Model 3500D Machine Serial # Engine Model # Engine Specification # Engine Serial # Purchase Date Dealer Carlton J. P. Carlton Company Div. DAF 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.
3500D SAFETY ALERT
3500D SAFETY ALERT
3500D SAFETY ALERT
3500D SAFETY ALERT
3500D 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.
3500D TABLE OF CONTENTS INTRODUCTION FOREWORD 1 GENERAL INFORMATION 2 MACHINE FEATURES 3 MACHINE SPECIFICATIONS 4 OPERATION SAFETY PRECAUTIONS 6 DAILY CHECKLIST 9 MACHINE CONTROLS 10 TOWING 17 MACHINE OPERATION 18 MAINTENANCE MACHINE MAINTENANCE 22 LUBRICATION CHART 27 TROUBLESHOOTING GUIDE 28 WIRING DIAGRAM 30 LIGHTS & BRAKES ASSEMBLY 34 SERVICING CUTTER WHEEL 37 SERVICING HYDRAULICS 42 SERVICING BOOM PIVOT 44 SERVICING BELTS 45 SERVICING BEARINGS 54 SERVICING STUB S
3500D FOREWORD Congratulations on your purchase of a new Carlton® Professional Stump Grinder! Carlton® Stump Grinders have a reputation for superior performance and reliability. Each and every machine has been over designed and overbuilt to ensure years and years of trouble-free operation. In this, we take pride. Read this manual carefully and TAKE RESPONSIBILITY for thoroughly familiarizing yourself with the controls and the concepts behind the operation of this machine before attempting to operate it.
3500D 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.
3500D MACHINE FEATURES (Remote machine shown here.) • • • • • • • • • • Direct hydraulic drive pump. Low Maintenance drive belts. Self-purging roller bearings. Counterbalance valves. Replaceable rod ends. Hardened bushings. Blanchard ground 1” thick cutter wheel Carbide tipped teeth. Center lube spindles. Belt Guards. • • • • • • • • • • Rubber and Metal chip guards. Control guards. Optional hour meter. Optional Key switch. High quality epoxy primer. Dupont Imron® Finish. Optional Remote control.
3500D MACHINE SPECIFICATIONS Engine .................................................................. 60 HP Deutz Turbo Diesel Weight.................................................................. 2900 lbs. Length. ................................................................. 11’ 6” Tongue Extension ................................................ 48” Height .................................................................. 70” Width ................................................................
3500D MACHINE SPECIFICATIONS 5
3500D 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.
3500D 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.
3500D SAFETY PRECAUTIONS • Never allow spectators to stand and watch machine in operation without proper hearing and eye protection and standing at a safe distance. Loud noise and flying debris may cause severe injury. Do not operate around water, gas, power or phone lines. Check with property owner or call utilities if not sure. Avoid fences and clear away other objects (i.e. sticks, stones, metal, etc.). Be aware of the possibility of foreign objects imbedded in or buried around the stump.
3500D • • • • • • • • • • • Make sure safety pins and safety chock are in position before towing. Always crisscross safety chains when towing. Check engine oil at dipstick. Add to full mark, if required. Engine must be level (see Machine Maintenance section). Check hydraulic oil level. A sight glass is located on the hydraulic tank. Add oil if required. Check air filters. REPLACE, if necessary, WITH FACTORY AIR FILTER ONLY. Do not blow out or tap on ground.
3500D MACHINE CONTROLS ENGINE CONTROLS - Refer to engine manufacturers owners’ manual for controls, operation, and service. • Start the engine using the key switch located on the lower left hand side of the swing-out control panel. Press and hold the Murphy By-Pass while turning the key switch. Run the engine a few minutes to allow the oil to circulate before starting to operate the functions.
3500D MACHINE CONTROLS SWING SPEED ADJUSTMENT • Adjust swing speed for smooth operation. Turn valve counter-clockwise to slow cutter head swing as engine speed increases. Close valve by turning clockwise to allow head to move side to side at low engine RPM. CUTTER WHEEL ENGAGEMENT • • With the engine RPM at idle, engage the cutter wheel by lifting the engine slide lock and slowly pulling the engagement lever toward the front of the machine.
