 on page 143, for a 7/8 in. chip,
extension = 0.533 in.
2. Chipper Disk Speed (by tachometer) = 491 RPM
3. Feed Speed (feet/minute):
= Chip Length x Number of Knife Pockets x Disk
RPM ÷ 12
= 0.875 x 3 x 491 ÷ 12
= 107.4 ft/min (fpm)
F05203
Figure 179: Chipper Sheave, Measuring Shaft RPM 4. Feed Roll Settings:
Using Tables 2 and 3, a feed speed of 107 fpm
requires these settings:
NOTE: 1. Alternative methods (not as accurate): Upper and Lower Feed Roll = 25.9 RPM
• Note the engine RPM and obtain the chipper (equivalent upper drive shaft speed = 45.9 RPM)
RPM from a table:
Chipper Feed Roll = 25.9 RPM
Table 18 on page 148 for 53-in. sheave
(equivalent upper drive shaft speed = 45.9 RPM)
5000

Table 20 on page 152 for 65-in. sheave Lower Debarker Feed Roll = 41.9 RPM
• Use this formula: Chipper RPM = Engine RPM Roll Case rolls = 71.1 RPM
x Engine Sheave Diameter ÷ Chipper Sheave
Diameter 5.4.1.2 Formulas for Other Sheaves
(Engine sheave diameter is 12.5 in.) For other engine sheave diameters:
4. Determine the feed speed by one of the following Chipper Disk RPM = Engine RPM x [Engine
methods:
Sheave Diameter ÷ Chipper Sheave Diameter]
• Use this formula:
For chipper disks having four knife pockets:
Feed Speed (ft/min) = Chip Length (in.) x No.
of Knife Pockets x Disk RPM ÷ 12 Feed Speed (feet/minute) = Chip Length (inches) x
• Use a table based on chipper sheave diameter: 4 x Disk RPM ÷ 12
Table 19 on page 150 for 60-in. sheave 5.4.1.3 Standard Knife Setup Data
Table 20 on page 152 for 65-in. sheave Use Table 13 or Table 14 and Figure 180 to set up the
5. Record the feed speed from step 4 and look up the standard knives for the required chip length.
feed roll RPM values from Table 17 on page 146.
6. Set the feed roll speeds as described in “Feed Man-
ifold Setup” on page 144.

Table 13: Standard Knife Setups for Chip Size (Inches)

Chip Length Gap* Extension** Knife
(in.) + 0.10 ± 0.004 Width
- 0.00
1/2 0.500 0.397 0.305 4.918
5/8 0.625 0.496 0.381 5.077
3/4 0.750 0.595 0.457 5.210
7/8 .0875 0.694 0.533 5.343
1 1.000 0.793 0.609 5.475
1 1/8 1.125 0.892 0.685 5.581
1 1/4 1.25 0.991 0.761 5.711
* For other chip sizes, use formula: Gap = Chip Length x OLEdoc1
(0.793)
** For other chip sizes, use formula: Extension = Chip
Figure 180: Standard Knife Gap, Extension, and Width
Length x (0.609)
5.4.1.4 Key Knife Setup Data

Table 14: Standard Knife Setups for Chip Size (mm) Use Table 15 and Figure 181 to set up the Key knives
for the required chip length.
Chip Length Gap Extension Knife
(mm) Width
Table 15: Key Knife Setups for Chip Size (Inches)
5000
13 10.08 7.75 124.9
Chip Length Gap* Extension** Knife
16 12.59 9.65 129.0 + 0.10 ± 0.004 Opening
19 15.11 11.61 132.3 - 0.00
22 17.62 13.54 135.7 Inches Inches Inches Inches

25 20.14 15.47 139.1 5/8 0.625 0.496 0.381 6 1/2
29 22.65 17.40 141.8 3/4 0.750 0.595 0.457 6 5/8
32 25.17 19.33 145.1 7/8 0.875 0.694 0.533 6 11/16
1 1.000 0.793 0.609 6 13/16
1 1/8 1.125 0.892 0.685 6 15/16
1 1/4 1.25 0.991 0.761 7
* For other chip sizes, use formula: Gap = Chip Length x

(0.793)
** For other chip sizes, use formula: Extension = Chip
Length x (0.609)

Table 16: Key Knife Setups for Chip Size (mm)

5.4.2 Feed Manifold Setup
Creating chips of the proper size requires feeding logs
Chip Length Gap Extension Knife at the proper speed. To reset the feed speed requires
(mm) Opening adjusting the speed of the four feed rolls: two upper, one
16 12.6 9.7 165.1 lower, and one roll case. These adjustments are made to
the feed manifold manually.
19 15.1 11.6 168.3
The feed manifold is set at the factory on new machines.
22 17.6 13.5 169.9 Such setup requires many steps. Whenever any part of
the feed manifold requires service or repair, this entire
25 20.1 15.5 173.0
setup must be performed again, typically by a Peterson
29 22.7 17.4 176.2 Service Representative.
32 25.2 19.3 177.8 However, after the manifold has been set, you can make
small adjustments to the feed speed by simply adjusting
the needle valves, either manually or through the dis-
play screen, depending on how your machine is
equipped.
During extended operation at the same feed roll setting,
be sure to check the feed roll speed monthly.
The location of the feed manifold is on the right under-
side of the machine near the bark pusher (Figure 182).
5000
OLEdoc2
Figure 181: Key Knife Gap, Extension, and Opening
F06083
Figure 182: Feed Manifold Location
◆ To adjust the feed speed:

1. Back off the stroke limiter screw (Figure 183) on
the feed make-up pump. The stroke limiter cap
unscrews to expose the stroke limiter screw.

F)6051
1. Stroke Limiter Cap/Locking 2. Pump Compensator
Nut (the stroke limiter Adjustment Screw
adjusting screw is under the 3. Load Sense Screw F06052
cap) Figure 185: Feed Roll Speed Check
Figure 183: Makeup Pump

4. Recheck the speeds and adjust as needed after all
four roll speeds are set.
2. Start the engine and set it to high idle.
5. Monitor the feed speed on one roll (Figure 185)
3. Adjust the needle valves (Figure 184) as needed while an associate slowly screws in the stroke lim-
until the feed rolls are operating at the proper speed iter under the cap (Figure 183).
5000
(Figure 185) for the required chip length. To deter-
6. Continue to screw the stroke limiter in until the roll
mine the proper roll speed, see “Calculating for
speed begins to drop.
Setup” on page 141 or see “Feed Speed Setup” on
page 159 for calculating roll speeds automatically. 7. Back out the stroke limiter until the roll returns to
its proper speed, and then lock it in position with the
cap.
4 3 2 1
F06047
1. Valve 110.1, Case Rolls
2. Valve 110.2, Lower Feed
3. Valve 110.3, Upper Feed
4. Valve 110.4, Chipper Feed
Figure 184: Feed Manifold Prepared for Setup

5.4.3 Feed Speed Tables

5.4.3.1 Feed Roll RPM Values Table 17: Feed Roll RPM Values (Continued)
Feed Rolls RPM

RPM for Upper
Table 17: Feed Roll RPM Values
Feed Speed
Feed Rollsa
Drive Shaft
in Feet Per
Equivalent
Roll Case
Feed Roll
Feed Rolls RPM
Chipper
RPM for Upper
Minute
Lower
(FPM)
RPM
Feed Speed
Feed Rollsa
Drive Shaft
in Feet Per
Equivalent
Roll Case
Feed Roll
Chipper
Minute
Lower
(FPM)
75 29.4 32.2 49.8

