Model Hurricane RS Model Hurricane TRX Machine Serial # Engine Model & Spec # Engine Serial # HPTO/Clutch Model & Spec # Clutch Serial # Purchase Date Dealer Carlton 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.
DIESEL ENGINE EXHAUST WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproduction harm.
HURRICANE TRACK SAFETY ALERT
HURRICANE TRACK SAFETY ALERT
HURRICANE TRACK SAFETY ALERT
HURRICANE TRACK SAFETY ALERT
STUMP GRINDER LIMITED WARRANTY J.P. Carlton Co. Inc., hereafter referred to as the “Manufacturer”, warrants each new Carlton Grinder to be free of defects in workmanship and material for a period of one year. This warranty takes effect upon delivery to the original retail purchaser. The manufacturer, at its option, will replace or repair, at a point designated by the manufacturer, any parts which appear to have been defective in material or workmanship.
STUMP GRINDER LIMITED WARRANTY EXPLANATION OF LIMITED WARRANTY The manufacturer will not reimburse the customer or dealer labor cost incurred for installing “bolt-on” or “slip-on” items, such as pumps and motors, bearings, belts, pulleys, etc. The manufacturer will provide replacement parts at no cost to the customer for defective parts during the warranty period. Defective parts must be returned to J.P. Carlton Company.
Warranty Validation Form Congratulations on your purchase of a Carlton Stump Grinder. This product has been designed and manufactured to provide years of profitable service while minimizing maintenance and downtime. Please take the time now to complete this warranty validation form. This information is necessary for Carlton to instate your warranty. Return Form To: J.P. Carlton Company, Div. D.A.F. Inc.
Hurricane Track TABLE OF CONTENTS INTRODUCTION FOREWORD 1 GENERAL INFORMATION 2 MACHINE FEATURES 3 MACHINE SPECIFICATIONS 4 OPERATION SAFETY PRECAUTIONS 5 DAILY CHECKLIST 10 MACHINE CONTROLS 11 TRANSPORT MACHINE 20 MACHINE OPERATION 22 MAINTENANCE MACHINE MAINTENANCE 26 LUBRICATION CHART 29 TROUBLESHOOTING GUIDE 30 SERVICING BELTS 32 SERVICING BEARINGS 42 SERVICING CUTTER WHEEL 44 SERVICING HYDRAULICS 51 WIRING DIAGRAM 54 ENGINE BELT ASSEMBLY 55 POLY CHAIN® BELT ASSEMBL
Hurricane Track FOREWORD Congratulations on your purchase of a new Carlton® Professional Stump Grinder! Carlton® Stump Grinders have a reputation for superior performance and reliability. A machine is not profitable if it’s broken-down and we do our absolute best to help you avoid costly downtime. Each and every machine has been over designed and overbuilt to ensure years and years of trouble-free operation. In this, we take pride.
Hurricane Track GENERAL INFORMATION The J. P. Carlton Company constantly strives to create the best equipment available in the stump cutting industry. Therefore, the material in this manual is correct at the time of publication. Carlton® reserves the right to make improvements, modifications and even discontinue features, as we deem necessary to meet our goal. Carlton® also reserves the right to discontinue models without any prior notification or obligation.
Hurricane Track MACHINE FEATURES Available Machine Features: • • • • • • • • • • Proportional wireless remote control with tether back-up Continuous 360° rotation swing Swing motor brake lock Clutch actuated engine engagement RS – 81” track length RS – 12” track footprint TRX – 97” track length TRX – 16” track footprint Direct drive hydraulic pump Proportional solenoid operated • • • • • • • • Oil cooler with electric fan Hydraulic oil and fuel filters Large hydraulic oil reservoir with lockable cap
Hurricane Track MACHINE SPECIFICATION Hurricane RS General: Weight: ------------------ 8500 Pounds Length:------------------- 170” Height: ------------------- 83” Width:-------------------- 65” Controls: ----------------- Wireless Remote w/ Tether Back Up Fuel Capacity:----------- 36 Gallons Battery:------------------- 800 CCA Track Length: ----------- 81” Track Footprint: -------- 12” Wireless Remote: ------- Full Proportional Control Engine: (Varies depending on selection of engine make & model) Manufa
Hurricane Track MACHINE SPECIFICATION Hurricane TRX General: Weight: ------------------ 12500 Pounds Length:------------------- 185” Height: ------------------- 83” Width:-------------------- 78” Controls: ----------------- Wireless Remote w/ Tether Back Up Fuel Capacity:----------- 50 Gallons Battery:------------------- 800 CCA Track Length: ----------- 97” Track Footprint: -------- 16” Wireless Remote: ------- Full Proportional Control Engine: (Varies depending on selection of engine make & model) Manu
Hurricane Track SAFETY PRECAUTIONS Before operating the stump cutter, read this manual, the engine manual, and all the safety decals on the machine. Know all parts of the machine and their functions, especially the shut down procedures in case of emergency. No inexperienced person may operate machine. Inexperience may cause injury. SAFETY FIRST ALWAYS! This is the Safety-Alert Symbol. This symbol is placed on the machine and in the manual to alert the operator to the potential for bodily injury or death.