3500D OPTIONAL REMOTE CONTROL OPERATION – WIRED • The control functions operate the same on a remote control machine as they do on a swing-out machine. Instead of having the machine mounted control levers as described earlier in this section, there are toggle switches on the machine control box and on the remote control unit. The toggle switches on the machine control panel can be used to operate the machine for short-term operation to test the operation of the functions.
00D 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.
3500D MACHINE CONTROLS OPERATION – WIRELESS • • • • • • • • THE CUTTER WHEEL MUST BE DISENGAGED BEFORE STARTING THE MACHINE. To start the engine and radio control transmitter, follow these instructions. On the machine, turn the ignition key switch to ON and the engine switch to Remote On. On the transmitter, press the E-STOP button down. Toggle any switch on the transmitter. Twist the E-STOP button clockwise to release.
3500D MACHINE CONTROLS PROGRAMMING – WIRELESS • • • If there is a problem with the receiver or the transmitter and either has to be replaced, you will need to program the new unit to communicate with the existing unit. Or if you have more than one transmitter for this machine, it will need to be programmed to communicate with the existing receiver. To program the transmitter and receiver, you have to download the transmitter’s unique code into the receiver.
3500D MACHINE CONTROLS TROUBLESHOOTING LOW BATTERY LIGHT SEE THE RADIO CONTROL MANUAL FOR ANY OPERATING PROBLEMS WITH THE RADIO RECEIVER & TRANSMITTER (Included in the back of this manual) • • • First check the batteries to make sure they are providing enough power to operate the transmitter. There is a low battery light on the transmitter, when it starts flashing you have approximately 10 hours of operation left. Remove the back cover on the transmitter.
3500D TOWING GUIDE SAFETY: NEVER ALLOW INEXPERIENCED DRIVERS TO TOW MACHINERY. Always make sure ball size is same size as coupler on equipment. • • • • • • • • • • • • • • Always make sure safety pins and chock block are in place before towing. Always make sure towing ball and hitch coupler are the same size and that they are not worn. Check hitch for secure installation and make sure safety chains are properly installed. Crisscross safety chains under hitch to provide support in the event of failure.
3500D MACHINE OPERATION STARTING - READ ENGINE MANUFACTURERS OWNERS’ MANUAL BEFORE STARTING. • • • • • • • • • • Check all fluids before starting. Drive belts must be disengaged before starting. Inspect all connections, teeth, tires, etc. (See Daily Checklist). Start engine at half speed and allow sufficient time for oil to circulate before proceeding. (See Machine Control section for starting the machine with a remote or radio control transmitter.) Test controls for proper operation.
3500D • MACHINE OPERATION Lift boom and remove boom chock block. REMOVE BOOM CHOCK BLOCK • • • • • • • • Reduce engine RPM to idle. Raise cutterhead clear of stump. Engage cutterhead drive belts by pushing down on engagement handle to relieve pressure on engine slide stop. Lift slide stop and slowly pull handle back to engage belts. Increase engine RPM to full. Test controls for proper operation, speed, and unobstructed movement.
3500D • • • • • • • • • • • • • MACHINE OPERATION Lower spinning cutter wheel to stump and make a few light passes at stump to get a feel for the cutting action. Gradually increase cutting action and work away at stump by swinging cutter wheel left-to-right-to-left through stump in a sideways motion. Smooth, effortless cutting lengthens machine life, minimizes downtime and is more profitable in the long run.
3500D MACHINE OPERATION For optimal performance, the stump should be cut with the portion of the cutter wheel shown. NEVER UNDERCUT THE STUMP. Undercutting the stump can cause severe kickback, vibration and component damage. NEVER CUT THE STUMP FROM THE TOP. The cutter wheel will throw debris up and toward the operator, instead of down and under the machine.
3500D 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.