RPM
76 29.8 32.6 50.5

52 20.4 22.3 34.5
77 30.2 33.1 51.2
53 20.8 22.8 35.2
78 30.6 33.5 51.8
54 21.2 23.2 35.9
79 30.9 33.9 52.5
55 21.5 23.6 36.5
80 31.3 34.3 53.1
56 21.9 24.0 37.2
81 31.7 34.8 53.8
57 22.3 24.5 37.9
82 32.1 35.2 54.5
58 22.7 24.9 38.5
83 32.5 35.6 55.1
59 23.1 25.3 39.2
84 32.9 36.1 55.8
60 23.5 25.8 39.9
85 33.3 36.5 56.5
5000
61 23.9 26.2 40.5

86 33.7 36.9 57.1
62 24.3 26.6 41.2
87 34.1 37.3 57.8
63 24.7 27.0 41.9
88 34.5 37.8 58.5
64 25.1 27.5 42.5
89 34.9 38.2 59.1
65 25.5 27.9 43.2
90 35.3 38.6 59.8
66 25.9 28.3 43.8
91 35.7 39.1 60.5
67 26.2 28.8 44.5
92 36.0 39.5 61.1
68 26.6 29.2 45.2
93 36.4 39.9 61.8
69 27.0 29.6 45.8
94 36.8 40.4 62.4
70 27.4 30.0 46.5
95 37.2 40.8 63.1
71 27.8 30.5 47.2
96 37.6 41.2 63.8
72 28.2 30.9 47.8
97 38.0 41.6 64.4
73 28.6 31.3 48.5
98 38.4 42.1 65.1
74 29.0 31.8 49.2
99 38.8 42.5 65.8

Table 17: Feed Roll RPM Values (Continued) Table 17: Feed Roll RPM Values (Continued)
Feed Rolls RPM
Feed Rolls RPM

RPM for Upper
RPM for Upper

Feed Speed
Feed Speed
Feed Rollsa
Feed Rollsa
Drive Shaft
Drive Shaft
in Feet Per
in Feet Per
Equivalent
Equivalent
Roll Case
Roll Case
Feed Roll
Feed Roll
Chipper
Chipper
Minute
Minute
Lower
Lower
(FPM)
(FPM)
RPM
RPM
100 39.2 42.9 66.4 127 49.8 54.5 84.4
101 39.6 43.4 67.1 128 50.1 54.9 85.0
102 40.0 43.8 67.8 129 50.5 55.4 85.7
103 40.4 44.2 68.4 130 50.9 55.8 86.4
104 40.7 44.6 69.1 131 51.3 56.2 87.0
105 41.1 45.1 69.8 132 51.7 56.7 87.7
106 41.5 45.5 70.4 133 52.1 57.1 88.4
107 41.9 45.9 71.1 134 52.5 57.5 89.0
108 42.3 46.4 71.7 135 52.9 58.0 89.7
109 42.7 46.8 72.4 136 53.3 58.4 90.3
110 43.1 47.2 73.1 137 53.7 58.8 91.0
111 43.5 47.6 73.7 138 54.1 59.2 91.7
5000
112 43.9 48.1 74.4 139 54.5 59.7 92.3
113 44.3 48.5 75.1 140 54.8 60.1 93.0
114 44.7 48.9 75.7 141 55.2 60.5 93.7
115 45.1 49.4 76.4 142 55.6 61.0 94.3
116 45.4 49.8 77.1 143 56.0 61.4 95.0
117 45.8 50.2 77.7 144 56.4 61.8 95.7
118 46.2 50.7 78.4 145 56.8 62.2 96.3
119 46.6 51.1 79.1 146 57.2 62.7 97.0
120 47.0 51.5 79.7 147 57.6 63.1 97.7
121 47.4 51.9 80.4 148 58.0 63.5 98.3
122 47.8 52.4 81.0 149 58.4 64.0 99.0
123 48.2 52.8 81.7 150 58.8 64.4 99.6
124 48.6 53.2 82.4 a. The feed roll shafts (debarker feed and chipper feed) are in-
accessible for measurement. Instead, the reducer drive
125 49.0 53.7 83.0 shaft RPM is measured to get chipper feed roll and upper
debarker feed roll speeds. Use the formula:
126 49.4 54.1 83.7 Feed Roll RPM = Reducer Drive Shaft RPM x 0.563

5.4.3.2 Feed Speeds, 53 In. Chipper

Sheave
Table 18: Feed Speeds, 53 Inch Chipper Sheave (Three Knife Disk)a
Engine Chipper Disk Log Feed Speed (FPM)
RPM RPM
5/8 in. Chip 3/4 in. Chip 7/8 in. Chip 1 in. Chip
1760 415 65 78 91 104
1770 417 65 78 91 104
1780 420 66 79 92 105
1790 422 66 79 92 106
1800 425 66 80 93 106
1810 427 67 80 93 107
1820 429 67 80 94 107
1830 432 67 81 94 108
1840 434 68 81 95 108
1850 436 68 82 95 109
1860 439 69 82 96 110
1870 441 69 83 96 110

5000
1880 443 69 83 97 111
1890 446 70 84 98 111
1900 448 70 84 98 112
1910 450 70 84 99 113
1920 453 71 85 99 113
1930 455 71 85 100 114
1940 458 71 86 100 114
1950 460 72 86 101 115
1960 462 72 87 101 116
1970 465 73 87 102 116
1980 467 73 88 102 117
1990 469 73 88 103 117
2000 472 74 88 103 118
2010 474 74 89 104 119
2020 476 74 89 104 119

Table 18: Feed Speeds, 53 Inch Chipper Sheave (Three Knife Disk)a (Continued)
RPM RPM
2030 479 75 90 105 120
2040 481 75 90 105 120
2050 483 76 91 106 121
2060 486 76 91 106 121
2070 488 76 92 107 122
2080 491 77 92 107 123
2090 493 77 92 108 123
2100 495 77 93 108 124
2110 498 78 93 109 124
2120 500 78 94 109 125
2130 502 78 94 110 126
2140 505 79 95 110 126
2150 507 79 95 111 127
2160 509 80 96 111 127
5000
2170 512 80 96 112 128
2180 514 80 96 112 129
2190 517 81 97 113 129
2200 519 81 97 114 130
2210 521 81 98 114 130
2220 524 82 98 115 131
2230 526 82 99 115 131
2240 528 83 99 116 132

a. This table applies to machines with:
12.5 in. diameter engine sheave
3 knife pockets on the disk
NOTE: Disk RPM values shown in this table are calculated by formula. Actual disk RPM values can differ from
table values by +/- 2%. Chipper drive belt slippage can increase error.
For other size engine sheave diameters or 4 knife pockets, use the following formulas:
For other engine sheave diameters:
Chipper Disk RPM = Engine RPM x [engine sheave diameter / chipper sheave diameter]
For Chipper Disks having four knife pockets:
Feed speed (feet/minute) = Chip length (inches) x 4 x disk RPM /12


Sheave
RPM RPM
1750 365 57 68 80 91
1760 367 57 69 80 92
1770 369 58 69 81 92
1780 371 58 70 81 93
1790 373 58 70 82 93
1800 375 59 70 82 94
1810 377 59 71 82 94
1820 379 59 71 83 95
1830 381 60 71 83 95
1840 383 60 72 84 96
1850 385 60 72 84 96
1860 388 61 73 85 97
5000
1870 390 61 73 85 97
1880 392 61 73 86 98
1890 394 62 74 86 98
1900 396 62 74 87 99
1910 398 62 75 87 99
1920 400 63 75 88 100
1930 402 63 75 88 101
1940 404 63 76 88 101
1950 406 63 76 89 102
1960 408 64 77 89 102
1970 410 64 77 90 103
1980 413 64 77 90 103
1990 415 65 78 91 104
2000 417 65 78 91 104
2010 419 65 79 92 105