Hurricane Track SAFETY PRECAUTIONS Be Safe and Practice Safe Operation using the following guidelines. • • • • • • • • • • • • • • • Any individual operating this machine must first read and understand this manual, the engine manual, all component manuals, and all safety decals on machine. DO NOT permit children to operate machinery or to play near machinery during operation. Always wear face shield and hearing protection during operation. Loud noise and flying debris may cause severe injury.
Hurricane Track • • • SAFETY PRECAUTIONS Battery fumes are explosive. Recharge battery in an open area away from fire, sparks, or other sources of ignition. Battery acid can cause severe burns. Keep away from eyes, skin, and clothing. Always remove battery before welding on equipment. • PT TECH HPTO WARNING: to avoid any electrical malfunction, the user should disconnect the wiring harness from the controller when welding on the equipment. Failure to do so may result in loss of controller warranty.
Hurricane Track • • • • • • • SAFETY PRECAUTIONS Allow all machine parts to cool sufficiently before servicing or making adjustments. Hot machine parts can cause severe burns. Do not run the machine without a complete number of teeth in the cutter wheel tightened to the correct torque. Park machine on level surfaces only. Lower cutter head to the ground. Do not operate stump cutter in dark, dim lit, or concealed areas. Keep machine clean and clear of debris to eliminate fire hazard.
Hurricane Track DAILY CHECKLIST DAILY CHECKS SHOULD BE PERFORMED BEFORE STARTING ENGINE FOR THE DAY. DO NOT INSERT KEY INTO ENGINE UNTIL ALL CHECKS HAVE BEEN COMPLETED. • • • • • • • • • • • • Check engine oil at dipstick, located inside the cover of the engine. Engine must be level. Boom in raised position will not affect the engine position; machine must be on level ground. Add recommended oil as required (see engine manual). Check fuel filter for debris or water.
Hurricane Track MACHINE CONTROLS ENGINE CONTROLS – Refer to the engine manufacturer’s operating manual for controls, operation and service. Never weld on a machine without disconnecting the ECU on the engine. DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR. PROPER ENGINE OIL LEVEL MUST BE MAINTAINED TO ACHIEVE MAXIMUM ANGLE OF OPERATION OF 25°. (See Engine Owner’s Manual for proper oil level.
Hurricane Track MACHINE CONTROLS HYDRAULIC CONTROLS • A series of hydraulic controls are located on the radio control transmitter and are clearly marked for operation. All machine controls are operated from the radio control transmitter. RIGHT TRACK – LEFT TRACK • The radio control transmitter has right and left track paddles as well as a paddle for both tracks. To operate the paddles push them toward the direction you want to move (Fwd or Rev).
Hurricane Track SWING PADDLE • The swing paddle controls the rotation and moves the machine back and forth in a right and left direction as well as a continuous 360° rotation. • The swing knob controls how fast the machine moves back and forth when operating the swing paddle. Turn the knob clockwise to increase swing speed or counter-clockwise to decrease swing speed. The swing needs to be set at a speed that will allow smooth sweeping cuts across the stump.
Hurricane Track THROTTLE • The radio control transmitter has a throttle switch for the operator to control the engine speed. Push the switch away from the operator to increase the engine speed and pull the switch toward the operator to decrease engine speed. The engine speed must be at idle to engage the cutter wheel. MACHINE CONTROLS THROTTLE SWITCH CLUTCH SWITCH CLUTCH • The clutch can be engaged from the transmitter.
Hurricane Track MACHINE CONTROLS MACHINE HYDRAULIC CONTROLS • A series of hydraulic controls are located on the radio control transmitter and the machine and are clearly marked for operation. DO NOT USE THE MACHINE MOUNTED CONTROLS TO GRIND STUMPS. The machine mounted control levers are to be used only for positioning the machine at slow speeds and to check hydraulic operation. RIGHT TRACK – LEFT TRACK • The first two machine levers, control the forward and reverse movement of the right and left tracks.
Hurricane Track MACHINE CONTROLS SWING ROTATION • The third lever, in the middle, is the swing rotation and moves the machine back and forth in a right and left rotation as well as a continuous 360° rotation. DO NOT GRIND STUMPS USING THE MACHINE MOUNTED SWING ROTATION LEVER. SWING BRAKE • The swing brake switch locks or unlocks the swing brake. The brake must be unlocked to operate the swing rotation lever and move the cutter head from left to right.
Hurricane Track PT TECH CLUTCH CONTROL • The PT TECH Clutch control console is located at the operators’ station. The engine must be at idle to engage or disengage the PT TECH clutch. With the engine at idle hold the engage/disengage button until the green engage light comes on. The PT TECH clutch will now go through a series of bumps to get the cutter wheel started. • The Power LED light in the upper left illuminates green to show the clutch is receiving switched power from the ignition.
Hurricane Track MACHINE CONTROLS SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track TROUBLESHOOTING MACHINE CONTROLS LOW BATTERY LIGHT SEE THE RADIO CONTROL MANUAL FOR ANY OPERATING PROBLEMS WITH THE RADIO RECEIVER & TRANSMITTER (Included in the back of this manual) • • • • • • • Contact your Carlton dealer if you need assistance not the radio control manufacturer. Check the batteries to make sure they are providing enough power to operate the transmitter.