3500D • • • • • MACHINE MAINTENANCE Check hydraulic oil tank. A sight glass is provided on the tank for easy viewing. Keep filled to proper level. The machine is equipped with Citgo AW32 hydraulic oil at the time of manufacture. To access the jackshaft bearings you will have to remove the jackshaft cover. Check setscrews in jackshaft bearings and cutter wheel bearings for tightness (weekly). Clean out Poly Chain® guard by removing bottom portion of guard (weekly).
3500D • MACHINE MAINTENANCE Check cutter wheel, pockets, and teeth for wear. If any repair is needed, see Servicing Cutter wheel section for further instructions. DO NOT OPERATE STUMP CUTTER WITHOUT A COMPLETE SET OF TEETH. Always clean tip of grease gun fitting and grease fitting on machine before attaching hose to prevent dirt from being forced into machine parts. ENGINE SLIDE GREASE FITTING • Grease engine slide assembly daily. Use Texaco® Starplex II grease. Wipe off excess grease.
3500D • Grease cutter wheel shaft bearings daily. These bearings should be purged using grease EVERYDAY. Purge until clean grease is seen. Use Texaco® Starplex II grease. Wipe off excess grease. Excess grease will attract dirt. Always clean tip of grease gun fitting and grease fitting on machine before attaching hose to prevent dirt from being forced into machine parts. • Grease the bearing supported stub shaft every 1000 hours of operation using Texaco® Starplex II grease.
3500D • Grease bottom pivot hardened bushings weekly. Use Texaco® Starplex II grease. Wipe off excess grease. Excess grease will attract dirt. • Grease spindles every 2 to 3 months. Spindles are easy lube type. Remove rubber grommet and grease at grease fitting until grease is seen around grease fitting. • Grease tongue extension every 6 months with a light coating of Texaco Starplex II grease.
3500D • The model 3500D, 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 SCHEDULE A regularly scheduled maintenance program will pay big dividends in machine life, performance and avoided downtime. Lubrication Schedule • USE TEXACO® STARPLEX II GREASE.
3500D TROUBLESHOOTING GUIDE COMPLAINT CAUSE CORRECTION Engine will not start. (See Engine Manufacturers’ Manual for further information.) Hydraulic system loss of power. • • • • • • Loose ground wire. Loose hot wire. Dead battery. Low oil. Valve set too low. Splined pump coupling worn. Bad cylinder. Bad Pump. Cutterhead speed adjustment screw turned wide open. • • • • • • Clean and tighten. Clean and tighten. Recharge or replace. Refill with correct oil. Adjust relief valve. Remove pump coupler.
3500D TROUBLESHOOTING GUIDE COMPLAINT CAUSE CORRECTION Cutter wheel stops turning. • • • • • • • Belt not engaged. Belt loose. Engine belt broke. Poly Chain® belt broken. Sheared key in shaft. Broke cutter wheel shaft. Belt guards rubbing on jack shaft or cutter wheel shaft. Jackshaft or cutter wheel bearings going bad. Stub shaft bearing bad. Grease fitting clogged. Counter-balance valve is out of adjustment. • • • • • • • Adjust yoke assembly. Tighten belt. Replace belt. Replace belt.
3500D MACHINE WIRING STANDARD WIRING DIAGRAM 30
3500D MACHINE WIRING REMOTE WIRING DIAGRAM 31
3500D MACHINE WIRING REMOTE BOX WIRING 32
3500D MACHINE WIRING RADIO WIRING DIAGRAM SEE RADIO CONTROL MANUAL, INCLUDED IN THIS MANUAL, FOR MORE 33
3500D LIGHTS & BRAKES ASSEMBLY LIGHT ASSEMBLY ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PART NO 0350008 0350004 0150140 0150218 0350046 3500163 0350050 0550211 0350044 0350045 0150141 0150301 0150221 3500267 DESCRIPTION Coiled Connector Assembly Connector Socket 1/4-20 x 3/4 HCS 1/4-20 Lock Nut Breakaway Switch Light Connector Bracket 1” Loom Clamp Brake Drum w/studs & races Tail Light Kit Tag Light #10 x 3/4 Machine Screw #10 Flat Washer #10 Lock Nut Tail Light Bracket QTY 1 1 4 4 1 1 3 2 2 1 4 8 4 1
3500D LIGHTS & BRAKES ASSEMBLY ELECTRIC BRAKE ASSEMBLY ITEM NO 1 2a 2b 3 4 5 6 7 8 9 10 11 12 13 PART NO 0550220 0550221 0550222 0550223 0550224 0550225 0550226 0550227 0550228 0550229 0550230 0550231 0550232 0550233 DESCRIPTION Backing plate assembly Left hand actuating lever Right hand actuating lever Anchor post washer Wire clip Retractor spring Shoe & lining kit Adjuster assembly Adjuster shoe spring Magnet kit Plug Wire grommet Brake mounting bolt Brake mounting nut QTY 1 1 1 1 3 2 1 1 1 1 1 1 4
3500D LIGHTS & BRAKES ASSEMBLY TRAILER LIGHTS & BRAKES WIRING 36
3500D 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.