RPM RPM
2020 421 66 79 92 105
2030 423 66 79 93 106
2040 425 66 80 93 106
2050 427 67 80 93 107
2060 429 67 80 94 107
2070 431 67 81 94 108
2080 433 68 81 95 108
2090 435 68 82 95 109
2100 438 68 82 96 109
2110 440 69 82 96 110
2120 442 69 83 97 110
2130 444 69 83 97 111
2140 446 70 84 98 111
2150 448 70 84 98 112
5000
2160 450 70 84 98 113
2170 452 71 85 99 113
2180 454 71 85 99 114
2190 456 71 86 100 114
2200 458 72 86 100 115
2210 460 72 86 101 116
2220 463 72 87 101 115
2230 465 73 87 102 116
2240 467 73 88 102 117

Feed speed (feet/minute) = Chip length (inches) x 4 x disk RPM /12


Sheave
RPM RPM
1750 337 53 63 74 84
1760 338 53 63 74 85
1770 340 53 64 74 85
1780 342 53 64 75 86
1790 344 54 65 75 86
1800 346 54 65 76 87
1810 348 54 65 76 87
1820 350 55 66 77 88
1830 352 55 66 77 88
1840 354 55 66 77 89
1850 356 56 67 78 89
1860 358 56 67 78 90
5000
1870 360 56 68 79 90
1880 362 57 68 79 91
1890 363 57 68 79 91
1900 365 57 68 80 91
1910 367 57 69 80 92
1920 369 58 69 81 92
1930 371 58 70 81 93
1940 373 58 70 82 93
1950 375 59 70 82 94
1960 377 59 71 82 94
1970 379 59 71 83 95
1980 381 60 71 83 95
1990 383 60 72 84 96
2000 385 60 72 84 96
2010 387 60 73 85 97

RPM RPM
2020 388 61 73 85 97
2030 390 61 73 85 98
2040 392 61 74 86 98
2050 394 62 74 86 99
2060 396 62 74 87 99
2070 398 62 75 87 100
2080 400 63 75 88 100
2090 402 63 75 88 101
2100 404 63 76 88 101
2110 406 63 76 89 102
2120 408 64 77 89 102
2130 410 64 77 90 103
2140 412 64 77 90 103
2150 413 65 77 90 103
5000
2160 415 65 78 91 104
2170 417 65 78 91 104
2180 419 65 79 92 105
2190 421 66 79 93 106
2200 423 66 79 93 106
2210 425 66 80 93 106
2220 427 67 80 93 107
2230 429 67 80 94 107
2240 431 67 81 94 108

Feed speed (feet/minute) = Chip length (inches) x 4 x disk RPM /12.

5000

S ECTION 6000
DISCHARGE SYSTEM
The chip spout requires little maintenance other than daily inspection of the spout support cable and lubrication of
the spout grease points. See “General Maintenance” on page 49 for the maintenance schedule.
6000

SECTION 6000 DISCHARGE SYSTEM
6000

S ECTION 7000
DISPLAY SCREENS
The Peterson Adaptive Control System provides display screens for tracking maintenance intervals. For a complete
list of display screens, refer to the 5000H Operator Safety Manual.
7.1 Directory
F06145
Figure 186: Directory Screen

The Directory screen (Figure 186) displays the machine The sub-menus on the bottom of the screen take you to
7000
serial number and Peterson contact information. the following screens:
To navigate to the Directory screen, press F5 on the • Machine Status (Home) (Press F1)
Machine Status (Home) screen. • Machine Performance (Press F2)
The sub-menus on the right side of the screen take you • Feed Speed Setup (Press F3)
to the following screens:
• Knife Setup (Press F4)
• Troubleshooting Menu (Press A)
• Revision History (Press F5)
• Maintenance Menu (Press B)
Refer to the 5000H Operator Safety Manual, Chapter 4
• Common Parts (Press C) for additional display screens.

SECTION 7000 DISPLAY SCREENS
7.2 Fuel Usage
F06135
Figure 187: Fuel Usage Screen
The Fuel Usage screen (Figure 187) displays the current

fuel consumption rate of the machine. Like a trip odom-
eter in a car, it has two fuel monitors that can be reset
independently. For example, one fuel usage monitor can
be reset at every fill-up, and the other can be left to show
total fuel consumption over the life of the machine.
This screen also displays the total engine hours, current
fuel rate (in gallons per hour), and the current load on
the engine.
7000
Press A to reset the upper right fuel-used value.

Press C to reset the lower right fuel-used value.
The display system captures the Total Fuel Used value
from the engine ECM. The engine start switch must be
in the ON position for the value to appear on the screen.
◆ To navigate to the Fuel Usage screen:

1. Press F1 on the Machine Status (Home) screen.
2. Press F2 on the Engine screen.

7.3 Feed Speed Setup
F06115
Figure 188: Feed Speed Setup Screen
The Feed Speed Setup screen (Figure 188) allows selec- • Roll Case
tion of three parameters for calculating feed roll speed. • Chipper Feed Roll Reducer
The feed roll speeds can then be used as the set points
for adjusting the feed speeds on the hydraulic feed man-
ifold (see “Feed Manifold Setup” on page 144).
◆ To calculate feed roll speeds:

1. Press F2, and turn the knob to select the sheave and
knife setup (53 in., 3 knife; 53 in., 4 knife; 60 in., 63
7000
in.). Then press the knob.
2. Press F3, and turn the knob to select the engine
speed in RPM. Then press the knob.
3. Press F4, and turn the knob to select the required
chip size. Then press the knob.
4. Write down the calculated RPM values for the fol-
lowing four feed roll speeds:
• Lower Feed
• Upper Feed Roll Reducer

7.4 Maintenance Schedule
F06147
Figure 189: Maintenance Schedule Screen
The Maintenance Schedule screen (Figure 189), avail- ◆ To reset the hydraulic oil change timer:
able from the Directory screen, displays the following • Press and hold F4 for 3 seconds.
items:
• Engine Hours IMPORTANT: The maintenance schedule
Note: This measure is generated by the ECM. screens for daily, weekly, and monthly mainte-
• Machine Hours nance are provided for your convenience. They
might not include all recommended service inter-
Note: This measure is generated by the machine
vals. For a complete list of service intervals, see
control system.
“Maintenance Schedule” on page 49.
7000
• Engine Oil Change Schedule

• Hydraulic Oil Change Schedule
You can also navigate to the following sub-menus:
• Daily Maintenance (Press A)
• Weekly Maintenance (Press B)
• Monthly Maintenance (Press C)
◆ To reset the engine oil change timer:

• Press and hold F2 for 3 seconds.

S ECTION 8000
LOG LOADER
Log loader maintenance includes inspection and tightening of loose fasteners and regular lubrication of moving
parts.
8.1 Loader Table 21: Rotobec Loader Assembly Items
Assembly Items Item Model without

Grapple Saw
Model with
Grapple Saw
This section summarizes requirements for routine main- Loader 180 PPC 180 PPC
tenance of the log loader (Figure 190). For more Grapple Joint 715-0037 731-8290
detailed maintenance instructions, refer to the Rotobec (Yoke)
manuals that are shipped with your machine.
Rotator 9150 RT-504
Grapple 4642 4042
Grapple Saw Not installed RC-404
F05832
Figure 190: Log Loader
To guide you in locating that information, see Table 21,

which lists the various model numbers of loader compo-
nents, with and without the grapple saw.
NOTE: The optional grapple saw is described in “Grapple
Saw” on page 171.
8000

