Model SP4012 Equipped with a 27HP Kohler Engine

Transcription

1 Model SP4012 Equipped with a 27HP Kohler Engine 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 Ph. (864) Fax (864)

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3 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.

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5 SAFETY ALERT

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7 SAFETY ALERT

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9 SAFETY ALERT

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11 SAFETY ALERT DIESEL MACHINES ONLY

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13 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. The manufacturer is not responsible for consequential damages. This warranty will not apply if the grinder is not operated in a manner recommended by the manufacturer. The following examples would void warranty: 1. The grinder has been abused. 2. The machine is involved in or damaged by an accident. 3. Repairs or attempted repairs were made without prior written authorization. 4. Including but not limited to repairs made due to normal wear. The owner is responsible for all regular maintenance as explained in the operators manual. Neglect in regular maintenance or failure to replace normal wear items such as teeth, pockets, lubrication oils, filters, belts, bearings, etc. may void warranty. This warranty is expressly in lieu of any other warranties, expressed or implied, including any implied warranty or merchantability of fitness for a particular purpose and of any non-contractual liabilities including product liabilities based upon negligence or strict liability. J.P. Carlton Co. Inc. will not be liable for consequential damages resulting from breach of warranty. IT IS NECESSARY TO RETURN THE WARRANTY VALIDATION FORM AND NOTIFY J.P. CARLTON CO. INC. IN WRITING WITHIN TEN (10) DAYS FROM DELIVERY DATE TO VALIDATE THIS WARRANTY. NOTE: This warranty applies only to new and unused equipment or parts thereof manufactured by J.P. Carlton Co. Inc. ANY MACHINES USED FOR LEASE OR RENTAL - WARRANTY IS LIMITED TO 90 DAYS FROM FIRST DAY OF INITIAL SERVICE. NOTICE: All power units and associated components are NOT warranted by J.P. Carlton Co. Inc. or their dealers. It is the customers responsibility to return machine to the local engine distributor. INFORMATION PHONE NUMBERS TO FIND YOUR LOCAL ENGINE & PARTS SERVICE CENTERS: Honda (GA-Eastern Time Zone) Kohler Engines (Toll Free) Briggs & Stratton Engines (Toll Free) Lombardini (GA-Eastern Time Zone) Deutz Engines (Toll Free) John Deere Engines (Toll Free) Caterpillar (Toll Free) Kubota (IL-Central Time Zone) Kawasaki Engines (MI-Eastern Time Zone) Wisconsin Engines (Toll Free) Onan Engine (Toll Free) In order to process any warranty claims. It is the owners responsibility to report claims promptly to us or our authorized dealer from whom the equipment was purchased. It is necessary to include the following information on any and all request for warranty: 1. Dealer from whom purchased 5. Engine make and serial number 2. Date of delivery 6. Length of time in use 3. Serial number of unit 7. Date of failure 4. Model number of unit 8. Nature of failure

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15 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. It will be the customers responsibility to install the replacement parts unless arrangements are made with the selling dealer. The manufacturer will not reimburse travel cost to servicing dealer. It is the customers responsibility to deliver machine to dealers facility, unless other arrangements have been agreed to between the selling dealer and the customer. The manufacturer may elect, at its discretion, to reimburse reasonable labor cost to customer or dealer for major defect repairs. Prior approval must be obtained from J.P. Carlton Company Inc. IMPORTANT NOTICE 1. AIR FILTER MAINTENANCE IS CRITICAL ON STUMP GRINDING MACHINES. DIRT INGESTION WILL NOT BE WARRANTIED BY THE ENGINE MANUFACTURER OR J.P. CARLTON COMPANY. 2. OIL AND OIL FILTER MAINTENANCE AND STAYING WITHIN THE LIMITS OF THE ANGLE OF OPERATION IS ALSO CRITICAL ON STUMP GRINDING MACHINES. STARVING THE ENGINE FOR OIL WILL NOT BE WARRANTIED BY THE ENGINE MANUFACTURER OR J.P. CARLTON COMPANY.

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17 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. 121 John Dodd Road Spartanburg, SC Phone: Purchaser Information: Company Name: Street Address: City: State: Zip Code: Telephone: Contact: Machine Information: Model Number : Serial Number : Engine Model : Serial Number : Dealer Information: Dealer Name: Street Address: City: State: Zip Code: Contact Name: 1. Customer has been instructed on operation and safety aspects of operating the equipment. 2. Customer has been advised not to reach into cutter wheel area. 3. Customer has been advised to stop machine and remove key before performing any type of maintenance. 4. Customer has been warned not to operate the machine without the cutter wheel guard in place. 5. Customer has been furnished with all parts and operators manuals. 6. Customer has been instructed on equipment maintenance schedules and procedures. 7. Customer has been advise that the engine or power unit that is used on this machine is warranted by the engine manufacturer and NOT J.P. Carlton Company. All engine warranty issues should be addressed to the local engine dealer. 8. Customer understands the importance of air and oil filter maintenance, and the importance of staying within the angle of operation of the engine. If either of these is not adhered to, the engine warranty is VOID. 9. Customer understands to keep locking collars tight and purge bearings with grease. 10. All operation and warning decals are properly displayed on equipment. 11. Customer understands it is his responsibility to train all operators on operator safety. I have inspected this equipment and find it in good working condition. To the best of my knowledge, the customer and his personnel are aware of the above procedures. Date: Signed: Dealer Representative The equipment has been thoroughly checked by the above named dealer representative, and I am satisfied with his instructions. Date: Signed: Purchaser

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19 TABLE OF CONTENTS INTRODUCTION OPERATION FOREWORD 1 GENERAL INFORMATION 2 MACHINE FEATURES 3 MACHINE SPECIFICATIONS 4 SAFETY PRECAUTIONS 5 DAILY CHECKLIST 10 MACHINE CONTROLS 11 TRANSPORTING 21 MACHINE OPERATION 23 MAINTENANCE PARTS MACHINE MAINTENANCE 26 LUBRICATION CHART 30 TROUBLE SHOOTING GUIDE 31 SERVICING BELTS 33 SERVICING BEARINGS 41 SERVICING FRONT AXLE 50 SERVICING BOOM PIVOT 51 SERVICING CUTTER WHEEL 52 SERVICING HYDRAULICS 57 MACHINE WIRING 60 HYDRAULIC ASSEMBLY 64 FRONT AXLE ASSEMBLY 77 REAR WHEEL ASSEMBLY 81 PIVOT ASSEMBLY 83 BOOM ASSEMBLY 86 CHIP GUARD ASSEMBLY 96 BACK ENGINE MANUAL RADIO CONTROL MANUAL