Hurricane Track TRANSPORT MACHINE DO NOT TOW! THE HURRICANE TRX IS DESIGNED TO BE TRANSPORTED TO THE JOB SITE AND WILL MOVE UNDER ITS OWN POWER ONCE ON SITE. SECURE HURRICANE TRACK MACHINE TO TRAILER USING TIE DOWN STRAPS ATTACHED TO THE TIE DOWN RINGS ON THE SIDE OF THE MACHINE. The Hurricane TRX requires a lowboy trailer that will support and carry 12000 pounds. The Hurricane RS requires a trailer rated for at least 10000 lbs.
Hurricane Track • • TRANSPORT MACHINE THE TRAILER MUST BE SECURELY ATTACHED TO THE TOW VEHICLE BEFORE LOADING OR UNLOADING THE STUMP GRINDER. DO NOT LOAD OR UNLOAD ON ANYTHING OTHER THAN LEVEL GROUND. LOADING • Start the machine using the key-switch on • • • • • the machine control panel and turn on the radio control and push the ON button. Increase engine RPM and raise cutter head to clear the ground. Position the machine behind the trailer and close to the loading ramps.
Hurricane Track MACHINE OPERATION STARTING – ALL OPERATORS MUST READ THIS MANUAL, ALL MACHINE DECALS, AND THE ENGINE AND OTHER COMPONENT MANUALS BEFORE STARTING. • • • • • • • • • • • • • • • • ALWAYS PERFORM DAILY CHECKLIST BEFORE STARTING MACHINE FOR THE DAY. REPLENISH FUEL AND OIL DAILY. AVOID TRANSVERSING SLOPES. ASCEND/DESCEND HILLS STRAIGHT UP AND DOWN NEVER STRAIGHT ACROSS. DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR.
Hurricane Track • • • • MACHINE OPERATION The E-STOP light will flash red quickly. Release the E-STOP button by twisting it clockwise. Release the E-STOP button within 10 seconds or the unit will power down. The Active light will flash yellow. Test controls for proper operation. LIGHT PANEL Read the radio control manual supplied in the back of this manual for more information. • • • • • Position machine at stump with cutter wheel a slight distance from stump.
Hurricane Track • • • • • • Release the swing brake by pressing the switch down and test cutter wheel swing controls for proper operation. DO NOT ALLOW ANYONE TO BE NEAR THE MACHINE WHEN THE SWING IS BEING OPERATED. THE ENTIRE MACHINE UPPER FRAME ROTATES WHEN THE SWING IS OPERATED. The cutter head should be moved back and forth in a smooth, flowing manner. The radio control is a proportional controller meaning that the amount of pressure applied to the control determines the speed of the function.
Hurricane Track • • • • • • • • • • MACHINE OPERATION Continue cutting the stump by adjusting the cutting head progressively lower until the stump is cut well below ground level. Raise and swing cutter wheel clear of stump and position machine closer to stump for next series of passes. Lower and continue cutting. Continue in this manner until stump has been removed. Larger stumps may require repositioning machine to work at best advantages.
Hurricane Track MACHINE MAINTENANCE SAFETY • • • • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track • The Hurricane track machine may come with an inline fuel filter. This filter must be changed every 50 hours of operation. Clamp the hoses on both sides of the filter and remove and replace with a new filter. Remove clamps before starting the machine. Fuel in the hose will spill out, clean any spilled fuel before operating the stump grinder. • Inspect air filters daily. REPLACE, if necessary, WITH FACTORY AIR FILTERS ONLY. Do not blow out filters or tap filters on the ground.
Hurricane Track • • • • • • • • MACHINE MAINTENANCE Check hydraulic oil daily and replenish as necessary. A site glass is provided for easy viewing. If oil can be seen in glass, there is enough oil in the tank. Do not fill the tank more than 7/8 full; operating at high temperature will cause oil to expand and spill over if tank is full. The machine is equipped with Citgo AW32 hydraulic oil at time of manufacture; use same or equivalent.
Hurricane Track MACHINE MAINTENANCE SAFETY • • • • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track • The Hurricane track machine may come with an inline fuel filter. This filter must be changed every 50 hours of operation. Clamp the hoses on both sides of the filter and remove and replace with a new filter. Remove clamps before starting the machine. Fuel in the hose will spill out, clean any spilled fuel before operating the stump grinder. • Inspect air filters daily. REPLACE, if necessary, WITH FACTORY AIR FILTERS ONLY. Do not blow out filters or tap filters on the ground.
Hurricane Track • • • • • • • • MACHINE MAINTENANCE Check hydraulic oil daily and replenish as necessary. A site glass is provided for easy viewing. If oil can be seen in glass, there is enough oil in the tank. Do not fill the tank more than 7/8 full; operating at high temperature will cause oil to expand and spill over if tank is full. The machine is equipped with Citgo AW32 hydraulic oil at time of manufacture; use same or equivalent.
Hurricane Track • The Hurricane track model, as well as all of our machines, is built to be a rugged performer. Your new machine is sturdy and our design goals are simplicity and reliability. LUBRICATION CHART • A regularly scheduled maintenance program will pay big dividends in machine life, performance, and avoided downtime. Lubrication Schedule • Use Texaco® Starplex II grease.