SECTION 8000 LOG LOADER
8.2 Loader Safety 8.3 Loader

The log loader is powered by high pressure hydraulics.
Be aware of the following safety concerns: Maintenance
1 WARNING Schedule
Hydraulic fluids escaping under pressure can Tighten bolts according to the following schedule and
penetrate your skin and cause severe injury. grease all components according to the schedule in
• Do not use your hands to locate hydraulic Table 22 on page 165. Lubrication locations are shown
hose leaks. in Figure 195 on page 164.
Escaping fluids can penetrate your skin and
enter your bloodstream, causing serious
Every 12 hours of operation or once a day
internal injuries. If any fluid is injected into • Inspect the collector and other hydraulic compo-
your skin, seek medical attention immedi- nents for any leaks.
ately. • Lower the boom onto the boom rest at the end of the
Use a piece of cardboard or a sheet of paper work period. Do not leave it hydraulically sup-
to detect leaks. ported.
• Do not apply pressure to a damaged hydrau- • Lubricate according to Table 22 on page 165.
lic line, hose or fitting.
• Relieve all hydraulic pressure before discon- After the first week or 60 hours of operation
necting hydraulic lines, hoses, or fittings. Check all bolts for tightness, including the following:
• Slewing ring (turret) bolts (Figure 191 and
1 WARNING •
Figure 192).
Swing hydraulic motor fixation bolts (Figure 193).
Avoid serious injury or death from excessive
hydraulic pressure. • Collector flange bolts (Figure 194).
• Do not exceed factory-adjusted relief pres-
sure settings. If control valves or cylinders
Every 60 hours or once a week
need service, contact an authorized service • Inspect all hydraulic lines, hoses, and fittings for
representative. Special tools and information leaks or damage.
are needed to service control valves and cyl- • Check the slewing ring seals and replace them if
inders. they are damaged.
• Never tamper with hydraulic valve pressure • Lubricate according to Table 22 on page 165.
settings.
• Never switch lines from one valve to another. Every 600 hours of operation or every 3
months
Check all bolts for tightness, including the following:
• Slewing ring (turret) bolts (Figure 191 and
Figure 192).
8000
• Swing hydraulic motor fixation bolts (Figure 193).

• Collector flange bolts (Figure 194).

F06022
Figure 191: Slewing Ring, Lower Bolts and Nuts F06021
Figure 193: Loader Swing Hydraulic-Motor Fixation Bolts
F06023
Figure 192: Slewing Ring, Upper Bolts and Nuts
F06267
Figure 194: Collector Flange Bolt (1 of 4)
8000

6
4 2a
2
3a 3
1a 1
8
9
10
F01441
Figure 195: Loader Lubrication Points

8000

See Figure 195 on page 164 for location of the lubrica-

tion points.
Table 22: Loader Lubrication Schedule
# Lubrication Point Daily Weekly or Lubricant Type
or 12 Hrsa 60 Hrsa
1 Slewing Ring Teeth (see Figure 196) Spray Open Gear Lubricant
1a Slew Bearing (see Figure 197) 2/3 Number 2 Lithium-Based Grease
2 Main Boom Pivot Pin 4/x
2a Rotary Manifold, Lower Bearing (see 1/2

Figure 199)
3 Main Boom Cylinder Base End 4/x
3a Rotary Manifold, Upper Bearing (see 1/2

Figure 198)
4 Main Boom Cylinder Rod End 4/x
5 Stick Boom Pivot 4/x
6 Stick Boom Cylinder Base End 4/x
7 Stick Boom Cylinder Rod End 4/x
8 715-0037 or 731-8290 Grapple Joint 4/x
9 9150 Rotator 2 / 1 at
100 hrs
9 RT-504 Rotator (optional):

• Grease fitting #1 (lower) 1/3
• Grease fitting #2 (upper) 1/2
10 4042 or 4642 Grapple:

• Grapple jaw pivots 4/2
• Cylinder pivots 4/2
a. Grease Fittings / Pumps per fitting at 2 cc each.
x = apply enough grease to force it out the joint.
8000

F05909
Figure 196: Slewing Ring Teeth Lube Spray

F06071
Figure 198: Rotary Manifold, Upper Grease Point
F06024
Figure 197: Slew Bearing Grease Point (1 of 2)

F06072
Figure 199: Rotary Manifold, Lower Grease Point

8000

S ECTION 9000
FRAME
The wheels, the accessories, and the optional equipment require different levels of regular maintenance.
9.1 Wheel Hubs and Loss of oil indicates a leaking seal, which requires a ser-
vice level of repair. In normal operation, hub oil needs
replacing only when the brakes are serviced.
Tires ◆ To add oil to the wheel hub:
1. Remove the red plastic cap in the center of the
9.1.1 Tire Pressure wheel hub.
2. Add gear lube oil: LS80W-90, Specification GL-5,
Maintain tire inflation pressure as indicated by tire man-
MIL-L-2105.
ufacturer. Under-inflated tires can overheat, fail, and
cause machine damage. Over-inflated tires can lead to 3. Replace the plastic cap.
tire failure and machine damage. The maximum load
and inflation pressures are printed on the tire sidewall 9.1.3 Trailer Wheel Lugs
and on the VIN label near the serial number plate
• Never mix hub-piloted and stud-piloted wheels,
(Figure 63 on page 71).
hubs, and nuts. The result could be loss of torque, a
9.1.2 Wheel Hub Oil

cracked wheel, or possible loss of the wheel.
• Do not lubricate nuts used on stud-piloted wheels.
Check the oil level in the wheel hubs weekly and main- Never lubricate wheel or nut ball seats or mounting
tain it at the full line, which is the inner circular line on faces. If lubrication is used, consult wheel manufac-
the clear plastic window on the wheel hub (Figure 200). turer for torque specifications.
• Install nuts in proper sequence: Snug up the nuts to
about 50 ft-lbs (68 Nm) torque. Do not tighten fully
until all nuts have been seated. Then continue to
tighten the nuts 1/4 turn at a time until they are
torqued to specifications (Table 23) using the tight-
ening sequence in Figure 201 or Figure 202.
F05887
Figure 200: Hub Oil Level at Full

9000

SECTION 9000 FRAME
• Check torque values as part of a vehicle’s scheduled

Table 23: Wheel Mounting Data maintenance program or at intervals of 10,000
miles (16,000 km), whichever comes first.
Mounting Type Thread Torque Value
Hub-piloted with M22 x 1.5 450-500 ft-lb

flange nut, all (oiled)*
European Axles 610-678 N-m
Stud-piloted, 3/4 inch - 16 450-500 ft-lb (dry)

double cap nut, 610-678 N-m
standard US axles
Spoked 3/4 inch - 16 250 ft-lb (dry)

339 N-m
* For nuts used on hub-piloted wheels only, apply two
drops of oil to a point between the nuts and the flang-
es and two drops to the last two or three threads at the
end of each stud. Also, lightly lubricate the pilots on
the hub to ease wheel installation and removal.
1 1
6 1 10 8
7 2
3 6
4 3 5 4
5 4
3 6
2 5 7 9
8 2
F00136B
Figure 201: Wheel Lug Torque Patterns, Hub and Stud Type
1 1
3 6
3 4
5 4
5 2 2 F05935
Figure 202: Wheel Lug Torque Patterns, Spoke Type
• After a wheel assembly has been installed, recheck

the wheel nut torque at 50 to 100 miles (80 to 160
km) and retighten if necessary to the recommended
torque, using the proper sequence (Figure 201 or
Figure 202).
• To check and retorque an inner cap nut, loosen the
outer cap nut first; then tighten the inner cap nut.
Outer cap nuts then must be retightened to the
proper torque.
9000

SECTION 9000 FRAME
9.2 Accessory 9.2.4 Fire Extinguisher

The red fire extinguisher (Figure 203) that shipped with
Maintenance the machine must be inspected annually. It requires test-
ing every 12 years.
The decals and fire extinguisher require minimal main-
tenance. The water pump sprayer is powered by its own
engine, which requires scheduled service. The air com-
pressor also requires regular service.
9.2.1 Guards and Shields