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21 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. The Carlton Model SP4012 is designed and intended for use in unique situations where size and maneuverability are foremost. As a result, the Model SP4012 has its own unique operational requirements. 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. Slowly experiment with the controls and gradually work yourself up to the full capabilities of this machine. The Carlton Model SP4012 is a durable and profitable professional stump grinder. Read this manual, the engine manual and the safety and operational decals on the machine. Use proper safety precautions. Follow the instructions and use common sense and your OX will perform like its namesake. If getting more work done in a day, with less trouble, is your idea of good business, then you ll love your new Carlton Stump Grinder. We welcome your suggestions on how we might better build our machines. We solicit any and all questions concerning the safe operation or proper servicing of your new stump grinder. Please feel free to write to us with any comments. We ll enjoy hearing from you! 1

22 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. Inspect your new Carlton Stump Grinder as soon as you receive it. Any damages incurred during shipment are not warranted and therefore not covered repairs. You should have the truck driver verify or acknowledge any damages caused during shipment. If not, contact the truck lines as soon as possible with your complaint. Any reference made to right, left, front or rear in relationship to the stump grinder is illustrated in the following picture. Please refer to these any time you call your dealer or J. P. Carlton Company for parts or assistance. Front Rear Front Left Right 2

23 MACHINE FEATURES Gas Power Direct drive hydraulic pump Dual hydraulic motor propulsion Hydraulic Controls Freewheeling capability Safety valves permit unaffected operation uphill, downhill or level Heavy construction 30 extension tongue Heavy duty tongue stake Counterbalancing valve Dual swing cylinders Hardened bushings in rotating cylinders Four wheel stance Hydraulic Steering Large hydraulic tank Adjustable Timken tapered roller bearings in the pivot head with hardened shafts Tapered roller bearings on cutter wheel & jackshaft 1 thick Blanchard ground cutter wheel Low maintenance, multiple drive belt 20 carbide tipped cutter teeth 35 width to clear narrow fence gates Front axle bearings Double wire braid hose & hydraulic lines Safety tie down loops 1/4 plate fenders Epoxy primer DuPont Imron protective finish Key start High capacity battery Premium tires Heavy duty rubber and metal chip guards Hour meter Hydraulic and fuel filters Removable chip flap Poly Chain to cutter wheel Easy engine belt adjustment We Pride Ourselves in the strength and quality of each and every machine 3

24 MACHINE SPECIFICATIONS Engine...Kohler Command 27HP Weight Lbs. Length Height...46 Width...35 Cutting Depth Below Ground...13 Cutting Height Above Ground...34 Cutter Head Swing...40 arc Number of Teeth on Cutter Wheel...20 Cutter Wheel Diameter w/teeth...21 Cutter Wheel Thickness...1 Blanchard Ground Jackshaft Bearings...1 7/16 Cutter Wheel Bearings...1 7/16 Cutter Wheel Speed RPM Fuel Tank Capacity Gallons Hydraulic Tank Capacity Gallons 4

25 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. The operator should pay close attention to the instructions whenever they see this symbol. The Safety-Alert Symbol will be accompanied by one of the following words: DANGER, WARNING, or CAUTION A DANGER symbol means that if the instructions are not followed the possibility of serious personal injury or death is probable. A WARNING symbol means that if the instructions are not followed there is a possibility of serious personal injury or death. A CAUTION symbol means there is an unsafe condition or practice that may cause personal injury or property damage. PERSONAL PROTECTION: Wear face shield and hearing protection Do not wear loose-fitting clothing Tie back long hair Do not wear jewelry Keep clear of cutter wheel Keep away from moving parts Only operate in a well ventilated area because of carbon monoxide P/N P/N P/N

26 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. Keep hands, feet, legs, clothing, hair and all other body parts away from cutter wheel and other moving machine parts to eliminate the possibility of injury. Shut down machine completely and remove key before removing debris from work area (i.e. clearing rocks, wood chips, etc.). DO NOT modify or change any part without written approval from J. P. Carlton Company. Do not ride, sit, stand, lay or climb anywhere on this machine during operation, while running, or during transport. Do not move, position, or transport this machine while cutter wheel is engaged. DO NOT operate any machinery while under the influence of alcohol or drugs (prescription, over the counter, or otherwise). Do not refill fuel tank while engine is hot, running, or indoors. Danger of fire or explosion exists. Fuel and its vapors are highly flammable and explosive. Handle with care. Only use approved (red) fuel containers for storage. Do not store fuel containers near any open flames, sparks or other sources of ignition. Do not store equipment with fuel in the tank. 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. Never check for hydraulic leaks using hand or finger, use cardboard or wood. Keep away from pressurized leaks. Pressurized fluid can penetrate the skin and cause injury or even death. Seek immediate medical attention if penetration occurs. Always wear eye protection. 6

27 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. 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. Do not cut crosswise of roots above ground to prevent roots being thrown. If unusual vibration occurs, stop engine immediately and correct problem before continuing operation. Keep all guards in place and properly secured during operation. Keep all safety devices working properly and all other machine parts in good working condition. Never leave the controls unattended while in operation. Be sure machine is not capable of operation when left unattended. Stop engine and remove key when repairing or adjusting machine or drive belts. Keep engine in good condition service as instructed in engine manual. Do not touch engine while running or hot (serious burns may result). Allow all machine parts to cool 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. Do not place machine in free wheel without first placing tongue stake in the ground. Park machine on level surfaces only. Lower cutter head to the ground and use wheel chocks to prevent unattended movement. Do not operate stump cutter in dark, dim lit, or concealed areas. Keep machine clean and clear of debris to eliminate fire hazard. It is especially important to clean any oil or fuel spills to prevent the danger of fire. Keep cutter wheel skirt guards in good condition to help control chips during grinding. Keep safety and instructional decals clean and replace any that are damaged, difficult to read, or missing. Decals may be purchased from J. P. Carlton or an authorized dealer. 7

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29 SAFETY PRECAUTIONS ATTENTION: The Carlton Model SP4012 Stump Grinder CAN be overturned on steep inclines. This can cause serious injury to operator and machine. DO NOT OVERTURN! P/N Avoid steep side inclines when operating this machine! The narrow design width required in operating the model SP4012 in tight confines makes it susceptible to tipping over sideways. Overturning this machine can result in personal injury, property damage and/or seizing the engine. USE CAUTION. Positioning the cutter wheel uphill and as close to the ground as possible while in transit will minimize the danger of tipping over and maximize the steadiness of the Model SP4012. When encountering a hill, the best approach is straight up or straight down. Avoid any side angles whenever possible. NEVER ALLOW INEXPERIENCED PERSONS TO OPERATE THIS MACHINE. 9