Hurricane Track TROUBLESHOOTING GUIDE COMPLAINT CAUSE CORRECTION Engine will not start. (See Engine Manufacturer Manual for further information.) Belt Squeal. • • • Loose ground wire. Loose hot wire. Dead battery. • • • Clean and tighten. Clean and tighten. Recharge or replace. • Belt tension too loose. • • • • Belt out of line. Tooth missing. Pocket out of balance. • • • • Improper tooth arrangement. • • • Bad pocket. Dirt in pocket. • • • • Worn cutter wheel.
Hurricane Track TROUBLESHOOTING GUIDE COMPLAINT CAUSE CORRECTION Loss of oil pressure. • Hose leaking oil. • • • • • Hydraulic oil level low. Oil filters dirty or clogged. Oil cooler has a leak. Pressure switch wires loose or broken. Pressure relief valve dirty. • • • • • • • Power light goes out on PT Tech control panel. Roar in machine when cutter wheel is engaged. Check all hoses for leaks using a board or cardboard. DO NOT use hand or finger. Replace hose as necessary. Replenish tank.
Hurricane Track SERVICING BELTS Servicing Engine Belt SAFETY • • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track SERVICING BELTS Servicing Engine Belt • There is a dust protection plate, in two sections, that goes behind the engine sheave and bolts to the engine belt guard using four 1/4” bolts and nuts. Loosen all four bolts enough to be able to move the engine to loosen the belt and remove it. LOOSEN NUTS ON DUST PROTECTION PLATE – 4 PLACES • • There are two adjustment bolts at the front of the machine attached to the engine mounting bolts.
Hurricane Track SERVICING BELTS Servicing Engine Belt • When the belt is loose enough, remove the belt by pulling it off the engine sheave and then the jackshaft sheave. Removing the belt from the engine sheave first should be easier because of the size of the sheave. • Replace the engine belt. • After replacing the engine belt, reposition the engine by loosening the inside jam nuts and then turning the outside jam nuts to pull the engine back into position.
Hurricane Track SERVICING BELTS Servicing Engine Belt • When the belt is tightened slightly, check the alignment of the sheaves using a straight edge. If sheaves are out of line, use the adjustment nuts to align the sheaves. You will need to loosen one adjustment bolt’s jam nut and tighten the other, making only slight adjustments until the sheaves are aligned. When the sheaves are aligned, check the belt tension.
Hurricane Track Servicing Engine Belt • When belt tension is adjusted properly, tighten all four engine bolts (3/4”) and torque bolts to 300 ft-lb. Next make sure all jam nuts on the adjustment bolts are tightened. • Retighten the bolts on the dust protection plate that is behind the engine sheave and attached to the belt guard. Make sure the sections of the plate are pushed as close together as possible without rubbing the engine shaft to keep out as much debris as possible.
Hurricane Track SERVICING BELTS Servicing Poly Chain® Belt SAFETY • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track SERVICING BELTS Servicing Poly Chain® Belt • Loosen the Poly Chain® belt by loosening the cutter wheel bearing bolts; DO NOT remove the bolts. There are two lock nuts on each bolt that have to be loosened to loosen the bearing bolts. MARK THE LOCATION OF EACH BEARING TO MAKE ADJUSTMENTS EASIER WHEN BELT IS REPLACED. • There is a dust protection plate, in two sections, that goes behind the jackshaft sprocket and bolts to the Poly Chain® belt guard.
Hurricane Track SERVICING BELTS Servicing Poly Chain® Belt • • Remove the belt. Place the new belt on the jackshaft sprocket first and then put the cutter wheel sprocket in the belt and put it on the cutter wheel shaft. Replace the bushing in the sprocket and position it as close to the mark made earlier as possible. Replace the three screws and just get them started in each of the holes. Tighten the screws a little at a time working from one to another until the bushing is starting to get tight.
Hurricane Track SERVICING BELTS Servicing Poly Chain® Belt • • • • Check the Poly Chain® belt tension. See the chart that follows for tensioning specifications. If belt tension needs adjustment, use the jam bolts to move the cutter wheel to get the proper tension. Remember to make equal adjustments to both bearings to keep the sprockets aligned and the belt running true. NOTE: These instructions are also for making adjustments to worn belts that just need the tension adjusted.
Hurricane Track SERVICING BELTS Servicing Poly Chain® Belt • Retighten all the bolts and nuts in the belt guard. The nuts are easily accessible on the back of the guard. • Replace all 14 bolts with flat and lock washers. Tighten the bolts in the belt guard covers. NEVER run a machine without the guards and covers in place and secured properly, severe personal injury could occur.
Hurricane Track SERVICING BEARINGS Always clean tip of grease gun fitting and grease fitting on machine before attaching hose to prevent dirt from being forced into machine parts. After applying grease, remove excess grease from the grease fitting to prevent dirt build up. There are four (4) bearings on the jackshaft; two (2) mounted on the inside of the supports and two (2) mounted on the outside of the supports. These bearings should be greased daily to keep dirt and moisture out.