The machine includes guards and shields to help pre-
vent personal injury. Make sure that they are secure in
place and are in good working condition.
• The belt guard doors and the belt cover protect
against becoming entangled in the rotating shafts
and drive belts. F02935
• A welded wire frame keeps hands and fingers away Figure 203: Fire Extinguisher
from the engine fan.
• A ladder provides safe access to the area above the
chip chamber. 9.2.5 Air Compressor
• Hand holds and handrails are located where opera- The air compressor requires the following scheduled
tors need support or a grab point. maintenance:
• The air filters for the engine and the compressor
9.2.2 Decals (Figure 204) require frequent inspection and clean-
Peterson decals and labels are designed to last at least 5 ing or replacement.
years in heavy-use operating conditions. With regular • The compressor belt requires regular checks for
cleaning and care, they can last longer than 5 years. condition and tension.
However, direct scraping, blows with hard objects, • The air tank requires daily draining of water.
excessive heat, and other abuse can damage the decals.
• The engine and the compressor require regular oil
Keep informational and hazard alert decals in good con- changes.
dition and clean so they are readable. Replace any that
become damaged, lost, or illegible. For complete air compressor maintenance, refer to the
operating instructions that came with the equipment.
9.2.3 Paint Color Numbers

The following DuPont color mix codes may be used to
obtain correct paint colors for touching up and repaint-
ing the 5000H.
• Peterson Blue is DuPont No. K9740
• Peterson White is DuPont No. 817
These paint codes are accessible in most regions. Other
paint brands can usually cross-reference to the widely-
used DuPont color codes.
9000

SECTION 9000 FRAME
9.2.6.1 Water Hose

The length of the 1-inch diameter sprayer hose is 50 feet
2
(15 meters). The nozzle adjusts from a fog to a solid
stream discharge.
1
9.2.6.2 Tank Freeze Protection

To safeguard the water sprayer system during freezing
weather, add an anti-freeze to the water tank
(Figure 206) or take the system out of service by drain-
ing the tank.
Consult a local supplier of fire fighting equipment for
anti-freeze. If you take the system out of service, drain
the tank, the pump, and the hose.
F06000
1. Engine Air Cleaner
2. Compressor Air Cleaner
Figure 204: Air Compressor
9.2.6 Water Pump Sprayer

For complete water pump maintenance, refer to the
operating instructions that came with the equipment.
The engine air filter (Figure 205) requires frequent
inspection and cleaning or replacement.
F06060
2 4 Figure 206: Water Tank

1
9.2.7 Cab Climate Controls

For maintenance instructions on the cab heater and air
3 conditioner, refer to the product guides that shipped
with the machine.
F05932
1. Hose Reel 3. Pump Engine Air Cleaner
2. Hose Nozzle 4. Water Tank
Figure 205: Water Pump Sprayer
9000

SECTION 9000 FRAME
9.3 Optional Equipment Maintenance

Optional equipment requires regular maintenance. For details on performing maintenance and trouble-
shooting, refer to the Rotobec Model RC-404 Opera-
9.3.1 Grapple Saw tor’s & Installation Manual that shipped with your
machine.
The saw system requires periodic maintenance (see
Table 24). Also, the grapple saw chain (Figure 207)
needs tensioning during the break-in period. 1 WARNING
Read and understand all safety notices in the
Table 24: Grapple Saw Maintenance Schedule Rotobec manual before operating or servicing
the grapple saw.
Period Activity Description
◆ To prepare the grapple saw for
Daily Inspect • Chain tension
• Saw unit’s structure for
maintenance activities:
damage 1. Rotate the key in the cab (Figure 208 on page 172)
• Hydraulic system for oil counterclockwise. The Power ON light turns off.
leaks
• Saw bar and chain for 2. Remove the key.
sharpness 3. Close the high pressure ball valve (Figure 209 on
• Chain lubrication page 172).
• Chain oil level
4. Lock out the ball valve handle.
Semi-weekly Lubricate Saw cylinder
(every 10
work hours
or 3 days)
Weekly Inspect • All nuts and bolts for

tightness
• Saw unit support plate
to grapple and hydraulic
hoses
Quarterly Inspect • Accumulator nitrogen

charge
• All nuts and bolts for
tightness
• All electrical
components
Clean • The strainer in the fill

cap
• The vent in the fill cap
F05847
Annually Inspect Grapple saw
Figure 207: Grapple Saw Chain
Clean Oil tank and saw bar
lubricating pump
Change • Drain filter cartridge

• Check the pressure and
flow adjustments
9000

SECTION 9000 FRAME
F05883 F05745
Figure 208: Grapple Saw Activation Key in the Cab Figure 210: Proheat X45 Heater
F05884
Figure 209: Grapple Saw Ball Valve in the Open Position
9.3.2 Cold Weather Kits

Maintenance instructions for the Proheat X45 heater
(Figure 210) are provided in the two manuals that arrive
with the kit: one for the heater and one for the timer.
Fuel is supplied from the main fuel tank. Electrical
power is supplied from the positive terminal on the
starter motor solenoid of the main engine. An in-line
fuse 6 inches from the terminal on this line protects the
unit.
9000

INDEX
Page numbers in bold indicate machine controls.
Page numbers in Italic indicate photos and illustrations.
Numerics retraction nuts 137, 139
1st Feed Roll 118 rotating and replacing 139
1st upper flail housing 20, 21 Anvil and feed plate illustration 137
2nd Feed Roll 118 Anvil clearance 137
2nd upper flail housing 20, 21 Anvil maintenance 136
Anvil-extend nut 138
A
Anvil-retract nut 138
Accessories 169 Authorized personnel 36
Accessory maintenance 169
Air cleaners 81, 81 B
Air compressor 169, 169, 170 Babbitted areas 131
Air filter service indicator 81 Bark Mover 119
Air filters Bark mover 37
pre-cleaners 81 Bark mover hazards 25
service indicator 81, 81 Bark Mover Off/On/Rev 118, 119
Air filters, canisters 82 Bark mover, pump 97
Air pre-cleaners 82, 82 Bark mover, stalled 118
Air pressure 35 Bark removal 41
Alert messages 5, 5 Batteries, cables, and connections 104
Caution 5 Battery
Danger 5 cable routing 105
Important 5 cables and connections 104
Warning 5 maintenance 105
ANSI B18 69 Battery 1 105
Anvil 124, 134 Battery 2 105
clearance 138 Battery box 104
clearance and knife extension 134 Battery disconnect lockout 17
clearance illustration 134 Battery disconnect lockout/tagout 17
extend 138 Battery disconnect switch 16, 16, 16, 16, 17, 103, 103,
extension nuts 137, 139 105
hidden, and feed plate 137 Battery disconnect switch, lockout/tagout 17
insert 138 Bearing failure examples 108
maintenance 136 Bearing lubrication 56
orientation for clearance adjustment 138 Bearing protection 108
Bearings
positioning screw 138
chipper bearings 56
positioning screws 139
failure examples 108
retract 138

