Carlton SP6016 Series Owner'S Manual Download Page 1

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Machine Serial #

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Engine Model & Spec #

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Engine Serial #

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Purchase Date

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Dealer

_____________

REVISION: 220926-1

J.P.Carlton Company
Div. D.A.F. Inc.
121 John Dodd Road
Spartanburg, SC 29303
Ph. (864) 578-9335
Fax (864) 578-0210
www.stumpcutters.com

SP6016 SERIES

Owner’s

Manual

Summary of Contents for SP6016 Series

Page 1: ..._____ Engine Serial _____________ Purchase Date _____________ Dealer _____________ REVISION 220926 1 J P Carlton Company Div D A F Inc 121 John Dodd Road Spartanburg SC 29303 Ph 864 578 9335 Fax 864 578 0210 www stumpcutters com SP6016 SERIES Owner s Manual ...

Page 2: ...BLANK SHEET ...

Page 3: ...e this product Gasoline or Diesel and the products of combustion of such fuels can expose you to chemicals including benzene which is known to the State of California to cause cancer birth defects or other reproductive harm For more information go to www p65Warnings ca gov ...

Page 4: ...SP6016 SAFETY ALERT ...

Page 5: ...SP6016 SAFETY ALERT OPERATE MACHINE FROM 25 FEET AWAY KEEP SPECTATORS AWAY ...

Page 6: ...SP6016 SAFETY ALERT ...

Page 7: ...SP6016 SAFETY ALERT ...

Page 8: ...Carlton Co Inc will not be liable for consequential damages resulting from breach of warranty IT IS NECESSARY TO RETURN THE WARRANTY VALIDATION FORM AND NOTIFY J P CARLTON CO INC IN WRITING WITHIN TEN 10 DAYS FROM DELIVERY DATE TO VALIDATE THIS WARRANTY NOTE This warranty applies only to new and unused equipment or parts thereof manufactured by J P Carlton Co Inc ANY MACHINES USED FOR LEASE OR REN...

Page 9: ...s the customers responsibility to deliver machine to dealers facility unless other arrangements have been agreed to between the selling dealer and the customer The manufacturer may elect at its discretion to reimburse reasonable labor cost to customer or dealer for major defect repairs Prior approval must be obtained from J P Carlton Company Inc IMPORTANT NOTICE 1 AIR FILTER MAINTENANCE IS CRITICA...

Page 10: ...BLANK SHEET ...

Page 11: ...d to stop machine and remove key before performing any type of maintenance 4 ______ Customer has been warned not to operate the machine without the cutter wheel guard in place 5 ______ Customer has been furnished with all parts and operators manuals 6 ______ Customer has been instructed on equipment maintenance schedules and procedures 7 ______ Customer has been advised that the engine or power un...

Page 12: ...BLANK SHEET ...

Page 13: ...DAILY CHECKLIST 10 MACHINE CONTROLS 11 TRANSPORTING 19 MACHINE OPERATION 21 MAINTENANCE MACHINE MAINTENANCE 27 TROUBLESHOOTING GUIDE 35 SERVICING CUTTER WHEEL 37 SERVICING HYDRAULICS 42 SERVICING BELTS 45 SERVICING BEARINGS 49 SERVICING STUB SHAFT 51 TRACK SYSTEM MANUAL TAPER LOCK AND QD BUSHING INSTALL REMOVAL APPENDIX A CONTACT INFORMATION BACK ...

Page 14: ...te it Slowly experiment with the controls and gradually work yourself up to the full capabilities of this machine The Carlton Model SP6016 is a durable and profitable professional stump grinder Read this manual the engine manual along with the safety and operational decals on the machine Use proper safety precautions Follow the instructions provided and use common sense and your OX will perform li...

Page 15: ...ut any prior notification or obligation Inspect your new Carlton Stump Grinder as soon as you receive it Any damages incurred during shipment are not warranted and therefore not covered repairs You should have the truck driver verify or acknowledge any damages caused during shipment If not contact the truck lines as soon as possible with your complaint Any reference made to right left front or rea...