Hurricane Track SERVICING BEARINGS TURNTABLE BEARING While turntable bearings require almost no attention, what little they are given will pay big dividends in long life, high performance, and trouble free service. Lubricate the bearing every 100 operating hours. When greasing the turntable bearing, lower the cutter wheel to the ground. Apply grease to the grease fitting shown at the right. Lift the cutter wheel off the ground, rotate the upper frame 90°, lower the cutter wheel, and apply grease again.
Hurricane Track SERVICING CUTTER WHEEL SAFETY • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • • • Inspect pockets, teeth and bolts for damage • and replace as required. When replacing pockets, always replace • new pockets across form each other in order to prevent vibration. Replacement teeth must be carbide tipped • and have like design as provided with the machine. Use anti-seize on threads to prevent bolts from “freezing up” in cutter wheel pockets.
Hurricane Track SERVICING CUTTER WHEEL Hurricane RS OPTIONAL: Sandvik® Dura Disk II Cutter Wheel • • • • • • • • THE PICTURES SHOWN BELOW ARE FOR A DIFFERENT MACHINE BUT THE WHEEL CONFIGURATION IS THE SAME. If the Hurricane RS is supplied with the optional Dura Disk II cutter wheel, there are sixty-eight (68) teeth to a complete set. There are twelve (12) Short Plow Bolt Bits (Carlton part #0450121) and fifty-six (56) Plow Bolt Bits (Carlton part #0450120).
Hurricane Track SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • • • • • • • Inspect pockets, teeth and bolts for damage and replace as required. When replacing a cutter wheel tooth, replace the tooth and nut as a set and use anti-seize on the threads. When replacing teeth and pockets, also replace the teeth and pockets across from each other diagonally in order to maintain wheel balance and prevent vibration.
Hurricane Track SERVICING CUTTER WHEEL Hurricane TRX OPTIONAL: Sandvik® Dura Disk II Cutter Wheel • • • • • • • • If the Hurricane TRX is supplied with the optional Dura Disk II cutter wheel, there are one hundred four (104) teeth to a complete set. There are sixteen (16) Short Plow Bolt Bits (Carlton part #0450121) and eighty-eight (88) Plow Bolt Bits (Carlton part #0450120). DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED.
Hurricane Track SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • • • • • • • Inspect pockets, teeth and bolts for damage and replace as required. When replacing a cutter wheel tooth, replace the tooth and nut as a set and use anti-seize on the threads. When replacing teeth and pockets, also replace the teeth and pockets across from each other diagonally in order to maintain wheel balance and prevent vibration.
Hurricane Track SERVICING CUTTER WHEEL TOOTH SHARPENING Begin by chamfering shank back past edge of carbide. You do this because if it is not back far enough the shank will hit the stump and not 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 the carbide with a silicone carbide or diamond rock. CAUTION: GRINDING CARBIDE CAN BE A HEALTH HAZARD.
Hurricane Track SERVICING HYDRAULICS SAFETY • • • • • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE. OTHERWISE SEVERE PERSONAL INJURY COULD OCCUR AS WELL AS MACHINE DAMAGE.
Hurricane Track • • • • • There are three hydraulic filters on the Hurricane track machine. Two are return filters and the other is a highpressure line filter. Replace all hydraulic filters after the first 50 hours of operation for a new machine. Thereafter, replace all filters every 200 hours of operation. Unscrew the old filters and O-rings on the return lines and discard properly. Replace with new filters and new Orings. Screw in filters hand tight only.
Hurricane Track • • SERVICING HYDRAULICS Inspect hydraulic hoses and fittings daily for leaks, tightness, wear, or damage. Repair or replace as needed. FLUID UNDER PRESSURE CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY. CHECK HOSES AND FITTINGS USING A BOARD OR CARDBOARD; DO NOT USE HAND OR FINGER. SEEK IMMEDIATE MEDICAL ATTENTION IF SKIN IS PENETRATED. ALWAYS WEAR EYE PROTECTION. READ PT TECH HPTO MANUALS FOR COMPLETE SERVICE INFORMATION.
Hurricane Track MACHINE WIRING 54
Hurricane Track ENGINE BELT ASSEMBLY Hurricane RS ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 19040079 0150304 0150206 0400121B 0250109 0250182B 0250127 0250186 19040080 0150404 0150303 0150119B 19040082 0150218 DESCRIPTION Weldment, Engine Belt Base 1/2”-13 x 1 1/2” Carriage Bolt 1/2” Flat Washer 1/2”-13 Lock Nut V-Belt – 6/B173 Engine Sheave – 6B8.0 SF Tapered Bushing – SF x 2 1/8 Tapered Bushing – SF x 2 7/16 Jackshaft Sheave – 6B18.
Hurricane Track ENGINE BELT ASSEMBLY Hurricane TRX ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 19040073 0150304 0150206 0400121A 0250185 0250182A 0250125A 0250148 19040074 0150404 0150303 0150119B 19040076 0150218 DESCRIPTION Weldment, Engine Belt Base 1/2”-13 x 1 1/2” Carriage Bolt 1/2” Flat Washer 1/2”-13 Lock Nut V-Belt – 8RB195 Engine Sheave – 8B6.8 SF Tapered Bushing – SF x 2 1/2 Tapered Bushing – F x 3 3/16 Jackshaft Sheave – 8B18.