30 DAILY CHECKLIST Check engine oil at dipstick. Take reading with engine sitting level (see photos). Add recommended oil (see engine owners Manual) as required. Check fuel filter for debris or water. Replenish fuel tank with fresh fuel. Check condition and tightness of drive belts. (See Servicing Belts) New belts will stretch and become loose as machine runs. Check belt tension often when belts are new. Check for any loose, broken or missing cutter teeth and pockets. Inspect bolts, hydraulic fittings, wiring harnesses, hoses and equipment for tightness, wear, or leakage. Replace if necessary. Check air filters & precleaners. Inspect dry air cleaners. Do not blow out or tap on ground. REPLACE WITH MANUFACTURER RECOMMENDED AIR FILTER ONLY. Check hydraulic oil level. This Carlton stump grinder is equipped with a gauge that shows the level of oil and the temperature of the oil. When filling the tank with oil, the window of the gauge will also fill with oil, as the level gets higher in the tank. Never fill the oil tank above the BLACK line at the top of the gauge. Do not run the machine with the oil level below the RED line at the bottom of the gauge. Check condition of tires. Inflate to proper pressure. Grease cutter wheel and jackshaft bearings daily. Purge bearings until new grease is seen. INCORRECT POSITION CORRECT POSITION OIL LEVEL/TEMP GAUGE 10

31 MACHINE CONTROLS ENGINE CONTROLS - Refer to engine manufacturers owners manual for controls, operation, and service. The Key Switch for starting the engine is located on the Kohler engine. There is also a choke lever and throttle lever on the engine. Read the engine manual for proper starting and operating instructions. CUTTER WHEEL MUST BE DISENGAGED WHEN STARTING THE MACHINE. 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.) CHOKE THROTTLE KEY SWITCH HYDRAULIC CONTROLS A series of hydraulic controls are located on the machine and are clearly marked. STEERING TRAVEL - (lever 1) Push or pull control lever to control steering, right or left. 11

32 MACHINE CONTROLS UNIT TRAVEL - (lever 2) Push or pull control lever to control travel, forward or reverse. This lever controls the dual drive motors on the rear wheels. The Cutter Head may be moved in any of three directions. CUTTER WHEEL (Lift) - (lever 3) (Shown as CUTTER HEAD UP/DOWN on radio transmitter.) This lever operates the cutter head lift function, which raises and lowers the cutter head. TONGUE - (lever 4) This lever operates the tongue extension function, which moves the machine toward the stump and pulls the machine back away from the stump. BOOM TRAVEL (Swing) - (lever 5) (Shown as CUTTER HEAD RIGHT/LEFT on radio transmitter.) This lever operates the cutter head swing function, which swings the boom back and forth in a left-right-left-right-left motion. 12

33 MACHINE CONTROLS GROUND STAKE Pushed firmly into the ground, the stake anchors the machine against pressure during cutting. Provides a push point for tongue extension. Ground stake must be used during operation. The hydraulic motor will not keep machine from creeping while grinding stump. After stake is in ground, place machine in freewheel position. CUTTER WHEEL ENGAGEMENT LEVER Always start engine with cutter wheel disengaged. With engine idling, slowly move lever towards cutter wheel to engage engine drive belt. Lock lever in position during operation. DO NOT ENGAGE OR DISENGAGE BELT AT HIGH ENGINE SPEED. Injury and damage will occur. 13

34 MACHINE CONTROLS Gear Selector Freewheeling Valve Travel Speed Adjustment Swing Speed Adjustment GEAR SELECTOR Push switch up to run machine at high gear and push switch down to run machine at low gear. Machine has more climbing power in low gear. MUST BE IN HIGH GEAR TO CHANGE INTO FREEWHEEL. FREEWHEELING VALVE Releases wheels from the drive system by overriding the hydraulics. To engage, push knob in and turn a quarter turn counterclockwise. Tongue extension can be accomplished by setting the lever to freewheeling position. Always make sure that the ground stake is in the ground before placing machine in free wheel. To disengage freewheel, push knob in and turn clockwise back to original position. Knob will pop out when freewheeling is disengaged. FREEWHEEL WILL ONLY OPERATE WITH GEAR SELECTOR IN THE HIGH POSITION. TRAVEL SPEED ADJUSTMENT Adjust travel speed for smooth operation. Turn valve counter-clockwise to decrease travel speed. SWING SPEED ADJUSTMENT Adjust swing speed for smooth operation. Turn valve counter-clockwise to slow cutter head swing. Close valve by turning clockwise to allow head to move side to side at low RPM. 14

35 MACHINE CONTROLS OPTIONAL 4-WHEEL DRIVE AND BLADE FUNCTIONS If a machine is ordered as a 4-wheel drive unit, it will come with drive motors on the front as well as the rear wheels. The 4- wheel drive unit can also be supplied with a Blade option. The following is the control operation information about these optional functions. FRONT DRIVE MOTORS STEERING TRAVEL - (lever 1) Push or pull control lever to control steering, right or left. The steering travel function will operate in the same manner but the machine will look slightly different, as shown in the picture to the right. UNIT TRAVEL - (lever 2) Push or pull control lever to control travel, forward or reverse. This lever controls the four drive motors on the front and rear wheels. BLADE - (lever 4) (Optional) This lever operates the blade function, which moves the scrape blade up and down. To backfill the hole after grinding the stump, lower the scrape blade by pulling the lever back. At all other times keep the scrape in the raised position. 15

36 MACHINE CONTROLS OPTIONAL REMOTE CONTROL OPERATION WIRED The control functions operate the same on a remote control machine as they do on a standard 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 position the machine or to test the operation of the functions. Use the switches on the remote transmitter to operate the machine when moving the machine to the job site and when grinding the stumps. For a remote control machine with a wired remote transmitter, turn the Machine ON/Remote ON switch to Remote On and turn the Engine switch on the transmitter to RUN. Now start the engine using the key switch, run the engine a few minutes to allow the oil to circulate before starting to operate the functions. After the engine has been running for a few minutes, test the remote transmitter by testing the functions for correct operation. After testing the functions and everything is operating correctly, proceed to the job site. REMOTE CONTROL MACHINE TOGGLE SWITCHES MACHINE ON / REMOTE ON SWITCH WIRED REMOTE TRANSMITTER WITH 25 CORD REMOTE TRANSMITTER PLUG RECEIVER HIGH/LOW GEAR SWITCH Some functions require using the machine mounted controls, such as the Swing Speed Adjustment Valve, the Ground Speed Adjustment Valve, the Freewheel Valve on machines equipped with freewheel motion, and the Engagement Lever to engage the cutter wheel. The Swing Speed Adjustment, Freewheel, and Ground Speed Adjustment Valves are on opposite sides of the machine from the standard machine but still operate the same. GROUND SPEED ADJUSTMENT FREEWHEEL VALVE SWING SPEED ADJUSTMENT 16

