Model 7500 Machine Serial # Engine Model & Spec # Engine 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.
7500 SAFETY ALERT
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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.
7500 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 MACHINE WIRING 30 LIGHTS & BRAKES ASSEMBLY 34 SERVICING CUTTER WHEEL 37 SERVICING HYDRAULICS 42 SERVICING BOOM PIVOT 44 SERVICING BELTS 45 SERVICING BEARINGS 53 SERVICING STUB SH
7500 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.
7500 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.
7500 • Direct hydraulic drive pump. • Low maintenance drive belts. • Self-purging roller bearings. • Counterbalance valves. • Replaceable rod ends. • Hardened bushings. • Blanchard ground cutter wheel - 1 1/2" thick. • Carbide tipped teeth. • Center lube spindles. • Belt guards. MACHINE FEATURES • Rubber and metal chip guards. • Control guards. • Optional hour meter. • Key switch. • High quality epoxy primer. • Dupont Imron® finish. • Optional remote control. • Double wire braid hydraulic hose.
7500 MACHINE SPECIFICATIONS Engine .................................................................. 78 HP Turbo Deutz Diesel Weight.................................................................. 4400 lbs. Length .................................................................. 13’ 3” Height .................................................................. 75” Width ................................................................... 80” Cutting Depth Below Ground.....................................
7500 MACHINE SPECIFICATIONS 5
7500 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.
7500 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.
7500 SAFETY PRECAUTIONS • 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.) • 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.
7500 • • • • • • • • • • • 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. Inspect dry air filters. REPLACE, if necessary, WITH FACTORY AIR FILTER ONLY. Do not blow out or tap on ground.
7500 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.
7500 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.
7500 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.
7500 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.
7500 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. Release the E-STOP button within 10 seconds to power up or the unit will power down.
7500 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.
7500 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.
7500 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.
7500 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. Test controls for proper operation. Avoid transversing slopes. • DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR.
7500 • MACHINE OPERATION Lift boom and remove boom chock block. LIFT ENGINE SLIDE LOCK HANDLE • • • • • Reduce engine RPM to idle. Raise cutter head clear of stump. Engage cutter head 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.
7500 • • • • • • • • • • • • • 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-toright-to-left through stump in a sideways motion. Smooth, effortless cutting lengthens machine life, minimizes downtime and is more profitable in the long run.
7500 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.
7500 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.
7500 • • • • • 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).
7500 • 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, 6 places. Use Texaco® Starplex II grease. Wipe off excess grease.
7500 • 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.
7500 • Grease bottom pivot hardened bushings weekly. Use Texaco® Starplex II grease. Wipe off excess grease. Excess grease will attract dirt. The bottom pivot grease fittings (3) are located on the tongue below the battery box. • 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.
7500 • The model 7500, as well as all of our machines, is built to be rugged performers. 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.
7500 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. Cutter head 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.
7500 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. Replace key.
3 5 7 4 6 8 R BATTERY STARTER PRE-HEATER ENGINE CONNECTOR 10 9 1 2 BIG R BIG R BIG BK (GROUND TO ENGINE) BIG BL 58 30 40 AMP FUSE 19 KEY SWITCH 50 15/54 17 O Y BK BIG BL/BK BR BK BL BY-PASS GR BL Y/BK 86 87 87A ENGINE 85 30 RELAY BR/BK BIG BK STARTING SERIAL # 302 ('06) BL HOUR METER ALT. LIGHT OIL TEMP LIGHT DIODE 85 86 30 OIL PRESS.
30 58 BATTERY STARTER BIG BL 19 50 15/54 17 KEY SWITCH BIG R BL BIG BL/BK Y/BK BL/BK R/BK O TERMINAL BOX 1 2 O 5 4 BL/BK O O 6 Y/BK 10 9 11 3 DIODE 5 13 4 12 14 6 DIODE BL BL Y R Y/B R 15 7 Y BK 16 8 R BIG R BL Y BIG BL/BK R BIG BK BIG BK DIODE BIG BK Y/BK 85 30 BR/BK ENGINE O/BK DIODE EXT.