3500D SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • • • Inspect pockets, teeth and bolts for damage and replace as required. When replacing pockets, always replace new pockets across from 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. When replacing complete set of teeth, be sure to duplicate original factory tooth arrangement.
3500D SERVICING CUTTER WHEEL OPTIONAL: Sandvik® Dura Disk II Cutter Wheel • • • • • • • • If the machine is supplied with the optional Dura Disk II cutter wheel, there are fifty (50) teeth to a complete set. There are ten (10) Short Plow Bolt Bits (Carlton part #0450121) and forty (40) Plow Bolt Bits (Carlton part #0450120). DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED.
3500D SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • • • • • • • Inspect pockets, teeth and nuts 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.
3500D 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 carbide with a silicone carbide or diamond rock. CAUTION: GRINDING CARBIDE CAN BE A HEALTH HAZARD.
3500D 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.
3500D SERVICING HYDRAULICS REPLACING ROD ENDS • • Should a rod end need replacing, loosen through bolt clamping rod end to cylinder rod and unscrew rod end. Reverse process to install new rod end. Tighten through bolt and use new cotter pins, and cylinder pins. REPLACING BUSHINGS • • • • Hardened bushings have been incorporated into the machine to protect the main frame from wear and damage. Should a bushing need replacing, disconnect rod end from mainframe and swing cylinder out of the way.
3500D SERVICING BOOM PIVOT 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.
3500D SERVICING BELTS Replacing V-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.
3500D SERVICING BELTS Replacing V-Belt • Remove the belt keeper at the jackshaft pulley for easier belt removal. REMOVE THIS BELT KEEPER • • Remove and replace the engine belt. If you have difficulty replacing the new belt, you may need to relieve some of the tension that was applied to the old belt. Read the information on adjusting tension below and loosen the belt tension. • After replacing the V- belt, check the tension.
3500D SERVICING BELTS Replacing V-Belt • Replace the belt keeper at the jackshaft pulley. • When adjusting engine belt tension, you will also have to adjust engine slide stop. Shorten engine slide handle as you lengthen the linkage assembly. Loosen the jam nut and turn the handle one turn and check to see if the engine is locked in the disengaged position. Make more adjustments, if necessary, until the engine is locked in the disengaged position. Then retighten the jam nut.
3500D SERVICING BELTS Replacing 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.
3500D SERVICING BELTS Replacing Poly Chain® Belt • Loosen, do not remove, the nuts on the bolts that are holding the belt guard to the machine. • Loosen Poly Chain® belt by moving jackshaft bearings back toward rear of machine. MARK THEM SO THAT YOU KNOW HOW THEY ARE POSITIONED ON THE JACKSHAFT PLATE. Loosen, do not remove, the four bolts that hold the jackshaft bearings down. • Loosen the jam bolts in the back and move the bearings toward cutter wheel.
3500D SERVICING BELTS Replacing Poly Chain® Belt • • • • • Remove old belt and replace with new one. Replace the belt over the jackshaft sprocket first. Put the cutter wheel sprocket and the Poly Chain® belt on the cutter wheel shaft at the same time, with the sprocket inside the belt. Put the cutter wheel tapered bushing on the cutter wheel shaft and inside the sprocket. Push the bushing as close to the position you marked earlier as possible. Replace and tighten the screws. Torque screws to 67 ft.