Page 16: ...el stance Track version is hydraulically expandable to 55 and retracts to 35 width to clear narrow fence gates Tapered roller bearings on cutter wheel jackshaft 1 thick Blanchard ground cutter wheel Low maintenance drive belt Carbide tipped cutter teeth Standard Cutter Wheel 20 teeth Optional Razor Wheel 36 teeth Easy engine belt adjustment Safety tie down loops Epoxy primer Key start High capacit...

Page 17: ...7 63 cm Height 50 127 cm Cutting Depth 16 40 64 cm Cutting Height 25 63 5 cm Cutting Swing 60 152 4 cm Number of Teeth on Cutter Wheel 36 Razor Wheel 20 Standard Wheel Cutter Wheel Diameter with Teeth 21 53 34 cm Fuel Tank Capacity 8 Gallons 30 3 Liters Hydraulic Tank Capacity 4 5 Gallons 17 Liters Approximate weights depending on engine and optional equipment Width is based on single wheel config...

Page 18: ... Height 60 152 4 cm Cutting Depth 14 35 56 cm Cutting Height 33 5 85 09 cm Cutting Swing 58 147 32 cm Number of Teeth on Cutter Wheel 36 Razor Wheel 20 Standard Wheel Cutter Wheel Diameter with Teeth 21 53 34 cm Fuel Tank Capacity 8 Gallons 30 3 Liters Hydraulic Tank Capacity 4 5 Gallons 17 Liters Approximate Weights and Height depending on engine and optional equipment Width is based on retracted...

Page 19: ...this symbol The Safety Alert Symbol will be accompanied by one of the following words DANGER WARNING or CAUTION A DANGER symbol means that if the instructions are not followed the possibility of serious personal injury or death is probable A WARNING symbol means that if the instructions are not followed there is a possibility of serious personal injury or death A CAUTION symbol means there is an u...

Page 20: ...on while running or during transport DO NOT move position or transport this machine while cutter wheel is engaged DO NOT operate any machinery while under the influence of alcohol or drugs prescription over the counter or otherwise DO NOT refill fuel tank while engine is hot running or indoors Danger of fire or explosion exists Fuel and its vapors are highly flammable and explosive Handle with car...

Page 21: ... Never leave the controls unattended while in operation Be sure machine is not capable of operation when left unattended Stop engine and remove key when repairing or adjusting machine or drive belts Keep engine in good condition service as instructed in engine manual DO NOT touch engine while running or hot serious burns may result Allow all machine parts to cool completely before servicing or adj...

Page 22: ...es it susceptible to tipping over sideways Overturning this machine can result in personal injury property damage and or seizing the engine While in transit positioning the cutter wheel uphill and as close to the ground as possible will minimize the danger of tipping over and maximize the steadiness of the machine When encountering a hill the best approach is straight up or straight down Avoid any...

Page 23: ...r part numbers Check fuel filter for debris or water Replenish fuel tank with fresh fuel Check condition and tightness of drive belts See Maintenance Section New belts will stretch and become loose as machine runs Check belt tension often when belts are new Check for any loose broken or missing teeth and pockets Inspect bolts hydraulic fittings wiring harnesses hoses and equipment for tightness we...

Page 24: ...ch operates the front tires directing them right or left UNIT TRAVEL FWD REV Shown as TRAVEL on Remote This switch operates the drive motors CUTTER WHEEL DOWN UP Shown as CUTTER HEAD DOWN UP on Remote Use this switch to raise and lower the cutter wheel BLADE UP DOWN Note may be labeled as TONGUE on Remote This switch raises and lowers the push blade at the front of the machine BOOM TRAVEL LEFT RIG...

Page 25: ... or when more power is needed for climbing For further control of the ground speed when in low gear use the ground speed adjustment valve see below SWING SPEED ADJUSTMENT VALVE Located on the side of the control panel unit this valve controls the swing speed of the cutter head Adjust swing speed for smooth operation Turn the valve control knob counter clockwise to slow the swing speed at high engi...

Page 26: ...me in the forward or reverse directions Use controls opposite REV FWD or FWD REV of each other to turn machine either right or left When rotating the machine try not to leave one track stationary while rotating the other one around as this could cause the machine to jump a track If it is desired to spin the machine counter rotate the tracks CUTTER WHEEL DOWN UP Shown as CUTTER HEAD DOWN UP on Remo...