37 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. OPTIONAL REMOTE CONTROL CONVERTING FROM WIRED TO RADIO TRANSMITTER To change from a wired to a radio (wireless) transmitter, remove the lower cover on the control box. There are 2 bolts on each side. You can now see the wired remote control receiver. Remove the receiver cover. Drill holes in this cover for attaching the radio control receiver; make sure the hole locations match the bolt locations on the radio receiver. Bolt the radio receiver to the cover and then replace the cover on the wired remote receiver inside the control box. Use the wiring and connector diagrams, in the radio control manual included at the back of this manual, to wire directly to the appropriate contacts of the machine electronics. Contact your Carlton dealer if you need assistance not the radio control manufacturer. The radio transmitter and receiver will be programmed at the factory when purchased as a set. REMOVE THE CONTROL BOX BOTTOM COVER REMOVE THE COVER ON THE REMOTE RECEIVER AND DRILL HOLES TO ATTACH THE RADIO RECEIVER THE RADIO CONTROL RECEIVER, SHOWN AT THE RIGHT, MUST BE INSTALLED IN THE CONTROL BOX 17

38 OPERATION WIRELESS MACHINE CONTROLS GEAR SWITCH - HIGH POSITION 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 (see engine picture below right), the machine switch to Remote On, and make sure the Gear switch is in the HIGH position. 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. When the transmitter is operating there is a yellow light that will be flashing, the light is indicated in the picture at the right. (Read the radio control manual for more information on the meaning of different lights and colors.) If the transmitter doesn t start, check the transmitter for stuck switches, it will not start with a switch in the ON position. Now start the engine using the key switch. If the engine doesn t start right away and you have to restart it, make sure the light on the transmitter is still on, and restart the engine. If you lose the connection (light off), repeat the procedure from the beginning and perform each step exactly as described. Test controls for proper operation. LOW BATTERY / FAULT LIGHT TOGGLE ANY SWITCH PUSH SWITCH UP TO REMOTE ON E-STOP BUTTON A YELLOW LIGHT WILL BE FLASHING WHEN TRANSMITTER IS SENDING SIGNALS TO THE RECEIVER The E-STOP button turns off the transmitter and the machine when it is pressed down. When the Gear switch is toggled up to HIGH, it only operates when the Travel function is being used. NEVER WELD ON A MACHINE WITH RADIO CONTROLS WITHOUT FIRST DISCONNECTING THE RECEIVER WIRE HARNESS, OTHERWISE THE RADIO RECEIVER WILL BE DESTROYED. KEY SWITCH 18

39 MACHINE CONTROLS OPTIONAL REMOTE CONTROL 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. There are complete instructions along with colored illustrations in the radio control manual included in the back of this manual. To access the receiver, remove the front cover from the machine control box. Remove the cover of the remote receiver with the radio receiver attached. This will make it easier to work with the radio receiver. Remove the radio receiver panel by unlatching the plastic tabs on either side of the receiver; see the radio control manual included in this manual at the back. The receiver panel will now slide out of the cap. REMOVE COVER RELEASE THE RADIO RECEIVER CAP BY UNLATCHING THE TABS ON EACH SIDE Follow the instructions in the radio control manual to download the ID Code. There are specific instructions that need to be followed and corresponding illustrations. The radio control manual is included in the back of this manual. Push the receiver panel back up into the cap until the tabs snap back into place. REMOVE THE REMOTE COVER TO ACCESS THE RADIO RECEIVER UNIT Always replace the machine cover when maintenance or troubleshooting is complete. DO NOT RUN MACHINE WITHOUT ALL GUARDS & COVERS IN PLACE AND SECURED. 19

40 TROUBLESHOOTING SP4012 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) 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. Remove old batteries and replace with new batteries. The transmitter operates using 4 AA alkaline batteries. REMOVE THE BACK COVER TO ACCESS THE BATTERIES THERE ARE 4 SCREWS HOLDING IT IN PLACE. THE BATTERY COMPARTMENT IS LABELED FOR CORRECT BATTERY ORIENTATION. Next, open the cover on the machine control box. You will need to be able to see the lights on the receiver to compare to the trouble indicators on the receiver diagnostic list in the radio control manual. Check the light configuration and compare it to the Receiver Diagnostic list in the radio control manual. If status light on radio receiver is flashing red, a fuse is blown. To change a fuse, remove the receiver panel from the cap and change the fuse. Inspect wiring for short circuits (e.g. bare wires). If problem re-occurs, call for service. Push the receiver panel back up into the cap until the tabs snap back into place. Always replace the machine cover when maintenance or troubleshooting is complete. DO NOT RUN MACHINE WITHOUT ALL GUARDS & COVERS IN PLACE AND SECURED. COMPARE THE LIGHT CONFIGURATION ON THE RECEIVER TO THE DIAGNOSTIC CHART IN THE RADIO CONTROL MANUAL REPLACE FUSE REMOVE COVER 20

41 TRANSPORTING DO NOT TOW! THE MODEL SP4012 IS DESIGNED TO BE TRANSPORTED TO THE JOB SITE AND WILL MOVE UNDER ITS OWN POWER ONCE ON SITE. Transport machine in a suitable vehicle designed for a load of these dimensions and weight. A low trailer is recommended due to its decreased entry height, and will be safer all around. The model SP4012 can be loaded into a pick-up truck, but requires increased safety precautions against tipping. Tie-downs, a sturdy and stable loading ramp and extra caution are required. THE TRAILER MUST BE SECURELY ATTACHED TO THE TOW VEHICLE BEFORE LOADING OR UNLOADING THE STUMP GRINDER. LOADING RAMPS MUST BE STURDY AND SECURELY ATTACHED TO THE TRAILER BEFORE ATTEMPTING TO LOAD OR UNLOAD THE MACHINE. Check trailer for security and make sure chains are properly installed. Check tires inflation. Check trailer lights for proper operation. Never transport the machine with the engine running. Towing will affect handling. Allow for extra stopping distances. Start and stop gradually. Tow at a safe reasonable speed. 21