3500D SERVICING BELTS Replacing Poly Chain® Belt • Check belt alignment using a straight edge. Adjust belt alignment by loosening one jackshaft bearing jam bolt and tightening the other bearings jam bolt. Make only slight adjustments and recheck alignment. The alignment and tension of the V-belt will also need to be checked after changing and adjusting the Poly Chain® belt.
3500D SERVICING BELTS Replacing Poly Chain® Belt • Retighten the bolts in the jackshaft bearings when the tension is adjusted properly. • Retighten the nuts on the bolts that are holding the belt guard to the machine. • Replace belt guard cover and bottom. Tighten the bolts. DO NOT RUN MACHINE WITHOUT ALL GUARDS IN PLACE AND SECURED.
3500D SERVICING BELTS Replacing Poly Chain® Belt 53
3500D SERVICING BEARINGS Replacing Jackshaft Bearings 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.
3500D SERVICING BEARINGS Replacing Jackshaft Bearings • Remove the Poly Chain® guard cover and bottom cover. Follow the instructions in the Servicing Belts section to remove the Poly Chain® belt. SPROCKET • • • • Measure the distance from the jackshaft end to the bushing to place the bushing in the same place on the new shaft. Write this measurement down. After the belts have been removed, remove the jackshaft sprocket.
3500D SERVICING BEARINGS Replacing Jackshaft Bearings • Remove the four bolts holding the jackshaft bearings in place. Remove old bearings and shaft. • Replace with new bearings and shaft. Be sure to turn the end of the jackshaft with the longest keyway pocket toward the Poly Chain® belt side of the boom and make sure that the locking collars on the bearings are facing inward. Bolt the new bearings and jackshaft back into place.
3500D SERVICING BEARINGS Replacing Jackshaft Bearings • • • • • Replace the Poly Chain® belt. Follow the instructions in the Servicing Belts section for replacing the Poly Chain® belt. DO NOT ADJUST THE BELT TENSION AT THIS TIME. The cutter wheel sprocket will be replaced when replacing the belt. Line up Poly Chain® sprockets using a straight edge. Slide shaft through bearings to adjust in or out to line sprockets up. Replace the pulley on the jackshaft.
3500D SERVICING BEARINGS Replacing Jackshaft Bearings • • • • • • • Line the jackshaft pulley up with the engine pulley using a straight edge. When the pulleys are aligned, tighten the screws in the jackshaft pulley. Recheck the alignment to be sure nothing changed. Torque the screws in the jackshaft pulley to 30 ft. lbs Once the sprockets are lined up, tighten Poly Chain® belt by adjusting jam bolts on the jackshaft bearings.
3500D SERVICING BEARINGS Replacing Jackshaft Bearings • There are two setscrews in each bearing lock collar. Tighten one setscrew in each collar and remove the other setscrew. Punch a start point in the shaft and drill 3/8” diameter hole in jackshaft just deep enough for setscrew to enter shaft. Take care not to damage the screw threads. Replace setscrew with LocTite 242 and tighten. Do this for all four setscrews. This will help prevent shaft from spinning and walking inside of bearing.
3500D SERVICING BEARINGS Replacing Cutter Wheel Bearings 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.
3500D SERVICING BEARINGS Replacing Cutter Wheel Bearings • • • • • • Loosen the setscrews in the locking collars of the bearings. You may need to heat bearing collar to loosen the LocTite that was used during assembly. To remove the bearings from the cutter wheel shaft, use a steel hammer to strike the bearing housing until it cracks and breaks apart. Then use a torch to cut the bearing race off the shaft. Be very careful not to cut into the cutter wheel shaft with the torch.
3500D SERVICING BEARINGS Replacing Cutter Wheel Bearings Replace the Poly Chain® belt. Follow the instructions in the Servicing Belts section for replacing and tensioning the Poly Chain® belt. NOTE: Refer to SERVICING BELTS section for proper installation and tensioning of all belts. (Alignment and tension of Poly Chain® belt is very important. See information on alignment using straight edge in Replacing Jackshaft Bearings section of manual.