3 2 1 SWING O/BK EXT. 3 2 1 BL O/BK 3 2 1 BL/BK Y R ENGINE LIFT R/BK Y/BK O/BK O BK 7500 REMOTE BOX WIRING DIAGRAM W/16-PIN CONNECTOR 9 1 11 3 5 12 13 4 14 6 15 7 16 8 = = = = = = = = = = = = = = = = = = = = = RED YELLOW ORANGE PURPLE GRAY GREEN BLUE BLACK BROWN WHITE RED/BLACK ORANGE BLACK YELLOW/BLACK YELLOW/RED ORANGE/RED BLUE/BLACK BLUE/RED BROWN/BLACK BLACK/YELLOW BLACK/BLUE BLACK/RED 1 2 3 4 5 6 7 8 9 PIN # C7500-1 CHECKED BY: CURRENT (AHF/1/10/10) J.P.
58 30 BATTERY STARTER 50 15/54 BIG BL 19 17 KEY SWITCH BL BIG BL/BK ALT. LIGHT BL/BK R/BK O BL BIG BL/BK 1 R BL Y BIG R FUSE BOX BL SWING 2 O 3 BK/W/R BK ON/OFF SWITCH BL/BK LEFT RIGHT TERMINAL BOX Y/BK BIG R BL/R 5 4 BL/BK O OUT O IN 6 Y/BK 10 9 11 3 12 4 13 5 R/BK/W DOWN O UP 14 6 W/R/BK LIFT DIODE BL BL Y R Y/B R 15 7 Y BK 16 8 R/GR O/GR BL BR/BK ENGINE DIODE BIG BK GR BR BK O/BK DIODE EXT.
7500 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 7200267 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 34
7500 LIGHTS & BRAKES ASSEMBLY ELECTRIC BRAKE ASSEMBLY ITEM NO 1 2a 2b 3 4 5 6 7 8 9 10 11 12 13 PART NO 0550326 0550327 0550328 0550224 0550225 0550329 0550227 0550228 0550330 0550230 0550231 0550223 0550324 0550325 DESCRIPTION Backing plate assembly Left hand actuating lever Right hand actuating lever Wire clip Retractor spring Shoe & lining kit Adjuster assembly Adjuster shoe spring Magnet kit Plug Wire grommet Anchor post washer Brake mounting bolt Brake mounting nut QTY 1 1 1 2 2 1 1 1 1 1 1 1 5 5
7500 LIGHTS & BRAKES ASSEMBLY TRAILER LIGHTS & BRAKES WIRING 36
7500 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.
7500 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.
7500 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 eighty-four (84) teeth to a complete set. There are twenty (20) Short Plow Bolt Bits (Carlton part #04501311) and fifty-six (64) Plow Bolt Bits (Carlton part #0450130). DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED.
7500 SERVICING CUTTER WHEEL TOOTH ARRANGEMENT • ROTATION #1 #20 #2 C LTO N X CAR LTO R CA CA X OX CA RLTO N CAR LT L CA RLTO CA R CA RLTO N CA L T OX RL CA N ON R ON CA RLTO LTON AR LT R OX TO N RL A OX X #6 #16 C O X A OX LT R X N TO N OX L ON CA L R LT CA N RLT O N O N OX LT R CA O OX OX LT ON OX CA R CAR C AR CA R L T T OX OX ON C R OX C A RL T O OX TON RL N N RL CA R TO OX C A R L TO OX A #7 L ON TON
7500 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.
7500 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.
7500 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 main frame and swing cylinder out of the way.
7500 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.
7500 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.
7500 SERVICING BELTS Replacing V-Belt • • 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. Engage the belt by sliding the engine forward (reference engaged position on previous page). The belt should deflect 3/8” with 25 lbs.
7500 SERVICING BELTS Replacing V-Belt • • • When adjusting engine belt tension, you will also have to adjust the 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. Replace V-belt guard cover and tighten the bolts.
7500 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.
7500 SERVICING BELTS Replacing Poly Chain® Belt • Loosen Poly Chain® belt by moving jackshaft bearings back toward rear of machine. MARK THE JACKSHAFT BEARINGS SO THAT YOU KNOW WHERE 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. • Place a mark on the cutter wheel shaft next to the cutter wheel bushing for replacing the bushing and sprocket.
7500 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.
7500 SERVICING BELTS Replacing Poly Chain® Belt • • • • To tighten the belt more if needed, loosen the front bolts and tighten each of the back jam bolts the same number of revolutions, to keep the alignment true. Make only slight adjustments at a time and recheck tension; repeat as necessary until tension is correct. Then once the belt is adjusted, tighten the front bolts against the bearing. Recheck belt alignment after tightening all bolts and nuts to make sure the belt is sill aligned.