42 TRANSPORTING 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 Check valve to make sure machine is NOT in freewheeling mode. (See Machine Controls section for more information on freewheeling operation.) Start engine as recommended by the engine manufacturers manual. Increase engine RPM, and raise cutter head just off the ground. With operator in position, push the forward travel control lever and steer machine slowly up appropriate ramp into transport vehicle. KEEP MACHINE AS LEVEL AS POSSIBLE. Continually adjust cutter head height as you go, keeping the mass as low to the ground as possible. Once the machine is loaded, lower the cutter head, shut down engine and secure machine tightly with sufficient tie-downs to prevent any movement in transit. UNLOADING Freewheeling valve must be in drive position to avoid machine runaway on ramp. (See Machine Controls section for more information on freewheeling operation.) Undo tie down straps and check ramps for sturdiness and positioning. Start engine as recommended by the engine manufacturers manual. Increase engine RPM, and raise cutter head to just clear deck and/or ramp. DO NOT UNLOAD ON ANYTHING OTHER THAN LEVEL GROUND. Continually adjust cutter head height as you go, keeping the mass as low to the ground as possible. Proceed to work site using extreme caution on hills or uneven terrain. 22

43 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. Avoid transverse slopes. Ascend/descend hills straight up & down. A hydraulic safety valve prevents the machine from picking up speed downhill. This may also be used as a brake by decreasing engine speed. Hydraulic motor will not hold machine as a parking brake. Machine will creep. 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.) DO NOT OPERATE AROUND WATER, GAS, POWER OR PHONE LINES. IF IN DOUBT, CHECK BEFORE GRINDING. WEAR FACE SHIELD AND HEARING PROTECTION. KEEP CLEAR OF CUTTER WHEEL AND MOVING MACHINE PARTS. KEEP SPECTATORS AWAY. Position machine at stump with cutter wheel a slight distance away from stump. Do not engage cutter wheel when positioning machine near stump. Hitting the stump with cutter wheel running will break the Poly Chain belt. Remove clip and position ground stake as far into the earth as possible. Drive in with hammer if necessary. 23

44 MACHINE OPERATION Reduce engine RPM to idle. Raise cutter head clear of stump. Engage cutter head drive belts by slowly rotating engagement lever. Increase engine RPM to full. Test controls for proper operation, speed, and unobstructed movement. Cutter head swing speed should be adjusted to a rate that will allow cutter wheel to pass through stump smoothly. If jerking, bouncing or significant drops in engine speed occur, swing rate is too rapid and must be decreased. Swing speed should be determined and adjusted with the controls in the full open position. A counter-rotating valve is located within the hydraulic system to adjust this speed. Turning the handle counterclockwise will open the bypass and slow swing action. Turning it clockwise will increase swing rate. SWING SPEED ADJUSTMENT 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. Continue cutting stump by adjusting cutting wheel progressively lower until stump is cut well below ground level. 24

45 MACHINE OPERATION Swing cutter wheel clear of stump and extend tongue to 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. Raise cutter wheel clear of stump and return to center position. Reduce engine speed to idle. DO NOT TURN OFF MOTOR. Engine must be allowed to cool slowly at idle for 3-5 minutes to avoid damage. With engine at idle; disengage drive belts by slowly releasing engagement handle. DO NOT DISENGAGE DRIVE BELTS AT HIGH ENGINE SPEED. Damage to belts and machine will occur. Withdraw tongue extension; remove from free wheel position, extract tongue stake. Turn off motor. Allow cutter wheel to come to a full stop before inspecting work area. 25

46 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED. EXCESSIVE MACHINE VIBRATION WILL OCCUR CAUSING PREMATURE BEARING FAILURE AND EQUIPMENT DAMAGE. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. Check engine oil at dipstick daily; take reading with engine sitting level (see photos). Add recommended oil and change oil as required. (See engine owners manual.) INCORRECT POSITION SP4012 Engine Filters C Air - Main Filter D Air - Safety Filter E1 Oil Filter CORRECT POSITION 26

47 MACHINE MAINTENANCE Check hydraulic oil level daily. This Carlton stump grinder is equipped with a gauge that shows the level of oil and the temperature of the oil. When filling the tank with oil, the window of the gauge will also fill with oil, as the level gets higher in the tank. Never fill the oil tank above the BLACK line at the top of the gauge. Do not run the machine with the oil level below the RED line at the bottom of the gauge. The machine is equipped with Citgo AW32 hydraulic oil at the time of manufacture. Use the same or equivalent. For a new machine, change the hydraulic oil filter when the stump grinder has been operating for 10 hours. Replace with the same type of in-tank filter element supplied originally, available through Carlton or Carlton dealers. From this point on, change the filter every 200 hours of operation. Change hydraulic oil every 500 hours of operation or at least once a year depending on use. Flush the hydraulic tank when changing the hydraulic oil. Replace oil if it has a burnt odor or if it is contaminated. Replace oil if the stump grinder has been stored for a long period of time (all winter). Drain the hydraulic tank using the drain plug located on the bottom of the tank. Dispose of used oil according to state regulations. Check setscrews in Jackshaft Bearings and Cutter Wheel Bearings for tightness weekly. Remove the jackshaft bearing cover to access the jackshaft bearing collar setscrew. 27

48 MACHINE MAINTENANCE Check cutter wheel, pockets, and teeth for wear. If any repair is needed, see Servicing Cutter Wheel section for further instruction. 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 jackshaft bearings Daily. These bearings should be purged using grease EVERYDAY. Purge till new grease comes out. Use Texaco Starplex II grease. 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 cutter wheel bearings Daily. These bearings should be purged using grease EVERYDAY. Purge till new grease comes out. Use Texaco Starplex II grease. 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 idler engagement linkage Monthly. Use Texaco Starplex II grease. 28

49 MACHINE MAINTENANCE Remove bottom portion of guard and clean out Poly Chain Guard weekly. Chip build up will wear Poly Chain Belt. Grease boom pivot Monthly. Use Texaco Starplex II grease. DO NOT OVER GREASE. Grease bottom pivot bearings Monthly. Use Texaco Starplex II grease. You cannot over grease this area all parts are heat-treated. Grease steering wheel pivots every 2-3 months. Use Texaco Starplex II grease. DO NOT OVER GREASE. Extend the tongue and use a cloth covered with grease to lightly coat the tongue extension every 6 months. 29

50 The model SP4012, 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. 30

51 TROUBLE SHOOTING GUIDE COMPLAINT CAUSE CORRECTION Engine will not start. (See Engine Manufacturers Manual for further information.) Loose ground wire. Loose hot wire. Dead battery. Hydraulic system loss of power. Low oil. Valve set too low. Missing or sheared key on pump shaft. Bad cylinder. Swing cylinder loss of power. Cutter head speed adjustment screw turned wide open. Belt Squeal. Belt tension too loose. Belt out of line. Belt jumping off. Engaging or disengaging belt at high engine RPM. Belt keeper too far from belt. Cutter wheel vibration. Tooth missing. Pocket out of balance. Improper tooth arrangement. Cutter wheel throwing teeth. Bad pocket. Dirt in pocket. Worn cutter wheel. Cutter wheel breaking teeth. Teeth set too far out of pocket. Clean and tighten. Clean and tighten. Recharge or replace. Refill with correct oil. Adjust relief valve. Remove pump, replace or repair keyway. Replace cylinder packing. To slow cutter head swing at high RPM turn valve counter-clockwise. Re-adjust for no bounce cutting. Tighten. Align Pulleys. Only engage or disengage belts at low engine speeds. Adjust keeper closer to belt. Replace missing teeth. Always replace pockets in pairs across from each other. Install correctly with like pairs of teeth directly across from each other. Replace pocket. Clean pocket and replace missing teeth. Replace cutter wheel. Use gauge to set teeth correctly. 31