3500D SERVICING STUB SHAFT 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.
3500D • SERVICING STUB SHAFT Next you will need to remove the jackshaft sheave. Remove the bolts in the jackshaft sheave and screw them back into the empty 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 BOLTS AND SCREW INTO EXTRA HOLES REMOVE BOLTS • • Remove the bolts holding the belt guard onto the machine and remove the belt guard. Then remove the engine sheave.
3500D • You can now remove the bearing supported stub shaft plate. Remove the bolts holding the shaft plate to the engine. There are eleven 10MM bolts to remove. Pull the plate straight off. • There are two threaded holes that can be used to push the shaft plate off the engine mount. Insert two of the bolts that were removed from the stub shaft plate and slowly screw them in until the plate breaks loose.
3500D • Replace any parts found defective or worn. Put stub shaft coupling plate onto the flywheel. The plate is attached using eight 10MM-1.5 x 20MM bolts with a lock washer. Put LocTite® 242 (blue) on the end of the bolt and lightly tighten all bolts. When all bolts have been inserted and lightly tightened, torque all bolts to 35 ft. lbs. • Put anti-seize (coupling lubricant) on the inside of the coupling. Line up external splines with the coupling ID and slide the stub shaft plate into place.
3500D • • SERVICING STUB SHAFT Bolt grease fitting to the air filter bracket. Before starting the engine, apply grease to the grease fitting until the pin on the opposite side of the stub shaft pops out (see Machine Maintenance section for more information). • Start replacing parts in the opposite order in which they were removed. Replace the v-belt guard and then replace the engine and jackshaft sheaves. Torque the bolts in the sheaves to 30 ft. lbs.
3500D HYDRAULIC ASSEMBLY REMOTE CONTROL HYDRAULIC ASSEMBLY ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0300150A 0300142 0300105G 0300105E 0300105D 0300135C 0300135 0300220 0300218 0300234 0300245 0300205 0300236 0300217 0300237 0300215 0300238 0300239 DESCRIPTION Valve Manifold Assembly Hydraulic Pump Tongue Cylinder - 3 x 48 Lift Cylinder - 3 x 10 Swing Cylinder - 3 x 8 Filter Head Filter Element - 10 Micron 3/4 mp-mp 90 3/4 mp-jic 90 3/4 jic-orb 1/2 mp-5/8
3500D HYDRAULIC ASSEMBLY REMOTE CONTROL HYDRAULIC ASSEMBLY 69
3500D HYDRAULIC ASSEMBLY REMOTE MANIFOLD ASSEMBLY ITEM NO PART NO 1 2 3 4 5 6 0300150A 0300150AB 0300150AA 0300120A DESCRIPTION Aluminum Manifold Block Solenoid Valve - DO3 Swing Speed Control Cartridge Counter Balance Cartridge Valve – LKN Relief Cartridge Valve – Sun Lift Speed Adjustment - NCCB-KAN QTY 1 3 1 3 2 1 70
3500D HYDRAULIC ASSEMBLY SWING OUT CONTROLS HYDRAULIC ASSEMBLY ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 PART NO 0300130 0300142 0300105G 0300105E 0300105D 0300135C 0300135 0300257 0300236 0300258 0300223 0300210 0300225 0300240 0300137 0300122A 0300120 0300214 0300259 0300215 0300231 0300122 0300213 0300224 0300209 0300260 0300217 0300220 0300218 0300234 0300235 DESCRIPTION Hydraulic Control Valve Hydraulic P
3500D HYDRAULIC ASSEMBLY SWING OUT CONTROLS HYDRAULIC ASSEMBLY 72