INDEX
lubrication 70 Chip discharge 40, 40, 42

maintenance 56 Chip quality
protection 108 over-thick 63
Belt deflections 84 slivers and strings 62
Belt guard support bar 85 Chip size adjustment 141
Belts Chip size, adjusting 141
drive 83, 84, 169 Chip slot 130
installing used 83 Chip spout falling hazard 24
V-belt tension 83 Chip spout hazards 28
Belts, drive 25 Chip spout, plugged, troubleshooting 67
Blockage 24 Chip van 43
Breather cap 87, 93 Chip-making guidelines 62
Breathers 59, 60 Chipper
bearing grease 56
C
bearing, greasing procedure 56
Cab climate controls 170 knife system maintenance 123
Cab heater safety 30 setup instructions and calculations 141
Cab operator safety 29 wear plate inspection 140
Calculating for setup 141 wear plate, illustration 140
Cards, chip quality problem solving 63 Chipper bearing lubrication 56
Case roll, gearbox 99 Chipper disk 134, 138
Chain
belt guard 85
debarker, maintenance 112
locking pin 24
debarker, rotation 115
locking pins 24
debarker/flail, installation 113
nub 123
flail, inspection of 112
RPM 141
flail, maintenance of 112
safety pin 125
Chain guard 120
wear plate 140
Changing
Chipper disk hazards 27
clutch oil and filter 94
Chipper disk inertia 18
drive motor gearbox oil 101
Chipper disk wear plate 140
engine coolant 76
Chipper feed roll housing 20, 21
hydraulic oil and filters 89
Chipper feed, gearbox 99
pump-drive gearbox oil 98
Chipper Hood 23
Charge air cooler (CAC) 75
Chipper hood 125
Charge air cooler fan pump 97
Chipper hood, locking pin 24
Charge pressure filters, hydraulic 89
Chipper hood, switch 23
Charge pressure filters, replacing 89
Checking Chipper housing flange 135
anvil wear 136 Chipper knife 134
belt tension 83 Chipper knife edge 135
clutch oil 93 Chipper knife systems 123
Chipper sheave
drive motor gearbox oil 100
shaft guard 141
engine coolant 76
shaft rpm measurement 142
hydraulic oil 87
Chipper sheave shaft RPM 142
pump-drive gearbox oil 98

INDEX
Circuit breaker 103 screw 124

Circuit breaker panel 103 wear 127, 132
Circuit breaker, in JB1 104 Coupler 97
Circuit breakers 103 Crankcase breather 79, 79
Cleaning 30 Cranking power, 1300 amperes 24
Cleaning and checking the radiator 77 Crowding 35
Cleaning the primary filter element 82 Crushing and pinching hazards 25
Cleanliness 35
D
Clutch
changing oil and filter 94 Daily fire prevention 30
Debarker
checking oil level 93
chain maintenance 112
HPTO breather 95
feed roll housing 22
hydraulic oil 94
flail drum wear 111
hydraulic system 93
flail rod plug 114
oil filter 93
flail rod wear 111
oil tank 93
wear plates maintenance 116
tank drain 94
Debarker, feed roll housing 20, 21
Clutch hydraulic system 93
Decals 43, 70, 169, 169, 169
Clutch oil cooler 96
Decals, maintenance 70
Cold weather kit 172
Decibel (dBa) level 34
Cold weather kits 172
Definitions of terms 8
Color chips, specification 169
Design safety 69
Combustibles 31, 107
Dial gauge 134, 134, 135
Common practices 52
Directory 157
Compressed air 105
Directory screen 157
Compressor air cleaner 170
Discharge spout 37
Control panel 15
Disk 130
alert messages 5
Display, screens 157
display 157
Drain plug 98
electrical connectors 107
Drive belts 25, 84, 169
Control Power 103
Drive belts, tensioning 84
Controls, safety 15
Drive belts. See also belts
Coolant
Drive belts. See also V-belts
level sensor 73
Drive chains 119
temperature sensor 73
Drive motor 121
Coolant systems 75
Drive motor gearboxes 99
Coolant, disposal 61
Cooling system E
changing coolant 76 Ear protection 34, 35
integrated 75 ECM 17, 158
maintenance 75 Electrical
pressurized 76 cranking power 24
Counter knife 124, 130, 131, 132 grounding 108
pocket 128, 133 parts 103
replacement 127 system, 24-volt 24

INDEX
Electrical energy hazards 24 Engine, air cleaner 170

Electrical parts 103 Entering and leaving 30
Electrical shorts 31 E-Stop
Electronic control module (ECM) 17, 158 in the cab 16
Emergency exit 30 near the ladder 16
Emergency Stop 15, 103 on JB2 15
Emergency Stop (E-Stop) buttons 15 on JB3 16
Emergency Stop button 15, 16 E-Stop button 15, 16
Emissions 35 E-stop buttons 103
exhaust 35 Ether starting aid 74
motor oil vapors 35 Ether starting canister 74, 74
Engine 15, 17, 97 Example calculation 142
2150 rpm 34 Extension 134
coolant fan 75 Eye protection 35
coolant radiator 75 F
coolant, changing 76
Falling objects 18
coolant, checking 76
Fan blade 140
cooling system 73 Fan purge
ECM with two connectors 108 cycle 77
exhaust 35 feature 77
fluids and filters 78 Features and devices 13
fuel usage display 158 Federal vendor information notice (VIN) 71
oil and filter 78 Feed
oil dipstick 79 make up pump 97
oil drain valve 78 manifold 144, 145
oil fill tube 79 motor and chain 100, 121
oil filters 78 plate 124, 137, 138, 139
overheated, troubleshooting 66 plate bolts 137, 139
overheating 77 pumps 97
primary fuel filter 80 roll 37
secondary fuel filter 80 roll RPM values 146
sensor locations 73, 74 roll speed check 145
sensors 73 Feed and flail bearings 56
service 73 Feed manifold setup 144
sled adjusting screw 56 Feed roll and flail housing hazards 26
sled hold-down bolts 85 Feed roll and flail housings 21
sled jack bolts 85 Feed roll RPM values 146
switch at JB2 18 Feed roll RPM values 146
Engine air cleaner 170 Feed speed 141
Engine coolant 24 Feed speed setup 159
Engine fluids and filters 78 Feed speed setup screen 159
Engine maintenance interval 61 Feed speed tables 146
Engine oil and filters 78 Feed speeds
Engine sensors 73 53 in. chipper sheave 148, 148, 152
Engine service 73 60 in. chipper sheave 148, 150, 150

INDEX
65 in. chipper sheave 150, 152, 152 Flail stands 111, 111
Feed System 118 Flails
Feed System Off/On/Rev 118 access cover 114
Feeler gauge 136 drum 114
Fill pipe 76 drum wear 111
Fill tube 87 gearbox drain plugs 100
Filter assembly gearbox fill port 99
bottom, turning the nut 91 wear plates 116
gasket and O-ring, removal 91 Flails chains 114
magnet, blowing clean 91 areas of wear 116
removal from the tank 91 inspection 112
tank cover 92 installation 113
Filter locations 59 maintenance 112
Filters rotation, re-arranging 115
breathers 59, 60 rotation, replacement 112
charge pressure 89 thickness monitoring 113
handling 52, 61 to flip 115
hydraulic oil charge pressure 89 wear 113
hydraulic oil return 90 wear indications 113
hydraulic tank, replacement 90 Flails maintenance 111
locations 59 Flails, housing 37
Filters, pressure gauge 87 Float pumps 97
Fines, chip quality 64 Fluid leaks 61
Finish (machine paint) 169 Fluids and filters 57, 57
Fire extinguisher 31, 32, 32, 32, 32, 169, 169, 169 Fluids and filters service schedule 57
Fire extinguisher, location 32 Flying material hazard 40
Fire extinguisher, service 169 Flying objects hazard 34
Fire hazards Formulas for other sheaves 142
flammable materials 107 Freeze protection 170
prevention and suppression 30 Front feed plate bolts 138
reducing risk 30 Ft-lb torque 6
Fire prevention and suppression 13, 30 Fuel
Fire suppression equipment 32 diesel No. 1, No. 2 61
First aid 36 filters 80
First aid kit 36 filters, blocked 80
Flail chains 112 filters, maintenance 80
Flail chains, rearranging 115 filters, primary 80
Flail drums 111 filters, secondary 80
Flail rod 114, 115 lines, priming 80
plug 114, 114, 115 pressure 80
puller 114 pressure sensor 73, 74
removal 114 priming pump 80
tool 112, 112, 114, 115 specification 61
wear 111 temperature sensor 73
Flail rods 111 Fuel filters 80