52 TROUBLE SHOOTING GUIDE COMPLAINT CAUSE CORRECTION Cutter wheel stops turning. Belt not engaged. Engine belt broke. Poly chain belt broke. Sheared key in shaft. Broke cutter wheel shaft. Adjust yoke assembly. Replace belt. Replace belt. Replace key. Replace shaft. Roar in machine when cutter wheel is engaged. Belt guards rubbing on jackshaft or cutter wheel shaft. Jackshaft or cutter wheel bearings going bad. Re-position guards off of shafts. Replace bearings. Traction loss of power. Open free wheel valve. Worn free wheel valve. Relief valve set too low. Broken drive chain. Hydraulic motor worn. Close free wheel valve. Replace free wheel valve. Increase relief valve pressure by turning relief valve screw inward. Replace chain. Replace Hydraulic motor. Bearing will not take grease. Grease fitting clogged. Replace fitting. Cutter head swings faster one way than the other. Counter balance valve is out of adjustment. Adjust counter balance valve to equalize swing speed. For all Radio Transmitter or Receiver problems, see the Radio Control Manual included at the back of this manual. 32

53 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. Remove V-belt guard cover. Remove belt keeper on idler pulley and loosen belt keepers at engine pulley. Remove pump drive. Only remove the bolts at 12 o clock and 6 o clock. Remove the pump plate with the pump still attached, not necessary to remove and cap hoses. 33

54 SERVICING BELTS REPLACING V-BELT As you pull the pump off, the pump coupler and a rubber insert will come off with it. Take note of the insert and do not lose it. Remove old belt and replace with new one. After replacing belt, check the tension. Engage engine belt using the engagement handle to check tension. THE ENGINE MUST BE OFF WHEN WORKING ON THE STUMP CUTTER. When the V-belt is tensioned properly, it will deflect 1/4 with 25 lbs. of force applied. New belts will stretch and become loose as machine runs. Check belt tension often when belts are new. 34

55 SERVICING BELTS REPLACING V-BELT Use the linkage between the engagement handle and the idler arm, located on the operators side of the machine, to adjust the belt tension. Remove the cotter pin and the clevis pin from one side of the linkage assembly. Screw the free end counter-clockwise to lengthen the assembly in order to tighten the belt. Make only slight adjustments at a time and recheck tension; repeat as necessary until tension is correct. Reconnect all parts of the assembly to the machine and recheck the tension. New belts will stretch and become loose as machine runs. Check and adjust belt tension often when belts are new. Use the same procedure to tighten a loose belt. DO NOT OVER TIGHTEN BELT; OVERLY TIGHT BELTS WILL CAUSE BEARING AND ENGINE DAMAGE. Turn the free end clockwise to shorten the assembly to loosen belt tension. Replace belts when worn or when repeated adjustments are necessary. Belts should never get so loose that all of the adjustment capability is used. ENGAGEMENT LINKAGE REMOVE COTTER PIN TURN THIS END COUNTER-CLOCKWISE TO LENGTHEN ASSEMBLY LOOSEN ENGINE MOUNT BOLTS If belt doesn t need to be replaced and tension can t be adjusted using the above procedure, you may have to loosen the engine-mounting bolts and slide engine toward the front of the machine. Loosen, don t remove, the bolts on both sides of the engine. Use the adjustment bolts to move the engine toward the front of the machine. Make only slight adjustments and recheck tension. Be sure to retighten the engine mounting bolts and adjustment bolts and nuts. USE ADJUSTMENT BOLTS TO MOVE ENGINE 35

56 SERVICING BELTS REPLACING V-BELT Replace the clevis pin and the cotter pin onto the linkage assembly. After belt tension is adjusted properly, replace pump drive. Make sure that the rubber insert is in place when replacing pump drive. Replace belt keeper on idler pulley and retighten the beehive belt keepers. Replace belt keeper on idler pulley and tighten belt keepers at engine pulley. Replace V-belt guard cover and tighten bolts. DO NOT RUN MACHINE WITHOUT ALL GUARDS IN PLACE AND SECURED. GENERAL TENSIONING OF V-BELT DRIVES Tensioning of belts on the V-belt drive is critical to tighten the outboard bearing and pulley. A few simple rules about tensioning will satisfy most of your requirements: 1. The best tension for the V-belt drive is the lowest tension at which the belts will not slip under the highest load condition. 2. Check the tension on a new drive frequently during the first day of operation. 3. Thereafter, check the drive belt tension periodically. 4. Too much tension shortens belt and bearing life. 5. Keep belts and sheaves free from any foreign material that may cause slippage. 36

57 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. Special care needs to be taken with your Poly Chain belt. Alignment, tension, and cleanliness of this belt are very important. The Poly Chain belt needs to be checked for tension approximately every 70 to 100 hours of use. The Poly Chain belt must be running true. If you adjust one bearing more than the other, the belt will run on an angle and will cause belt failure. A belt broken straight across is the result of a shock load. In a shock load failure, the fibers are broken and over a period of time the belt will break down from the shock load and snap in half. A broken belt with lost teeth indicates that the belt was loose. When replacing the Poly Chain belt, do not try to pry belt on over pulley, this can break the fibers in the Poly Chain belt. After you have installed or re-tensioned the Poly Chain belt, you will have to re-adjust the engine V- belt for proper tension. Remove the Poly Chain guard cover and bottom cover. 37

58 SERVICING BELTS REPLACING POLY CHAIN BELT Loosen Poly Chain belt by moving jackshaft bearings. MARK THE BEARINGS SO THAT YOU KNOW HOW THEY ARE POSITIONED ON THE JACKSHAFT PLATE. Loosen bolts on bearing closest to Poly Chain guard and remove bolts on the bearing closest to engine belt guard so that side of the jackshaft may be lifted to remove Poly Chain belt. Loosen the jam bolts in the back and move the bearings back. You will need to loosen the engine belt guard in order to lift the end of the jackshaft so that the Poly Chain belt may be removed. Bolts are located at top, bottom, and rear. 38