7500 SERVICING BELTS Replacing Poly Chain® Belt 52
00 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.
7500 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. • 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.
7500 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.
7500 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.
7500 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.
7500 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.
7500 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.
7500 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.
7500 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.
7500 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.
7500 • SERVICING STUB SHAFT REMOVE BOLTS AND SCREW INTO EXTRA HOLES Next you will need to remove the jackshaft pulley. Remove the bolts in the jackshaft bushing and screw them back into the empty threaded holes to push the pulley off the bushing and remove the bushing and pulley. Make sure to keep all machine parts and hardware together to make reassembly easier. REMOVE BOLTS • • Remove the bolts holding the belt guard onto the machine and remove the belt guard.
7500 • 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.
7500 • 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.
7500 • • 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 pulleys. Torque the bolts in the pulleys to 30 ft. lbs.
7500 HYDRAULIC ASSEMBLY REMOTE CONTROL 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 PART NO 0300150A 0300142 0300105H 0300105L 0300105J 0300135C 0300135 0300220 0300218 0300234 0300245 0300205 0300236 0300217 0300237 0300215 0300238 0300239 DESCRIPTION 3 Station Remote Manifold Hydraulic Pump - Tow Behinds Hydraulic Cylinder - 3 x 60 Hydraulic Cylinder - 4 x 12 Hydraulic Cylinder - 3 1/2 x 8 Filter Head – 1 psi Hydraulic Filter - 10 Micron 3/4M
7500 HYDRAULIC ASSEMBLY REMOTE CONTROL HYDRAULIC ASSEMBLY 68
7500 HYDRAULIC ASSEMBLY REMOTE MANIFOLD ASSEMBLY ITEM NO PART NO 1 2 3 4 5 6 0300150A 0300150AB 0300150AA 0300120A DESCRIPTION 3 Station Remote Manifold Rexroth Solenoid Valve - DO3 Swing Speed Control Cartridge C/B Cartridge Valve – CBCG-LKN Relief Cartridge Valve – Sun Lift Speed Adjustment - NCCB-KAN QTY 1 3 1 3 2 1 69
7500 HYDRAULIC ASSEMBLY SWING OUT CONTROLS 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 0300130 0300142 0300105H 0300105L 0300105J 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 Pump –
7500 HYDRAULIC ASSEMBLY SWING OUT CONTROLS HYDRAULIC ASSEMBLY 71
7500 HYDRAULIC ASSEMBLY LIFT CYLINDER ASSEMBLY – 4 x 12 (Assembly Part # 0300105L) ITEM NO PART NO DESCRIPTION QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 *3 4 *5 6 *7 *8 *9 *10 11 *12 13 030015S 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 Prince Cyl.
7500 HYDRAULIC ASSEMBLY SWING CYLINDER ASSEMBLY – 3 1/2 x 8 (Assembly Part # 0300105J) ITEM NO PART NO DESCRIPTION QTY 1 2 *3 4 *5 6 *7 *8 *9 *10 11 *12 13 0300105S 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 Prince Cyl.
7500 HYDRAULIC ASSEMBLY TONGUE CYLINDER ASSEMBLY – 3 x 60 (Assembly Part # 0300105H) ITEM NO PART NO 1 2 *3 *4 *5 6 *7 8 9 *10 *11 *12 13 *14 ** DESCRIPTION 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 QTY 1 1 1 2 1 1 1 1 1 1 1 1 1 1 Packing Kit (includes all * items) 74
7500 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) 75
7500 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 PART NO 7200180 0550312 0550313 0550314 0550316 0550012 0550317 0550318 0550215 0550217 0550216 0550319 3500142 3500143 3500145 0150605 0550004 0200003 0200004 7200165 7200166 7200177 7200189 7200190 0150117 0150303 0150207 7200118 0150133 0150307 0150211 7200154 7200155 0150304 0150206 3500261 3500260 0300299G 0150707 72001