Page 27: ...d at high engine speeds Close the valve by turning clockwise to allow the cutter wheel to move side to side at low engine speed GROUND SPEED ADJUSTMENT VALVE Located on the side of the control panel this valve controls ground travel speed when in low flow mode Turn the valve clockwise to increase speed and counter clockwise to slow speed GEAR HIGH LOW Same on Remote Gear control affects both the t...

Page 28: ...l for specific controls operation and service Emergency Stop Button E STOP On a HATOX remote Twist E stop to activate remote On an OMNEX remote Press button then toggle any switch on the remote to activate transmitter Within 10 seconds twist E Stop button clockwise and release to turn on the transmitter for use To turn off the transmitter and immediately shut off the engine Press E Stop button Tog...

Page 29: ...screws in the junction box lid Then remove the circuit panel by unlatching the plastic tabs on either side of the receiver housing The receiver panel will now slide out of the cap Note you may need to unplug the wiring harness before removing the circuit panel Be sure to plug harness back in before attempting to program remote Follow the instructions in the radio control manual to download the ID ...

Page 30: ...o the Remote On position then turn the machine key switch to the on run position to activate the transmitter This begins the pairing process Stay within the 3 feet range for a minimum of 10 seconds to allow pairing to complete Pairing is successful once the remote transmitter fault light goes out and the green Active light is flashing NOTE This is a programmable remote system which should be confi...

Page 31: ...to the on position To shut off the engine return the On Off switch to the Off position Refer to Machine Operations Section of manual for startup and shutdown procedures Ignition Switch Turn the ignition key switch clockwise one stop On position to turn the electrical system on The key should remain in the on position while the engine is running Turn the key fully clockwise Start position this will...

Page 32: ...afer all around LOADING RAMPS MUST BE STURDY AND ATTACHED TO THE TRANSPORT VEHICLE BEFORE ATTEMPTING TO LOAD UNLOAD THIS MACHINE TRAILER MUST BE SECURELY ATTACHED TO TOW VEHICLE BEFORE LOADING OR UNLOADING THE STUMP GRINDER Check trailer for security and make sure chains are properly installed Check tire inflation Check towing lights for proper operation Never transport with motor running Towing w...

Page 33: ...e machine is loaded lower the cutter head shut down engine and secure machine tightly with sufficient tie downs to prevent any movement in transit UNLOADING Undo tie down straps and check ramps for sturdiness and positioning Start engine increase RPM and raise cutter head to just clear deck and or ramp Continually adjust Cutter head up and down to keep the center of gravity as low as possible Proc...

Page 34: ...t a remote set the On Off switch to the Machine On position and follow Start Engine process The GEAR High Low selector switch is located on the side of the control box and must be set accordingly for all remote functions to operate properly Wheel Machine HIGH GEAR Track Machine LOW GEAR CAUTION Do Not operate the engine at an angle greater than 25 or severe engine damage will occur Proper engine o...

Page 35: ...er is operating there is a yellow ACTIVE light that will be flashing the light is indicated in the picture at the right Read the radio control manual for more information on the meaning of different lights and colors If the transmitter does not start check the transmitter for stuck switches it will not start with a switch in the ON position On the HATOX transmitter twist the E STOP button clockwis...

Page 36: ...er is still on and restart the engine by turning the key If you lose the connection light off repeat the procedure from the beginning and perform each step exactly as described Start engine at half speed and allow enough time for oil to circulate before proceeding OPERATING MACHINE Test controls for proper operation Note The GEAR and or FLOW controls on the remote should be in LOW for proper cutte...

Page 37: ...n position Test controls for proper operation speed and unobstructed movement Cutter head swing speed should be adjusted to a rate that will allow cutter wheel to pass through stump smoothly If jerking bouncing or significant drops in engine speed occur swing rate is too rapid and must be decreased Swing speed should be determined and adjusted with the controls in the full open position A bypass f...