59 SERVICING BELTS REPLACING POLY CHAIN BELT Remove old belt and replace with new one. Do not pry new belt over sprockets since this can break the fibers in the Poly Chain belt. Check alignment of Poly Chain sprockets using a straight edge. To adjust tension of the belt, slide the bearings back into the place that you had marked. Tighten the jam bolts. To tighten the belts more if needed, loosen the front jam bolts and tighten each of the back jam bolts the same number of revolutions, to keep the alignment true. After the belt is adjusted, tighten the front jam bolts back against the bearing. After the Poly Chain belt has been adjusted; check the V-belt tension and alignment. When the V-belts are tensioned properly, they will deflect 1/4 with 25 lbs. of force applied. DO NOT OVER TIGHTEN BELTS; OVERLY TIGHT BELTS WILL CAUSE BEARING AND ENGINE DAMAGE. Replace Poly Chain belt guard cover and bottom cover and tighten bolts. DO NOT RUN MACHINE WITHOUT ALL GUARDS IN PLACE AND SECURED. 39

60 SERVICING BELTS REPLACING POLY CHAIN BELT 40

61 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. In all Carlton model Stump Grinders, you will find link belt bearings that are made to be purged with grease. It is necessary to purge these bearings everyday till clean grease is seen. CAUTION should be taken not to allow grease to build up inside the belt guards. Remove the V-belt guard cover Remove V-belt and jackshaft pulley. Remove the bolts from the bushing and use them to screw into the other threaded holes and tighten slowly to push the bushing out of the belt pulley. 41

62 SERVICING BEARINGS Replacing Jackshaft Bearings Remove Poly Chain belt guard cover. Remove Poly Chain sprocket by removing the bolts inside the sprocket and tapered bushing. Then screw one bolt into third hole to push sprocket off tapered bushing to remove. You may cut the jackshaft between the bearings and the Poly Chain guard. 42

63 SERVICING BEARINGS Replacing Jackshaft Bearings Remove old bearings and shaft and replace with new bearings and shaft. Be sure to turn 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 new bearings and jackshaft back into place. Just snug bolts down, do not tighten all the way down, you will need to move them later to adjust belt tension. NOTE: To make shaft installation easier, place shaft in a freezer for approximately one hour or overnight if possible. This will shrink the shaft and make installation into the new bearings much easier. Place Poly Chain sprocket and tapered bushing back onto jackshaft and tighten bolts. Replace Poly Chain belt. Alignment is very important, use a straight edge from the jackshaft sprocket down to the cutter wheel sprocket to line up sprockets. 43

64 SERVICING BEARINGS Replacing Jackshaft Bearings Using a straight edge, align the engine pulley with the jackshaft pulley and place bushing in and tighten the three bolts down. As you tighten the bushing, make sure that the pulleys stay aligned. There are two setscrews in each bearing. Tighten one of them down, remove one, and punch a start point in the shaft to drill a 5/16 diameter hole just deep enough for the screw to enter the shaft. Do this for all four setscrews. This will help prevent shaft from spinning inside of bearing. Use LocTite 242, when tightening setscrews in bearings, to prevent screws from loosening up. NOTE: Refer to SERVICING BELTS section for proper installation and tensioning of all belts. Replace V-belt and Poly Chain belt guards. DO NOT RUN MACHINE WITHOUT ALL GUARDS IN PLACE AND SECURED. 44

65 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. In all Carlton model Stump Grinders, you will find link belt bearings that are made to be purged. It is necessary to purge these bearing everyday until clean grease is seen. CAUTION should be taken not to allow grease to build up inside the belt guards. Remove the Poly Chain guard cover and bottom cover. Loosen Poly Chain belt by moving jackshaft bearings. MARK THE BEARINGS SO THAT YOU KNOW HOW THEY ARE POSITIONED ON THE JACKSHAFT PLATE. Loosen the four bolts that hold the jackshaft bearings down, do not remove the bolts. 45

66 SERVICING BEARINGS Replacing Cutter Wheel Bearings Loosen jam bolts in the back of the jackshaft bearings and move bearings back to remove the Poly Chain belt. You may need to unbolt V-belt guard and lift jackshaft end up to remove belt. Remove the four bolts on the cutter wheel bearings. Cutter wheel will be free from machine at this point. With the Poly Chain belt removed, you can start the machine and raise the boom up. Cut the cutter wheel shaft on one side of the cutter wheel so that you can get the cutter wheel off of the shaft. 46

67 SERVICING BEARINGS Replacing Cutter Wheel Bearings Remove Poly Chain sprocket by removing the bolts inside the sprocket and tapered bushing. Then screw one bolt into third hole to push sprocket off tapered bushing to remove. Take out the three bolts that hold the bushing to the cutter wheel and place them in the empty threaded holes on the bushing and tighten slowly. This will push the bushing out of the cutter wheel. Remove bushing and cutter wheel. Place cutter wheel, bushing and bearings back on new shaft. Place back up under machine and lower boom box on to bearings. NOTE: To make shaft installation easier, place shaft in a freezer for approximately one hour or overnight if possible. This will shrink the shaft and make installation into the new bearings much easier. 47

68 SERVICING BEARINGS Replacing Cutter Wheel Bearings Bolt bearings and cutter wheel back to boom box and tighten bolts down. Place Poly Chain sprocket and tapered bushing back onto cutter wheel shaft and tighten bolts. Replace Poly Chain belt. Alignment is very important, use a straight edge from the jackshaft sprocket down to the cutter wheel sprocket to line up sprockets. 48

69 SERVICING BEARINGS Replacing Cutter Wheel Bearings There are two setscrews in each bearing. Tighten one of them down, remove one, and punch a start point in the shaft to drill a 5/16 diameter hole just deep enough for the screw to enter the shaft. Do this for all four setscrews. This will help prevent shaft from spinning and walking inside of bearing. When putting setscrew in bearing, use LocTite 242 to prevent screw from loosening up. NOTE: Refer to SERVICING BELTS section for proper installation and tensioning of all belts. Replace Poly Chain belt guards and tighten bolts. DO NOT RUN MACHINE WITHOUT ALL GUARDS IN PLACE AND SECURED. 49

70 SERVICING FRONT AXLE 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED. EXCESSIVE MACHINE VIBRATION WILL OCCUR CAUSING PREMATURE BEARING FAILURE AND EQUIPMENT DAMAGE. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. Grease steering pivots at least every 2-3 months. Use Texaco Starplex II grease. DO NOT OVER GREASE. The steering axle is equipped with industrial hubs. To service, jack up the front end, remove cap. Loosen nut and slide wheel off. You are then able to inspect back seals, bearings and races. If necessary you may re-grease and install back on spindle. Tighten axle nut till bearing is tight and wheel will hardly turn. Then back off one notch. Do this at least every 6 months. (See Front Axle Assembly for breakdown) 50