3500D HYDRAULIC ASSEMBLY LIFT CYLINDER ASSEMBLY – 3 X 10 (Assembly Part # 0300105E) ITEM NO 1 2 *3 4 *5 6 *7 *8 *9 *10 11 *12 13 ** PART NO 0300195 0300110D DESCRIPTION Body Assembly Lock Nut 1 1/4”-12 Crown Seal Piston O-Ring Piston Rod O-Ring Bu-Washer Square Retaining Ring U-Cup End Cap Rod Wiper Clevis QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 Packing Kit (includes all * items) 73
3500D HYDRAULIC ASSEMBLY SWING CYLINDER ASSEMBLY – 3 X 8 (Assembly Part # 0300105D) ITEM NO 1 2 *3 4 *5 6 *7 *8 *9 *10 11 *12 13 ** PART NO 0300195 030011OD DESCRIPTION Body Assembly Lock Nut 1”-14 Crown Seal Piston O-Ring Piston Rod O-Ring Bu-Washer Square Retaining Ring U-Cup End Cap Rod Wiper Clevis QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 Packing Kit (includes all * items) 74
3500D HYDRAULIC ASSEMBLY TONGUE CYLINDER ASSEMBLY – 3 X 48 (Assembly Part # 0300105G) ITEM NO 1 2 *3 *4 *5 6 *7 8 9 *10 *11 *12 13 *14 ** PART NO DESCRIPTION 0300089 0150222 0300164 0300151 0300166 0300161 0300149 0300090 0300169 0300163 0300165 0300167 0300162 0300168 Body Assembly Lock Nut 1”-14 Piston Ring O-Ring Bu-Washer Piston O-Ring Piston Rod Bu-Washer Snap Ring Quad Ring Bu-Washer End Cap/Gland Rod Wiper 0300110F Packing Kit (includes all * items) QTY 1 1 1 2 1 1 1 1 1 1 1 1 1 1 75
3500D HYDRAULIC ASSEMBLY HYDRAULIC PUMP ASSEMBLY (Part # 0300142) ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ** PART NO DESCRIPTION QTY 0300170 0300171 0300172 0300173 0300174 0300175 0300176 0300177 0300178 0300179 Bolts Dowel Pins Snap Ring Front Plate Back Plate Bearing Case Assembly Pump Body Drive Gear Idler Gear Washer 4 4 1 1 1 1 1 1 1 4 0300180 0300181 0300182 0300183 Wear Plate Seal Back-Up Strip Shaft Seal 2 2 2 1 03001421 Pump Rebuild Kit (includes items 3, 14 & 15) 76
3500D FRAME ASSEMBLY BASE FRAME ASSEMBLY ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 PART NO 3500145 0550208 0550209 0550210 0550212 0550010 0550213 0550214 0550215 0550217 0550216 0550218 3500142 3500143 3500144 3500145 0550004 0200001 0200002 3500165 3500166 3500177 3500191 3500192 0150117 0150303 0150207 3500114 0150133 0150307 0150211 3500216 3500217 0150304 0150206 3500259 0300249 0300302 0150707 35
3500D FRAME ASSEMBLY BASE FRAME ASSEMBLY 78
3500D FRAME ASSEMBLY REMOTE BOX ASSEMBLY ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO 0300141 0350002 0350004 0350031 0350013 0350011 0350027 0350028 0350029 0350030 3500232 3500280 0150145 0150404 0150207 0150116 0150212 0150102 0150140 0150218 0150402 0150117 0150303 DESCRIPTION Remote Manifold Assembly 7 Pin Socket 6 Pin Socket Hour Meter Momentary Switch Switch - 2 Position Circuit Breaker - 20 Amp Circuit breaker - 40 Amp Junction Box - Fused Junction Box - Terminal C
3500D FRAME ASSEMBLY REMOTE BOX ASSEMBLY 80
3500D FRAME ASSEMBLY SWING OUT BOOM ASSEMBLY ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PART NO 3500245 0400210 0400300 3500273 3500272 0150117 0150303 0150207 0300130 0150103 0150404 0350031 3500276 3500274 3500275 0150608 A150T08 0150503 0150502 3500247 0150144 0150225 DESCRIPTION QTY Swing Out Boom Weldment Window Molding Lexan Shield Swing Out Boom Skirt Skirt Bracket 3/8-16 x 1 Carriage Bolt 3/8 Flat Washer 3/8-16 Lock Nut Control Valve 3/8-16 x 1 HCS 3/8 Lock Washer Hour Me