Page 38: ...itioning machine to work at best advantages Raise cutter wheel clear of stump and return to center position Reduce engine speed to idle DO NOT TURN OFF MOTOR Engine must be allowed to cool slowly at idle for 3 5 minutes to avoid damage With engine at idle Approx 1000 rpm disengage drive belts by slowly releasing engagement handle Turn off motor Allow cutter wheel to come to a complete stop before ...

Page 39: ...to be removed when required to access a narrow entryway or gate Properly reattach the outer wheels before continuing with normal operations and cutting The track machine comes equipped with expandable tracks The expanded wide stance should be used when maneuvering around the work area and when operating the boom when cutting The narrow track stance should only be used when accessing narrow entrywa...

Page 40: ...draulic hoses and fittings for leaks tightness wear or damage Daily Repair or replace as needed See hydraulic servicing section for details DANGER More accidents occur while performing maintenance than any other time Use extra caution DO NOT PERFORM MAINTENANCE OF ANY KIND ON THIS MACHINE UNLESS The engine is turned off The ignition key has been removed The positive battery cable has been disconne...

Page 41: ...ATE STUMP CUTTER WITHOUT A COMPLETE SET OF TEETH Check setscrews in jackshaft bearings for tightness Weekly NOTE to access the jackshaft bearings you will need to remove the jackshaft cover Check setscrews in cutter wheel bearings for tightness Weekly Clean out Poly Chain guard by removing bottom portion of guard Weekly Woodchip buildup will wear or break Poly Chain belt 28 ...

Page 42: ...ded deflection measurement See illustration If the measurement is more than recommended deflection the belt tension is too loose If the measurement is much less than recommended deflection the belt tension is too tight Follow procedure for Belt Tension Adjustment CHECKING SHEAVE ALIGNMENT Place a straightedge against the outside face across both sheaves Check that both sheave surfaces are flush wi...

Page 43: ... less important wear may be harder to spot with just your eyes A sheave gauge usually consisting of plastic wedges shaped like a new belt can be inserted into the groove If the gauge doesn t fit squarely into the groove and you can see daylight around the edges your sheave is worn and must be replaced Inspect sprocket grooves for unusual or excessive wear Check for excessive wear by both visually ...

Page 44: ...chieved Adjust slide lock lever as needed to ensure it locks properly when engagement handle is in the disengaged position Check sheave alignment with a straightedge NOTICE Inspect and or repair the following before continuing with setting belt tension Grease and oil on the belt Grease and oil on a belt will cause rapid deterioration Clean oil and grease from the sheaves wipe the belt with a clean...

Page 45: ... tightening both jam bolts equally To loosen belt tension loosen the two bolts securing each cutter wheel bearing both sides Next loosen the inside jam nut on both front jam bolts then loosen the bolts Note The bearing shaft should move due to belt tension but if necessary tightening the rear jam bolt to slide the shaft Make slight and equal adjustments at a time and recheck belt tension and sproc...

Page 46: ...2 Purge until clean grease is seen JACKSHAFT BEARINGS 2 BOOMBEARINGS 2 3 ENGAGEMENT LEVER 1 1 2 Pumps with hand grease gun TURNTABLE BEARING 6 ENGINE SLIDE FRAME 6 5 STUB SHAFT BEARING 1 500 hour increments add 2 3 pumps with hand grease gun 6 TRACK TENSION CYLINDER TRX 2 Check tension daily lubricate as needed 7 TRACK FINAL DRIVE TRX 2 Change after initial 200hrs After that every 1000 hrs or annu...

Page 47: ...SP6016 MACHINE MAINTENANCE 7 6 34 ...

Page 48: ... tension too loose Belt out of alignment Tighten Align Pulleys Belt jumping off Engaging or disengaging belt at high engine RPM Belt keeper too far from belt Belt worn Pulley worn Only engage or disengage belts at low engine speeds Adjust keeper closer to belt Replace belt Replace pulley Cutter wheel vibration Tooth missing Pocket out of balance Improper tooth arrangement Replace missing teeth Alw...

Page 49: ... position On Off switch is bad Shutdown machine and switch to the Remote On position then restart Replace switch Traction loss of power Hydraulic motor worn Hydraulic pump going bad Replace Hydraulic motor Replace Hydraulic pump Refer to dealer service center Popping clicking noise in rear end when moving wheel machine Dual Wheel spacer not properly aligned with inner hub Loose dual wheel center b...