INDEX
Fuel for cold weather 61 area 2, log handling and loader swing 39
Fuel primer pump 80 area 3, flying materials 40
Fuel specifications 61 area 4, skidder machine traffic 41
Fuel usage 158 area 5, falling material and loader 42
Fuel usage screen 158 area 6, truck traffic 43
Fuel-water separator 80 Hazards 13
Fuses 104, 104 fluid leaks 61
flying objects 34
G
rotation 123
Gear oil pump 97
zones 37
Gearboxes
Health restrictions 14
chipper feed 99
Hearing protection 34, 35, 38
lower feed and case roll 99
Heat sources 30, 31, 31
oil cooler 98
Heater, Proheat X45 172
pump drive 55, 98
High wear area 116
upper feed 99
Highest knife 134, 135
Glossary 8
High-level mark 94
Glossary of terms 8, 8
Hold-down bolts 85
Grapple saw 171
Hood, safety pin 125, 131
activation key 172
Horn 36
ball valve 172
Hose
chain 171
nozzle 170
Grapple saw maintenance schedule 171
reel 170
Grease
Hose, nozzle 32
chipper bearing 56
Hoses and clamps 74, 74
fitting cluster 53, 55
Hot bearings 31
fittings 53
Hub oil level 167
gun 53
Hydraulic clutch 97
lithium 53, 165
Hydraulic clutch, oil sight gauge 94
points 53, 54, 55
Hydraulic clutch, pump 97
Grease fittings 53
Hydraulic fan, pump 97
Grease points 53
Hydraulic fan, pump filter 89
Grease points 53
Hydraulic leaks 31
Grinder, jams and blockage 24
Hydraulic manifold setups 101
Ground straps 105
Hydraulic oil
Grounding properly 108
cooler 75, 95
Grounding, electrical 108
coolers 95
Guards and shields 25, 169, 169
daily check 70
H gauges 87, 90
Handle/ slide hammer 112 pumps 97
Handling filters 61 sample and test oil 52
Hard hats 35 sight gauge 87
Hardened face 124 suction valves 96
Hazard zones tank 87
area 1, high noise and hot surfaces 38 tank drain valve 89

INDEX
tank filter covers 88, 90 installation 126

temperature gauge 87 setup 143
Hydraulic oil cooler 95 Key Knife Inc. 123
Hydraulic pump descriptions 97 Key Knife maintenance 124
Hydraulic pumps and suction valves 96 Key Knife setup data 143
Hydraulic system 87 Key Knife setups
Hydraulic tank chip size (inches) 143
filler cap 92 chip size (mm) 144
filters 90 Key Knives, replacing 124
filters, maintenance procedure 90 Knife
oil level 87 extension (Offset) 134
Hydraulics 24, 24 width (W) 130
changing oil and filters 89 Knife clamp 124, 130, 132
checking system oil 87 bolt 124
system 87 nuts and washers 132
Hydraulics, hazardous leaks 24 pocket 128, 133
studs 131, 132
I
Knife extension and the highest knife 134
Important messages 5, 5 Knives 124, 130, 132
Important notice 5, 86 babbitted, minimum length 131
Inertia 18 burr removal 133
Input speed magnetic pickup 74 clamp nuts 132
Inspection point
counter knife wear 127, 132
chipper rotation 27, 127
description of knife systems 123
flail drum thickness 111
extension 134, 141
Installing and replacing flail chain 113
holder 124, 128, 130, 132, 133
Installing used belts 83
holder shim 124
IQAN. See Control panel
Key Knife system, replacing counter knives 127
J Key Knife system, replacing knives 124
Jack bolts 85 minimum size 131
Jack screw adjuster 120, 121 new without wear 127, 132
Jammed logs 26 offset 134
Jams 24, 118 offset illustration 134
Jams or blockage 24, 25 pockets 125
Job site safety 13, 34 removal when worn 132
Jump starting 106 shimming 124
Jump starting the machine 106 standard knife system illustration 130
K standard knife, replacing counter knives 130
standard knife, replacing knives 130
Key
worn with cupping 127, 132
battery disconnect 18
padlock 18 L
Key counter knives, replacing 127 Labels 43
Key Knife Lexan windows 30
components 124 Lift 118
gap, extension, and opening 144

INDEX
Lifting 35 warnings 47
Limited warranty 7, 7 Maintenance manual 5
Lithium grease 53, 165 Maintenance schedule 49, 49, 160, 160
Load sense screw 145 Maintenance schedule screen 160
Loader 161 Makeup pump 145
access zone 37, 42 Manual rotation hazard 123
assembly items 161 Measurement units 6
collector flange 163 Motor mount bolts 120, 121
lubrication points 164 Motor oil 35
maintenance schedule 162 Moving machinery hazard 34
safety 26, 162 Moving parts 24
swing motor fixation bolts 163 Mufflers 31
Loader falling hazard 24
N
Loader lubrication schedule 165
No smoking 31
Loader swing hazard 26
Noise hazard 34
Loader, pump 97
Noise levels 34
Locking pins 19
Nozzles 35
Locking the chipper disk 28
Nub 123, 125
Lockout and tagout 17
Nuts, crimp-style locking 69
Loctite 69
Log loader 37 O
Log loader hazards 29 Offset, chipper knife 134
Log loader, safety, hydraulics 162 Oil coolers 95
Log loading 42 Oil disposal 61
Low wear area 116 Oil drain plug 99, 100
Lower feed Oil fill and breather 99
drive motor and chain guard 120 Oil fill plug 99
gearbox 99 Oil level inspection plug 98, 99, 100
Lower flail pump 97 Oil pressure, sensor 73
Low-level mark 94 Operating and hazard zones 37
Lubrication 53, 53 Operator qualifications 14
M Optional equipment 171
Machine Optional equipment maintenance 171
emergency stop 15 Output speed magnetic pickup 73
purpose of design 14 Outriggers (landing gear) 37
safety 13, 15, 15 Overheated bearings 56
troubleshooting guidelines 66 Overheated engine, troubleshooting 66
Magnetic pickup Overs discharge 40
input speed 74 Overs spout hazards 29
output speed 73 Overs spout, discharge 40, 42
Main 87 P
Main hydraulic system 87
Paint 169
Maintenance
chip 169
decals 70
color numbers 169
special interval 60

INDEX
number, identification 169 Rear feed plate bolts 138

PPC colors 169 Replacing chipper sheave belts 84
Permatex 69 Replacing the alternator belt 84
Personnel, authorized 36 Reset button 81
Pin access cover 24 Return filters
Pin holders 24 hydraulic oil 90
Pins, chip quality 63 replacement 90
Pins, safety 19 Rev 118, 119
Plate clamp (nub) 140 Reverse disk rotation 28
Plugs, flail rod 115 Roll case
Pockets chain guard 119
Key Knife system 128 chains 120
standard knife system 133 drive motor adjuster 120
Point of operation 26, 26 Roll case and lower feed chains 119
Power distribution box (JB1) 105 Rotary manifold, grease point 166
Pre-cleaners and air filters 81, 81 Rotating and replacing the anvil 139
Pressurized gases and fluids 24 Rotating the disk manually 27
Primary air filter Rotobec loader assembly items 161
cleaning 82, 82 Rotor bearing damage 109
partially removed 82 Rub plates. See also Wear plates
Primary fuel filter 80, 80 S
Primer pump 80
Safe behaviors 36
Proheat X45 heater 172
Safe workplace 35
Protection
Safety
ears 34, 35
avoiding unsafe conditions 35
eyes 35
behaviors 36
toes 35
controls 15, 15
Protective gear 35
decal illustrations 43
Pump compensator adjustment screw 145
decals 43
Pump-drive gearbox 55, 98, 98
electrical energy 24
change oil 98
falling objects 18
check oil level 98
guards and shields 25
Pumps
improvement programs 14
feed 97
instructions 5, 5
float 97
labels 13, 43, 43
makeup 97, 145
locking stops and pins 19
R machine 15
Radiator moving machinery 34
cleaning 77 moving parts 24
drain valve 77 practices 36
engine and hydraulic 75 protective gear 35
fill level 76 responsibility 14
surge tank sight glass 76 summary 13, 13
Radiator purges 40 topics 13, 13
Radiator, cap 76 training 14