Hurricane Track POLY CHAIN® ASSEMBLY Hurricane RS ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 19040078 16 17 18 19 0150304 0150206 0250151 0250151A 0250150 0400124B 19040077 0150404 0150303 0150119B 19040081 0150218 DESCRIPTION QTY Weldment, Poly Chain® Base 1/2”-13 x 1 1/2” Carriage Bolt 1/2” Flat Washer 1/2”-13 Lock Nut Cutter Wheel Sprocket – 14M-56S-125 Tapered Bushing – 4535 x 2 15/16 Jackshaft Sprocket – 14M-38S-125 Key – 3/4” Square x 3 1/2” Key – 3/4” Square x 4 1/4” Poly Chain® B
Hurricane Track POLY CHAIN® ASSEMBLY Hurricane TRX ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 19040034 11 12 13 14 15 16 17 18 19 0150304 0150206 0250151 0250151A 0250150 0400124A 19040024 0150404 0150303 0150119B 19040075 0150218 DESCRIPTION Weldment, Poly Chain® Base 1/2”-13 x 1 1/2” Carriage Bolt 1/2” Flat Washer 1/2”-13 Lock Nut Cutter Wheel Sprocket – 14M-56S-125 Tapered Bushing – 4535 x 2 15/16 Jackshaft Sprocket – 14M-38S-125 Key – 3/4” Square x 3 1/2” Key – 3/4” Square x 4 1/4” Poly Chain® Belt –
TRACK MAINTENANCE RUBBER TRACK ON HURRICANE TRX 1
TRACK MAINTENANCE 2 3 1 2
TRACK MAINTENANCE 3
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TRACK MAINTENANCE 6
TRACK PARTS LIST 7
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TRACK PARTS LIST 15
TRACK PARTS LIST 16
STUMP CUTTERS MODEL TYPE ENGINE HP FUEL CUTTING DEPTH CUTTING HEIGHT CUT SWING NO. TEETH WHEEL DIA. WHEEL THICKNESS TONGUE EXTENSION WEIGHT (lbs.) 900H WalkBehind Honda 13 Gas 9" 21" N/A 12 12.25" .5" N/A 220 SP2000 WalkBehind Kohler 27 Gas 24" 27" N/A 16 19" .5" N/A 695 SelfPropelled Kohler 27 Gas 13" 34" 40" arc 20 21" 1" 30" 1,550 SelfPropelled BriggsVanguard 35 Gas 13" 34" 40" arc 20 21" 1" 30" 1,650 SelfPropelled Lombardini 28.
Installation and Maintenance Bulletin HPTO8TD-100 January 10, 2002 Hydraulic Power Take-off Rotating equipment is potentially dangerous and should be properly guarded. The user should check all applicable safety codes and provide suitable guards. The HPTO™ Hydraulic Power Take-off is a hydraulically actuated, enclosed dry clutch that requires no adjustment throughout its wear life. During a torque spike, the clutch will act as a torque limiter by slipping to absorb the shock load.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 4. Install flywheel ring gear to engine flywheel using the “Flywheel Mounting Bolts”. Torque all FLYWHEEL BOLTS to 44 lb-ft. ATTENTION: do not install washers under the heads of the bolts, as this may cause interference with the speed pickup that is installed later. 4. Check that the oil return line from the clutch manifold will be isolated from any return line that is pressurized.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 17. Insure that there is a clean 15-micron minimum oil filter in the hydraulic system. 8. Once the HPTO housing is piloted and flush with the engine housing, you can remove the crane support. 9. Install customer supplied sheave and QD bushing to the output shaft of the HPTO. Insure that belts (once installed) will be aligned and track straight. 10. Tension Belts according to Equipment Manufactures specifications. 11.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF MAINTENANCE INSTRUCTIONS The HPTO requires simple routine maintenance by maintaining the proper oil level in the hydraulic reservoir and replacing the oil filter when required by the equipment manufacturer. Maintenance and inspections should be performed as follows. SERVICE INSTRUCTIONS The HPTO can be reconditioned in the field or sent back to PT Tech. Contact PT Tech if any portions of these service instructions are unclear.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 9. Remove all seals from piston, shaft and backplate (Items 25,17 & 18). 21. Remove two seals from endcover (Items 12 & 13). 10. Remove quantity of three springs (Item 21). 22. Clean area around manifold and endcover. 11. Remove endplate (Item 8) by utilizing the 3/8-16 threaded holes in the endplate and ½-13 threaded hole in the end of the shaft. Important: Keep endcover and manifold ports clean and free from debris.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REBUILD INSTRUCTIONS Refer to exploded view drawing HPTO8TD-100 sheet 2 of 2. SHAFT SHOULDER Endcover Assembly 1. Apply Loctite 620 to steel cage of seals (Items 12 &13). 2. Install qty of 2, seals (Items 12 &13) into bore in endcover (Item 6). Press seals lightly. Note the direction of seal lip on drawing per Figure 1. Figure 1 Figure 2 3. Apply Mobilfluid 424 oil or similar to seal lip (Items 12 & 13). GREASE GREASE 4. Install qty.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF orientation of the dimpled side of the rings are extremely important. removed from the manufacturers package. 7. Endcover Sub-assembly ATTENTION: Check for burrs or debris in bore of endcover at oil inlet and outlet holes. Lightly lube ID and OD of bearing with Mobilifluid 424 or similar oil. Thread ½-13 rod into shaft. Use a bearing press fixture that contacts the inner bearing race. Install bearing and fixture over threaded rod.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Note: do not use any washers. Note: orientation of housing to endcover as shown on assembly drawing.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Clutch Sub-assembly 1. Press qty. of 3, dowel pins (Item 3) into endplate (Item 8). Apply Loctite 609 to dowel pins before installing. Dowel pins should be 1-1/4” above surface. 10. Install backplate (Item 10) over shaft end and into piston cavity. ATTENTION: do not pinch o-ring in O.D. groove of fixed end plate and o-ring on shaft while installing. 2. Align endplate (Item 8) with shaft and key. Apply Loctite 609 to shaft.