Page 50: ...th to this edge with gauge against pocket not against cutter wheel All teeth are set 1 1 4 out of the pocket to the edge of the carbide DANGER More accidents occur while performing maintenance than any other time Use extra caution DO NOT PERFORM MAINTENANCE OF ANY KIND ON THIS MACHINE UNLESS The engine is turned off The ignition key has been removed The positive battery cable has been disconnected...

Page 51: ... of teeth to cancel vibration Straight teeth are mounted in TWO OPPOSING OUTSIDE POCKETS A straight tooth must have a 45º tooth accompanying it in the same pocket set The opposite pocket set should have this same combination of straight and 45º teeth except with positions reversed Mounting these teeth opposite each other on the cutter wheel will cancel out damaging vibration The TWO OTHER OPPOSING...

Page 52: ...e pin will need to be removed and reinserted as wheel is rotated to change remaining teeth The teeth do not require a setting gauge The only requirement is to be installed in the proper direction and tightened to the proper torque as discussed in the next section NOTE When replacing a cutter wheel tooth replace the tooth and nut as a set and use anti seize on the threads CAUTION Do not operate mac...

Page 53: ...s the corner and this will turn the opposite corner out for use These teeth are tightened with nuts Torque on nuts is not to exceed 170 ft lbs All teeth on cutter wheel sides are Plow Bolt Bits When changing these teeth you must remove both teeth in the same pocket one on each side of the wheel When the nuts are torqued the pocket is jammed and the teeth can only be removed this way The pocket wil...

Page 54: ...ill hit the stump instead of the carbide thus causing a lot of vibration Once the shank is angled far enough back then begin sharpening carbide Cut shank with a standard rock and cut carbide with a silicone carbide or diamond rock WARNING Grinding carbide can be a health hazard Use a proper facemask to help prevent inhaling harmful materials while grinding 41 ...

Page 55: ...aulic oil every 500 hours of operation or at least once a year depending on use Flush the hydraulic tank when changing the hydraulic oil Replace oil if it is very dark contaminated has a burnt odor or if the machine has been stored for a long period of time Note Recommend Citgo AW46 hydraulic oil or equivalent Drain the hydraulic tank using the drain plug located on the bottom of the tank Dispose ...

Page 56: ...shing down into position displacing the old bushing Swing cylinder back into position Re install rod end to main frame using new pin assemblies REPLACING HYDRAULIC HOSES Place cutter wheel on ground before removing hydraulic hoses It is not necessary to drain the hydraulic system to replace hoses Loosen fitting and drain oil into suitable container for disposal Remove old hose and replace with new...

Page 57: ... go on and off as the temperature of the oil fluctuates Keep oil cooler fins clean Use a garden hose and a mild detergent CAUTION Do Not use a power washer as it may cause the fins to bend Do Not use an industrial strength detergent that may cause the metal to deteriorate Inspect all connections and hoses for leaks and wear Replace if necessary WARNING Hydraulic oil is under pressure Spraying flui...

Page 58: ... belt Install new belt then readjust and tighten belt keepers DANGER More accidents occur while performing maintenance than any other time Use extra caution DO NOT PERFORM MAINTENANCE OF ANY KIND ON THIS MACHINE UNLESS The engine is turned off The ignition key has been removed The positive battery cable has been disconnected The cutter wheel is disengaged All machine parts have come to a complete ...

Page 59: ...chieved Tighten jam nut if loose Adjust slide lock lever as needed to ensure it locks properly when engagement handle is in the disengaged position Replace cover and tighten all bolts GENERAL TENSIONING OF V BELT DRIVES A few simple rules about tensioning will satisfy most of your requirements 1 The best tension for the V belt drive is the lowest tension at which the belt will not slip under the h...

Page 60: ...shock load In a shock load failure the fibers are broken and over a period of time the belt will break down from the shock load and snap in half A broken belt with lost teeth indicates that the belt was loose When replacing the Poly Chain belt do not force the belt on over the sheave this can break the fibers After you have installed or re tensioned the Poly Chain belt you will have to re adjust t...