7500 FRAME ASSEMBLY BASE FRAME ASSEMBLY 77
7500 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 24 25 26 27 PART NO 0300150A 0350002(0350001A) 0350004(0350001C) 0350031 0200141(0200105R) 0350013 0350011 0200116(0200105M) 0200118(0200105O) 0200119(0200105P) 0350087B 0350087C 0350029 0350029A 3500232 3500280 0150145 0150404 0150207 0150116 0150212 0150102 0150140 0150218 0150402 0150117 0150303 DESCRIPTION 3 Station Remote Manifold 7 Pin Socket 6 Pin Socket Hour Meter - Datcon /Hobbs Deutz Key
7500 FRAME ASSEMBLY REMOTE BOX ASSEMBLY 79
7500 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 23 24 25 26 PART NO 4100245 0400210 0400300 3500273 3500272 0150117 0150303 0150207 0300130 0150103 0150404 0350031 3500276 3500274 3500275 0150608 A150T08 0150503 0150502 3500247 DESCRIPTION Swing Out Boom Weldment Rubber Molding for Swing Out Lexan - 3/16x20 1/4x32 1/4 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
7500 FRAME ASSEMBLY SWING OUT BOOM ASSEMBLY 81
7500 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 7200120 6500159 0500203 0500123 0500402 0500401 6500121 6500122 6500123(6500121A) 0150219 0150220 0150501 0150803 0300105R 6500189 0150310 0300105Q 0150123 0150124 0150308 0150801 A160T07 7200162 7200280 6500125 7200105 0150600 H752012 H752013 H752014 0300528 7200330 PIVOT ASSEMBLY DESCRIPTION QTY 7200 Pivot Weldment Swing Pivot Shaft – 1 1/2" Race – 65/75 #3820 Bear
7500 PIVOT ASSEMBLY 83
7500 ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NO 0200107 7200346 0150407 7200157 0150501 4100154 0150603 0150502 4404110 3504109 0150104 0150207 0200105C 0200105D 0200105E 0150625 ENGINE ASSEMBLY DESCRIPTION Engine -78 HP Deutz Diesel Engine Mounting Assembly 1/2-13 x 4" HH Bolt 1/2 Lock Washer Belt Engagement Handle Cotter Pin - 3/16” x 2” Engagement Linkage Assembly Clevis Pin - 1/2" x 1 3/8” Hair Spring Cotter (Pin Bridge Pin - 1/8" #4 Zinc) Engine Slide Rod Slide Rod Collar 3/8”-16 x 2 1
7500 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 0250109 0250181 0250110 0250127 0400110 7200254 7200257 7200121A 0150106B 0150407 0150304 0150206 0150118 0150404 0150303 0150207 050062 050060 0150303 A160T013 0150119B ENGINE BELT ASSEMBLY DESCRIPTION Sheave - 75 Engine - 6B8.
7500 ENGINE BELT ASSEMBLY 86
7500 ITEM NO 1 2 3 4 5 6 7 8 9 10 PART NO 7200185 0500116 0150307 0150211 0150115A 0150407 0150205 JACKSHAFT ASSEMBLY DESCRIPTION QTY Jackshaft - 2 7/16” Bearing - 2 7/16” – Link Belt 3/4-10 x 3 1/2" HCS 3/4 Flat Washer 3/4-10 Lock Nut Key - 1/2" x 5/8” x 2 3/4" Key - 1/2” Square x 3 1/4" 1/2-13 x 5 Square Head Bolt 1/2 Lock Washer 1/2-13 Hex Nut 1 2 4 8 4 1 1 4 4 8 87
7500 ITEM NO PART NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7200204 0400115 7200200 7200208 0150103 0150303 0150404 0150207 0250115B 0250115H 0250115N 0250115 0150212 0150116 0150304 0150407 0150206 POLY CHAIN® BELT ASSEMBLY DESCRIPTION PC Guard Cover - 7500 PC 6800 7200 7500 PC Guard - 7500 PC Guard Bottom 3/8-16 x 1 HCS 3/8 Flat Washer 3/8 Lock Washer 3/8-16 Lock Nut PC Sprkt 14MX-29S-68Taper Lock 2517 2 7/16” Taper Lock Bushing 3525 2 7/16” Taper Lock Bushing PC Sprocket - 65/75 CW 5/16-18 Lock
7500 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 PART NO 7200186 6500184 0150132 0150205 0500116 0150307 0150211 3500197 0150106A 0150304 0150206 0150118 0150207 6500128 0150605 0450105 0450104 0450110 0450101 0450102 0450103 A160T02 0150407 CUTTER WHEEL ASSEMBLY DESCRIPTION QTY Cutter Wheel - 7500 Cutter Wheel Shaft – 2 7/16” 1/2-13 x 2 1/2” HHCS 1/2 Hardened Flat Washer 1/2-13 Hex Nut Bearing - 2 7/16” – Link Belt 3/4-10 x4” lg.
7500 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.