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I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REVISION LOG SHEET REV DATE INITIALS CHANGES MADE A B 1/10/02 2/26/02 4/5/02 MC/glj BH BH C D 4/24/02 8/26/02 BH BH E F G 11/21/02 1/16/03 2/3/03 BH BH BH/cc H I J 9/4/03 11/25/03 12/29/03 BH BH BH K 1/26/04 BH L M 4/19/04 8/18/04 Newly created in word. Added Wiring Schematic and Hydraulic Schematic to end of file. Added Controller Functions section and updated troubleshooting section. Added installation of speed pickup by customer.
Installation and Maintenance Bulletin HPTO10TD-100 May 7, 2003 Hydraulic Power Take-off Rotating equipment is potentially dangerous and should be properly guarded. The user should check all applicable safety codes and provide suitable guards. The HPTO™ Hydraulic Power Take-off is a hydraulically actuated, enclosed dry clutch that requires no adjustment throughout its wear life. During a torque spike, the clutch will act as a torque limiter by slipping to absorb the shock load.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 4. Check that the oil return line from the clutch manifold will be isolated from any return line that is pressurized. ATTENTION: the oil return line from the manifold must not be attached to anything that could potentially create pressure in the line. The maximum height that the tank can be mounted above the centerline of the HPTO clutch is 4 feet. If tank is too high, over pressurization of internal shaft seals may result. 4.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 8. Once the HPTO housing is piloted and flush with the engine housing, you can remove the crane support. 9. Install customer supplied sheave and QD bushing to the output shaft of the HPTO. Insure that belts (once installed) will be aligned and track straight. 10. Tension Belts according to Equipment Manufactures specifications. 11. Install proper safety supplied by PT Tech®).
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF SERVICE INSTRUCTIONS The HPTO can be reconditioned in the field or sent back to PT Tech. Contact PT Tech if any portions of these service instructions are unclear. DISASSEMBLY INSTRUCTIONS Refer to exploded view drawing HPTO10TD-100 sheet 2 of 2. 1. Carefully remove all wiring and hydraulic hose connections to the manifold. ATTENTION: Leave manifold mounted to the HPTO at this time. 2. Remove speed pickup sensor (Item 4). 3.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 22. Remove two seals from endcover (Items 16 & 12). 23. Clean area around manifold and endcover. Important: Keep endcover and manifold ports clean and free from debris. 24. Remove four bolts (Item 45) from manifold and remove manifold (Item 48). REBUILD INSTRUCTIONS Refer to exploded view drawing HPTO10TD-100 sheet 2 of 2. Endcover Assembly 1. Apply Loctite 620 to steel cage of seals (Items 16 &12). 2.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Shaft Assembly 1. Using bearing heater, heat I.D. of bearing (Item 13) to 250 °F. Using protective gloves, slide bearing onto shaft (Item 8) until it contacts the shoulder of shaft. See Figure 2. 5. Lube shaft diameter and hook piston rings with Mobilfluid 424 or similar oil. 6. Visually inspect piston ring grooves on shaft for any signs of contamination.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Endcover Sub-assembly ATTENTION: Check for burrs or debris in bore of endcover at oil inlet and outlet holes. 1. 2. 3. Pack bearing (Item 13) on shaft with MOBILITH SHC 220 grease only to 20% capacity on outer bearing race. 4. 5. Pack end of endcover with the retaining ring with MOBILITH SHC 220 grease only to 20% capacity on outer diameter. See figure 2 for location where grease should be packed during this step.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 6. Install die springs (Item 41) qty 3 into end plate (Item 3). 7. Install friction plate (Item 6) into end plate. Note: friction plate will loosely pilot onto endplate step. Note: friction surfaces must be free of oil and contamination. 8. Install qty. of 3 (Item 42) springs into the counter bore holes in the end plate. Press dowel pin (Item 39) (short) qty 3 into end plate (Item 3), recessed section. Refer to drawing for proper orientation.
I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 15. Install backplate (Item 14) over shaft end and into piston cavity. ATTENTION: do not pinch o-ring in O.D. groove of fixed end plate and o-ring on shaft while installing. 16. Install piston (Item 9) into dowel pins of endplate (Item 3). ATTENTION: do not pinch o-ring in I.D. groove of piston while installing over shaft. 17. Using spanner wrench install clamp nut (Item 35) onto end of shaft. Tighten locknut until backplate (Item 14) stops moving. 18.