Page 61: ...oom Use the jam bolts on the cutter wheel bearings to adjust proper tension on the belt making sure to tighten or loosen them equally keeping the sprockets aligned Use a straight edge to check sprocket alignment after adjustments have been made Refer to the Machine Maintenance section for how to Check Belt Tension and Belt Tension Adjustments for the Poly Chain Belt Reposition front jam bolts agai...

Page 62: ...NG LIFE CUTTER WHEEL BEARINGS There are two 2 bearings on the cutter wheel shaft These bearings should be purged using grease EVERYDAY Purge until new grease is seen to keep dirt and moisture out PROPER MAINTENANCE IS CRITICAL TO ENSURE LONG BEARING LIFE DANGER More accidents occur while performing maintenance than any other time Use extra caution DO NOT PERFORM MAINTENANCE OF ANY KIND ON THIS MAC...

Page 63: ...turns to coat all surfaces with fresh grease Also inspect seals making certain that they are in proper position in grooves and intact Check tightness of mounting bolts and retighten if needed Be alert to changes in rotation unusual sounds and vibrations NOTICE This machine is lubed with Starplex II grease when it is delivered from the factory Starplex II is lithium complex soap grease which contai...

Page 64: ...hart REPLACE STUB SHAFT Remove the V belt following the instructions in the Servicing Belt Section of the manual Remove the engine belt keepers instead of just loosening the bolts and lay aside to put on new stub shaft plate assembly DANGER More accidents occur while performing maintenance than any other time Use extra caution DO NOT PERFORM MAINTENANCE OF ANY KIND ON THIS MACHINE UNLESS The engin...

Page 65: ...threaded holes to push the sheave off the bushing and remove the bushing and sheave Make sure to keep all machine parts and hardware together to make reassembly easier Remove the bolts holding the belt guard onto the machine and remove the belt guard Remove engine sheave by first removing bolts on outer stub shaft plate 5 16 18 x 3 4 bolt use 1 2 socket 52 ...

Page 66: ...coupling plate to avoid future damage and expense To remove the bearing sleeve and to access the coupling plate remove the bolts around the outside of the bell housing 3 8 16 x 1 4 bolt use 9 16 socket Inspect and replace any parts found defective or worn Replace coupling plate if damaged Prior to reinstalling the coupling plate apply anit seize coupling lubricant to the inside ID of the coupling ...

Page 67: ...ling plate Apply LocTite 242 blue 3 8 16 x 1 4 bolt use 9 16 socket Replace sheave and snap ring Apply anti seize to outside diameter of stub shaft splines Insert stub shaft into bearing sleeve Replace bolts around the outer sheave plate Apply LocTite 242 blue 5 16 18 x 3 4 bolt use 1 2 socket 54 ...

Page 68: ...nsion are very important for long bearing life Grease stub shaft bearing at the grease fitting on the end of the shaft Wipe off excess grease NOTE Excess grease will attract dirt DO NOT over grease over greasing could cause a hydraulic type lift on seals Follow the instructions in the Machine Maintenance section for frequency and application of grease Also see the Lubrication Chart Replace belt gu...

Page 69: ...1 RUBBER TRACK OPERATIONS MANUAL ...

Page 70: ...2 ...

Page 71: ...ns It is important not to carry out modifications to the track system which could compromise proper operation and safety Manufacturer is not responsible for any injury or damage caused by unauthorized modifications 1 3 Pressurized Items Avoid welding near pressurized hydraulic pipelines track tensioner track recoils or other flammable materials Excessive heating near to pressurized hydraulic pipel...

Page 72: ...ne hoist has an adequate load rating The below image demonstrates a track system being safely lifted with slings The belt lugs prevent the belt from slipping for this reason choker chains are not necessary Precautions Chains slings and hoists are identified by their safe load lifting capabilities Do not lift loads exceeding the rated capacity of chains sling or hoists Raise and lower the track sys...

Page 73: ... free from debris before moving the machine Make certain the tracks are not frozen to the ground before moving the machine Ensure no leakage of oil from gearbox roller and idler before and during tracking Never Attempt to track the machine if there is any build up of material around the tracks or drive sprockets Attempt to track the machine if the tracks are frozen to the ground Push or tow the ma...