INDEX
unguarded moving parts 37 Special interval 60

worksite 34 Spontaneous combustion 31
Safety first 13 Spout, angle 130
Safety first! 14 Spout, rotation coupling 56
Safety pins 19 Sprayer, water pump 32
feed and flail housings 20, 21 Stabilizers 37
flail housing 117 Stand back 36
pocket 140 Standard knife 131, 138
procedures 19 clamp 133
red 46 components 132
white 46 counter knife and knife clamp 131
Secondary air filter, service indicator 82 gap, extension, and width 143
Secondary fuel filter 80, 80, 80 maintenance 130
Securing the chipper hood 23 removal of defects 133
Self-contained water sprayer 32 setup data 142
Serial number and VIN 71 system 130
Serial number plate 71, 71 Standard knife setups
Service referrals 74, 74 chip size (inches) 143
Service schedule chip size (mm) 143
fluids and filters 57 Starters 105
general maintenance 49 Stay alert 36
grapple saw 171 Stop buttons 103
loader lubrication 165 Stored energy 18, 18
Shoes 35 Stroke limiter cap 145
Shout warnings 36 Surge tank 76
Sight gauge 93 Switch, battery disconnect 17
Signs of fire 31 System lockout 17
Skidder operations 42
T
Slew bearing grease point 166
Tagout and lockout 17
Slewing ring
bolts and nuts 163 Tank freeze protection 170
teeth lube spray 166 Tank return filters, replacing 90
Slivers/strings, chip quality 62 Techniques 13
Small numbers 5 Temperature range 77
Small spills 31 Tension 83
Smoking 31 Thread diameter 69
Smoking restriction 31 Tire pressure 167
Solenoid 1 105 Toe protection 35
Solenoid 2 105 Torque values 68, 68, 69
Sound national coarse (NC) threads 69, 69
decibels at 2150 rpm 35 national fine (NF) threads 68, 68
level at 7 meters 34 Trailer wheel lugs 167
safe levels 35 Training 31, 35
sources 35 Transporter 43
Sources and causes of fires 31 Tree delivery 41

INDEX
Troubleshooting chip production 62 Water/fuel separator 80

Troubleshooting machine operation 66 Water-fuel separator 80
Troubleshooting, machine 66 Wear plates 117, 130, 134, 140
Turret harness connector 107 bark mover 117, 117
chipper disk 140
U
flail housings 116
UHMW wear plates 116, 116, 117
UHMW 116
bark mover 117
un-worn area 140
flail housings 117
Wear protective gear 35
Units of weight and measure 6, 6
Welding 31
Unsafe conditions 35
damage caused by 107
Upper feed
precautions 107, 107
chain and sprocket 121
procedures 108
gearbox 99
sparks 107
Upper feed and chipper feed chains 121
Wheel hub oil 167
Upper flail #1 pump 97
Wheel hubs and tires 167
Upper flail #2 pump 97
Wheel lugs
Upper flail housing 22
installation tips 167
V torque values 167, 168
Valve 110.1, case rolls 145 Wheel mounting 168
Valve 110.2, lower feed 145 Windows 30
Valve 110.3, upper feed 145 Worksite, safety 34, 35
Valve 110.4, chipper feed 145 Y
V-belts 83, 83, 83
Yellow piston indicator 81
drive 83
See also Belts
See also Drive belts
tensioning 84
used, installation 83
Ventilation 35
VIN number 71
W
Warnings during maintenance 47, 47
Warranty, limited 7
Warranty, voided 14
Water 170
Water hose 32, 170
Water pump sprayer 32, 32, 32, 32, 170, 170, 170, 170,
170
hose 170
specifications 32
tank fill cap 33, 33
Water pump starter 32
Water separator, fuel filter 80
Water tank 32, 170, 170, 170

INDEX

5000h Oper Manut - 93146

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5000H Maintenance

93146 5000H CHIPPER MAINTENANCE MANUAL 1

2 5000H CHIPPER MAINTENANCE MANUAL 93146

7.1 Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

93146 5000H CHIPPER MAINTENANCE MANUAL 3

8.1 Loader Assembly Items . . . . . . . . . . . . . . . . . . 161

9.1 Wheel Hubs and Tires . . . . . . . . . . . . . . . . . . . 167

4 5000H CHIPPER MAINTENANCE MANUAL 93146

The Manual Set 1 CAUTION

93146 5000H CHIPPER MAINTENANCE MANUAL 5

Units of Weight and Measure

6 5000H CHIPPER MAINTENANCE MANUAL 93146

93146 5000H CHIPPER MAINTENANCE MANUAL 7

Chock A curved, wedge-shaped block placed against a wheel to prevent movement.

Dirt Separator Spout See Overs Spout.

8 5000H CHIPPER MAINTENANCE MANUAL 93146

Table 1: Glossary of Terms for the 5000H (Continued)

93146 5000H CHIPPER MAINTENANCE MANUAL 9

Table 1: Glossary of Terms for the 5000H (Continued)

Paddle See Fins

RPM RPM is an abbreviation for revolutions per minute.

10 5000H CHIPPER MAINTENANCE MANUAL 93146

Table 1: Glossary of Terms for the 5000H (Continued)

Wear Plate This term has two meanings on the 5000H:

93146 5000H CHIPPER MAINTENANCE MANUAL 11

12 5000H CHIPPER MAINTENANCE MANUAL 93146

93146 5000H CHIPPER MAINTENANCE MANUAL 13

14 5000H CHIPPER MAINTENANCE MANUAL 93146

Safe use of the machine during normal operation, main-

Emergency Stop (E-Stop) Buttons

IMPORTANT: Avoid engine damage. Do not use

◆ To shut down in an emergency: F05314

93146 5000H CHIPPER MAINTENANCE MANUAL 15

Figure 4: E-Stop in the Cab

Battery Disconnect Switch

16 5000H CHIPPER MAINTENANCE MANUAL 93146

Figure 6: Battery Disconnect Lockout

93146 5000H CHIPPER MAINTENANCE MANUAL 17

Inertia of the Chipper Disk

5000H Support System

18 5000H CHIPPER MAINTENANCE MANUAL 93146

Safety Locking Stops and Pins

93146 5000H CHIPPER MAINTENANCE MANUAL 19

1. Debarker Feed Roll Housing

Figure 8: Safety Pins: Feed and Flail Housings, Right Side

20 5000H CHIPPER MAINTENANCE MANUAL 93146

F05329 F05332b F05333

5. Chipper Feed Roll Housing

Figure 9: Safety Pins: Feed and Flail Housings, Left Side

93146 5000H CHIPPER MAINTENANCE MANUAL 21

◆ To remove safety pins from the feed roll or

22 5000H CHIPPER MAINTENANCE MANUAL 93146

◆ To open the chipper hood:

93146 5000H CHIPPER MAINTENANCE MANUAL 23

Jams or Blockage Moving Parts

24 5000H CHIPPER MAINTENANCE MANUAL 93146

93146 5000H CHIPPER MAINTENANCE MANUAL 25

Removing Jammed Logs

The following hazards are associated with the feed roll

26 5000H CHIPPER MAINTENANCE MANUAL 93146

◆ To rotate the chipper disk:

93146 5000H CHIPPER MAINTENANCE MANUAL 27

28 5000H CHIPPER MAINTENANCE MANUAL 93146