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I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REVISION LOG SHEET REV DATE INITIALS CHANGES MADE A B C 5/7/03 9/4/03 11/25/03 12/29/03 moc BH BH BH D 1/26/04 BH E F 4/19/04 8/4/04 BH/rr BH Newly created Updated controller callouts to match that of controller decal. Updated hydraulic schematic to callout ¾” hose for HPTO12 unit. Removed controller documentation and created a separate controller I&M Bulletin.
Installation and Maintenance Bulletin CMCCU-004 Basic Controller December 29, 2003 TABLE OF CONTENTS INSTALLATION INSTRUCTIONS ......................................................................................... 2 CONTROLLER FUNCTIONS................................................................................................. 4 Power LED Indicator .........................................................................................................................
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Electronic equipment is potentially dangerous and should be installed by a trained professional. To avoid any electrical malfunction, the user should disconnect the wiring harness from the controller when welding on the equipment. Failure to do so may result in loss of controller warranty. The Microprocessor Controller provides remote push button controlled clutch engagement of the HPTO.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER For 072 teeth, set the dials as follows: 0 7 2 6. Install the Microprocessor Controller in a location in the customer’s control panel that will provide visual accessibility. The customer’s control panel opening cutout, thru hole diameters and depth dimensions can be found on the controller mounting drawing at the end of this document. 7. Slide the controller through the opening in the machine’s control panel. 8.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER WARNING: The controller has been pre-programmed at PT Tech per the customer’s specifications. Failure to understand the specified operating parameters and conditions prior to initial startup and operation may result in unexpected results and/or possible damage to vital HPTO components. Contact PT Tech prior to initial startup to prevent possible injury and/or death.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER During this time the “CLUTCH ENGAGED” symbol will illuminate to indicate that the clutch is engaging. See sketch below. Clutch Engaged Symbol aborted startup attempt). If the operator keeps the speed above 1100 rpm and re-attempts clutch engagement, then the “RPM TOO HIGH” symbol will turn on SOLID, indicating that the clutch is still over-speed. If the operator then lowers the speed below 1100 rpm then “RPM TOO HIGH” symbol will turn off.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Once the lockout timer has expired, the light will turn off and the clutch can be engaged. TIMED LOCKOUT symbol ATTENTION: If engine ignition switched power is removed from the controller the lockout timer will continue to count down. If however the main battery power is disconnected from the controller, the lockout timer will stop counting down and restart once main power is supplied.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER SAFETY SWITCH Symbol OIL PRESSURE symbol FAULT – SAFETY SWITCH The Equipment Safety Switch (customer supplied) must be a normally closed switch (opens when safety hazard exists). The controller can be wired to a switch on the customer’s equipment that, when open, will prevent the clutch from engaging. This switch could be attached to a tub cover, mill box, etc.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER cause the controller to function similarly to pushing the “Engage/Disengage Button” on the front of the controller. This remote switch must be a momentary switch only. The controller will draw the following amps when the remote button is pushed: @ 5volts the draw will be 10mA @ 12volts the draw will be 24mA @ 24volts the draw will be 48mA Refer to the controller wiring harness drawing at the end of this document.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Once the “CLUTCH ENGAGED” symbol illuminates, the button can be released. Note: The controller will begin the engagement of the clutch and perform a series of “bumps” to engage the clutch and bring the driven equipment up to engine speed. During this time the “CLUTCH ENGAGED” symbol will illuminate to indicate that the clutch is engaging.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER TROUBLESHOOTING INSTRUCTIONS The following items may be helpful in determining what caused the various symbols to illuminate on the controller display. Check that the 3-dials on the back of the controller are set correctly to match the tooth count of the flywheel ring gear. HPTO 8 – has 72 teeth. HPTO10- has 72 teeth. HPTO 12 – has 59 teeth.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER probe end to make certain it is not damaged. Check reservoir fluid level. Replace speed pickup with a new one. Check cooler for a leak. Check oil filter. Check pressure switch wires for a cut wire. Install a pressure gauge with an SAE #4 o-ring fitting into the manifold at the location stamped “G”. On the pressure switch in the manifold, locate the pressure setting stamped on the pressure switch.
I & M BULLETIN CMCCU-004 BASIC CONTROLLER If a safety switch is present, insure that it is receiving power and in good working order. Check that the wire connected to pin 9 at the controller is not cut. COIL FAULT Check the following items: Check that the wires from pins 3 & 4 are neither cut or grounded, nor connected together, thus creating a dead short. Check that the voltage stamped on the side of the coil (either 12 or 24 volts) matches that of the equipments voltage supply.
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I & M BULLETIN CMCCU-004 BASIC CONTROLLER REVISION LOG SHEET REV DATE INITIALS CHANGES MADE A B 12/29/03 3/7/04 3/12/04 BH BH BH C D E 4/26/04 4/27/04 11/17/04 BH BH BH Newly created in word. Updated wiring harness schematic per ECN# 144. Added coil ohm measurement to coil fault troubleshooting section. Updated wiring harness schematic. Updated controller images to black face style. Added functionality of immediate lockout on last bump if engine stalls.