Page 74: ...act with sharp edges particularly sharp concrete edges This point loads the track and can cause damage to the internal steel cords in the belt 5 Rubber track systems are designed to be used on smooth soft ground 6 Do not attempt to track over obstacles which are taller than the centerline of the idler 1 8 OPERATING TEMPERATURE The operating temperature range for the track systems is 14 F to 104 F ...

Page 75: ...raulic system since oil may be very hot when the machine has just been working Use only supplied approved replacement parts Use of unapproved parts will invalidate the warranty Dispose of lubricants in the proper manner Dispose of worn tracks in the proper manner 2 2 MAINTENANCE CHECKS Please note the maintenance intervals specified below are for track systems working under normal conditions If th...

Page 76: ...immediately tighten bolts and nuts to correct torque as per Appendix A replace damaged or worn components and refill the oil to recommended levels WARNING DO NOT operate the tracks with damaged or defective components Any persistent problem should be reported to the machine manufacturer ...

Page 77: ...rack as shown below The above conditions must be fulfilled on any new track system This must also be regularly checked and corrected where necessary by adding grease to the grease tensioner as described in Section 2 4 WARNING DO NOT operate the tracks with the belt incorrectly tensioned Too loose and there is a risk it could de track Too tight and damage could be caused to the system 3 3 16 in 2 3...

Page 78: ...rease chamber tightening the track If this valve is loosened grease will escape causing the track to de tension Shown is a typical idler and tensioner assembly used on the rubber track system This is supplied as a whole unit On some systems the assembly is supplied as individual components The grease inside the track tensioner Lithium EP2 is pressurized so care must be taken when loosening the gre...

Page 79: ...en the grease fitting by turning in a counterclockwise direction using gradual increments until the grease begins to be expelled Care must be taken not to loosen the grease fitting too quickly When the correct track tension has been obtained tighten the grease fitting by turning in a clockwise direction and clean away all trace of extruded grease Be sure not to over tighten the grease fitting If t...

Page 80: ... counterclockwise If the grease does not start to drain out then slowly rotating the track can help Insert steel tubes as shown and slowly rotate the track in reverse This draws the tubes between the idler and the belt and de tensions the track Slide the belt off at the idler end using the tubes to help if required then remove the belt from the sprocket end WARNING The above procedure involves hea...

Page 81: ...n the valve and slowly apply grease The Idler will gradually move out to its working position 5 Set to the correct tension using the test methods mentioned in section 2 3 6 Clean off any loose grease and refit tensioner cover plate 7 Lower the machine back to the floor and check the machine by briefly tracking in each direction checking for belt slip de tracking 8 If not tensioned correctly repeat...

Page 82: ...he level indicated To drain track the machine until a plug is at 6 o clock position as shown below Unscrew both plugs and allow all oil to discharge into a suitable container Dispose of waste oil in a safe and approved container Dispose of waste oil in a safe and approved way WARNING Do not fill oil in the track drive without checking oil level inside it All track systems are supplied by manufactu...

Page 83: ...15 2 6 LUBRICATION CHART ...

Page 84: ...GENERAL COMPONENTS Item Part No Description Quantity 1 ROLLER NUT 2 SPRING WASHER 3 WASHER 4 ROLLER 5 SPROCKET 6 GEARBOX MOTOR 7 FRAME 8 DRIVE COVER PLATE 9 RUBBER BELT 10 TENSIONER COVER 11 TENSIONER AND SPRING 12 IDLER ...

Page 85: ...ould be replaced immediately to prevent damage to the system 3 3 WEAR LIMITS To ensure the most economical use of the track systems it is important to determine the appropriate time to replace each of the worn parts Exact wear limits are dependent on the specific parts fitted to the track system supplied Please refer to the Parts Supplement relative to the specification of your track system to fin...

Page 86: ...e tensioner access plate removed see Section 2 4 1 make a visual inspection of the greaser looking for any signs of leaking grease Possible Cause If grease is leaking from the base of the greaser where it screws into the end of the tensioner either the gasket has failed and needs replacing or the greaser is not screwed in properly and needs tightening If grease is leaking from the end of the greas...