3500D ITEM NO ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PART NO 3500120 3500159 0500202 0500122 0500403 0500404 3500121 3500122 3500123 0150214 0150215 0150501 0150802 0300140 3500189 0150310 0300138 0150123 0150124 0150308 0150801 A160T07 3500162 3500280 3500125 3500107 0150600 H752012 H752013 H752014 0300528 7200330 PIVOT ASSEMBLY DESCRIPTION QTY Pivot Hardened Swing Pivot Shaft Bearing Cup Bearing Cone Seal, Bottom Seal, Top
3500D PIVOT ASSEMBLY 83
3500D ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 02001051 4100346 4100120 0150501 4100154 0150603 4404110 3504109 0150104 0150207 0150625 ENGINE ASSEMBLY DESCRIPTION Engine - 60 HP Deutz Turbo Diesel Engine Slide Assembly 1/2”-13 x 4” HCS 1/2” Lock Washer Belt Engagement Handle Cotter Pin – 3/16” x 2” Linkage Assembly Clevis Pin – 1/2” x 1 3/8” Cotter Pin – 1/8” x 1 3/8” Engine Slide Rod Slide Rod Collar 3/8”-16 x 2 1/2” HCS 3/8”-16 Lock Nut Grease Fitting – 1/8” Straight QTY 1 1 4 4 1 1 1 2 2 2
3500D ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 0400104 0250105 0250179 0250106 0250122 A160T013 0150117 0150207 0150118 0150404 ― 0150206 0150303 050062 050061 4404156 0200105F 0200105G 0200105H 0150116A 0150303A 0150212 0150119B 0200192 0150304 ENGINE BELT ASSEMBLY DESCRIPTION Engine Belt – 4B82 Sheave - 4B5.4 Bushing - SD 1 1/2” Sheave - 4B13.6 Bushing - SK 1 11/16” Key - 3/8” Sq.
3500D ENGINE BELT ASSEMBLY NOTE: Make sure the grease fitting is on top of the stub shaft assembly before bolting the stub shaft plate into place, as illustrated in the Servicing Stub Shaft Section of the manual. Remove the grease fitting on the new stub shaft and replace with the Grease Fitting Extension Unit (#25).
3500D JACKSHAFT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY 1 2 3 4 5 6 7 8 9 10 3500185A 0500113 Jackshaft – 1 11/16” Link Belt Bearing - 1 11/16” 5/8”-11 x 3” HCS 5/8" Flat Washer 5/8”-11 Lock Nut Key – 3/8” Square x 2 5/8” Key – 3/8” Square x 3 3/4” 1/2”-13 x 5” SQHD 1/2” Lock Washer 1/2”-13 Hex Nut 1 2 4 8 4 1 1 4 4 8 0150305 0150216 0150205 87
3500D ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 3500204 0400113 3500196 3500208 0150118 0150303 0150404 0150207 0250115B 0250115G 0250115M 0250115C 0150212 0150116 0150304 0150205 POLY CHAIN® BELT ASSEMBLY DESCRIPTION Poly Chain® Guard Cover Poly Chain® Belt Poly Chain® Guard Poly Chain® Guard Bottom 3/8”-16 x 1” HCS 3/8” Flat Washer 3/8” Lock Washer 3/8”-16 Lock Nut Jack Shaft Sprocket – Taper Lock Taper Lock Bushing –1 11/16” Taper Lock Bushing – 2” Cutter Wheel Sprocket – Taper Loc
3500D ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NO 3500186 3500184 0150132 CUTTER WHEEL ASSEMBLY DESCRIPTION 0150118 0150207 3500264A 0150605 0450105 0450104 0450108 0450101 0450102 0450103 A160T02 Cutter Wheel Cutter Wheel Shaft – 2” 1/2”-13 x 2 1/2” HCS 1/2” Hardened Flat Washer 1/2” Hex Nut Pillow Block Bearing - 2” 5/8”-11 x 3” lg.
3500D CUTTER WHEEL ASSEMBLY 90
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.