Page 87: ...e values of flow and pressure passing to the hydraulic motors is less than that required to drive the tracks see machine manufacturer s separate publication there may be a fault in the machine hydraulic system Check 2 Test the hydraulic pressure being applied to the brake release port on the gearbox In order to release the brake this should be fed with a pressure of between 12 and 50 bar Possible ...

Page 88: ...dentified by a plug situated on the outer face of the gearbox end cover shown fig 1 above 1 Unscrew the disengagement plug from the end cover with a male hex head wrench 2 Use appropriate size TYP M6x50 8 8 grade bolt and screw into the threaded hole of the first reduction sun gear 3 Pull out the first reduction sun gear from the gearbox 4 Fit the disengagement plug back in place to the end cover ...

Page 89: ... being supplied to the motors is different from one another the machine hydraulic pressure and flow settings may need to be adjusted Check 2 Test to ensure a pressure is being applied to the brake release function on the gearbox To release the brakes generally pressure ranges between 12 and 50 bar Possible Cause If the pressure being applied at the brake release port is below the required pressure...

Page 90: ...22 APPENDIX A BOLT TORQUE TABLE ...

Page 91: ... Lock Bushing Installation and Removal To Install TAPER LOCK Type Bushings 1 Clean the shaft bore of bushing outside of bushing and the sprocket sheave hub bore of all oil paint and dirt File away any burrs Note The use of lubricants can cause hub fracture DO NOT USE LUBRICANTS when installing tapered bushings 2 Insert the bushing into the sprocket sheave hub and align the holes All of the holes s...

Page 92: ... specified in Table 1 below Taper Lock Bushings Bushing Bolts Torque Wrench Style Qty Size lb ft lb in 1008 2 1 4 20 x 1 2 4 6 55 1108 2 1 4 20 x 1 2 4 6 55 1210 2 3 8 16 x 5 8 14 6 175 1610 2 3 8 16 x 5 8 14 6 175 2012 2 7 16 14 x 7 8 23 3 280 2517 2 1 2 13 x 1 35 8 430 3020 2 5 8 11 x 1 1 4 66 7 800 3525 3 1 2 13 x 1 1 2 83 3 1000 4030 3 5 8 11 x 1 3 4 141 7 1700 4535 3 3 4 10 x 2 204 2 2450 504...

Page 93: ...ft bushing bore outside of bushing and the sprocket sheave hub bore of all oil paint and dirt File away any burrs Note Do not lubricate the bushing taper hub taper bushing bore or the shaft Doing so may result in sprocket sheave hub fracture DO NOT USE LUBRICANTS 2 For a conventional mount assemble the sprocket sheave and bushing combination by sliding the sprocket sheave taper bore into position ...

Page 94: ...h Style Qty Size lb ft lb in H 2 1 4 x 3 4 7 9 95 JA 3 10 24 x 1 4 5 54 SH SDS 3 1 4 20 x 1 3 8 9 0 108 SD 3 1 4 20 x 1 7 8 9 0 108 SK 3 5 16 18 x 2 15 0 180 SF 3 3 8 16 x 2 30 0 360 E 3 1 2 13 x 2 3 4 60 0 720 F 3 9 16 12 x 3 5 8 75 0 900 J 3 5 8 11 x 4 1 2 135 0 1620 M 4 3 4 10 x 6 3 4 225 0 2700 N 4 7 8 9 x 8 300 0 3600 P 4 1 8 x 9 1 2 450 0 5400 W 4 1 1 8 7 x 11 1 2 600 0 7200 S 5 1 1 4 7 x 15...

Page 95: ...Appendix A ...

Page 96: ...BLANK SHEET ...

Page 97: ...r working at its best Your authorized J P Carlton dealer knows your local conditions and is ready to deliver fast professional and expert service and or parts when you need it most Visit our website to find a dealer near you www stumpcutters com 800 243 9335 864 578 9335 ATTENTION Please have the machine Model and Serial Number available when contacting one of our parts and service professionals ...

Page 98: ...1 3 6 1 4 4 3 6 5 7 6 3 4 5 4 4 ...

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