71 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. Swing the cutter wheel to the right to access the boom pivot grease fitting. Grease boom pivot monthly. Do not over grease. There is a Pop-Out Valve above the grease fitting, if the pin pops out enough grease has been applied. Wipe off excess grease. Excess grease will attract dirt. POP-OUT VALVE The boom pivot is equipped with a hardened shaft and Timken roller bearings. If the boom becomes loose, you will need to apply pressure to the bearings to tighten it. To apply more pressure to the bearings, hold the bottom nut where the cotter pin is. Remove the first nut and tighten the second nut, which will apply pressure to the roller bearings and the boom swing. You can place cutter wheel on ground and put slight pressure on cutter wheel to adjust pivot bearings. If the main pivot bearings need replacing, you will have to remove the top pin and slide the main pivot out and install the new bearings. See Upper Pivot Assembly for breakdown. Boom must be placed in a fixture to hold steady when you remove the pivot pin. 51

72 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED. EXCESSIVE MACHINE VIBRATION WILL OCCUR CAUSING PREMATURE BEARING FAILURE AND EQUIPMENT DAMAGE. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. There are twenty (20) teeth to a complete set on the model SP4012. Two (2) straight teeth, nine (9) left 45 teeth and nine (9) right 45 teeth. A locking pin is provided to hold cutter wheel in position during tooth removal and re-installation. Locking pin will only lock on outer teeth. NEVER PLACE HAND ON CUTTER WHEEL TO HOLD IN PLACE WHILE CHANGING TEETH. BE SURE TO REMOVE PIN BEFORE OPERATING. A Tooth Setting Gauge (P/N ) is provided with each machine for proper tooth installation. Line all teeth up with the inside edge of the groove in the gauge. Set ALL teeth to this edge with gauge against pocket, not against cutter wheel. See Cutter Wheel Assembly for breakdown. 52

73 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. When replacing complete set of teeth, be sure to duplicate original factory tooth arrangement. Torque bolts to 150 ft/lbs. opposing outside pockets carry like arrangements of teeth to cancel vibration Straight teeth are mounted in TWO OPPOSING OUTSIDE POCKETS. A straight tooth must have a 45 tooth accompanying it in the same pocket set. The opposite pocket sets should have this same combination of straight and 45 teeth, except with positions reversed. Mounting these teeth opposite each other on the cutter wheel cancels damaging vibration. Two Remaining Outside Pockets must have 45 teeth overlapping centerline of wheel to make plunge cuts possible. Mount two left 45 teeth opposite two right 45 teeth. Inside pockets require 45 teeth mounted away from the wheel. 53

74 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 thirty-two (32) teeth to a complete set. There are eight (8) Short Plow Bolt Bits (Carlton part # ) and twenty-four (24) Plow Bolt Bits (Carlton part # ). DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED. EXCESSIVE MACHINE VIBRATION WILL OCCUR CAUSING PREMATURE BEARING FAILURE AND EQUIPMENT DAMAGE. A locking pin is provided to hold cutter wheel in position during tooth removal and re-installation. The locking pin will only lock in the deep slots of the outer teeth. Line the slot up with the locking pin slot and insert the pin to lock position. The pin will need to be removed and reinserted as wheel is rotated to change remaining teeth. (Some early machines will only lock on an outside 20 tooth.) NEVER PLACE YOUR HAND ON THE CUTTER WHEEL TO HOLD IT IN PLACE WHILE CHANGING TEETH. BE SURE TO REMOVE THE PIN BEFORE OPERATING THE STUMP CUTTER. The teeth do not require a setting gauge. The only requirement is to be installed in the proper direction and tightened to the proper torque as discussed in the next section. When replacing a cutter wheel tooth, replace the tooth and nut as a set and use anti-seize on the threads. 54

75 SERVICING CUTTER WHEEL OPTIONAL: Sandvik Dura Disk II 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. All teeth and pockets are of a specific design and must be replaced with original manufacturer s replacement parts. Replacement teeth must be carbide tipped. When replacing complete set of teeth, be sure to duplicate original factory tooth arrangement. SEE DIAGRAM BELOW. The seating surfaces of the tooth and pocket are formed, but make sure the tooth is inserted with the carbide facing the direction of rotation. The pictured view is the engraved side of the wheel. The wheel is engraved with outside pocket numbers, outside pocket angle/direction (20 R or 20 L), and wheel rotation. (The engraved side of wheel is marked left side of wheel; this is for manufacturing purposes only. It does not refer to the left side of the machine as described in the General Information section.) Outside pocket teeth are Short Plow Bolt Bits. These pockets are angled and welded in place. You can switch teeth from one outside pocket to a pocket that is the opposite direction to prolong tooth life, such as switching a tooth from a 20 R with a tooth from a 20 L pocket. The cutting edge is the corner and this will turn the opposite corner out for use. These teeth are tightened with Stover Lock Nuts. Torque on Stover locking nuts is not to exceed 270 ft/lbs. All teeth on cutter wheel sides are Plow Bolt Bits. When changing these teeth you must remove both teeth in the same pocket, one on each side of the wheel. When the nuts are torqued, the pocket is jammed and the teeth can only be removed this way. These teeth are also tightened with Stover Lock Nuts. Torque on Stover locking nuts is not to exceed 270 ft/lbs. The pocket will receive wear when cutting and can be switched from one side of the cutter wheel to the other to prolong life. Remember the teeth must be replaced in the original position on each side of the wheel. It may be necessary to use a 1 1/4 hole saw to remove debris around nut to make tooth removal easier. 55

76 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. Use facemask to prevent breathing in harmful material while grinding. 56

77 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. ALL MACHINE PARTS MUST COME TO A COMPLETE STOP AND HAVE TIME TO COOL COMPLETELY BEFORE SERVICING A MACHINE OR SEVERE INJURY COULD OCCUR, POSSIBLY SERIOUS BURNS AND/OR DISMEMBERMENT. PLACE THE CUTTER WHEEL ON THE GROUND WHEN PERFORMING SERVICE ON A MACHINE. RELEASE HYDRAULIC PRESSURE BEFORE PERFORMING ANY SERVICE TO HYDRAULIC LINES OR OTHER COMPONENTS. FLUID UNDER PRESSURE CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY. SEEK IMMEDIATE MEDICAL ATTENTION IF SKIN IS PENETRATED. CHECK HOSES AND FITTINGS USING A BOARD OR CARDBOARD; DO NOT USE HAND OR FINGER. ALWAYS WEAR EYE PROTECTION. HYDRAULIC OIL & FILTER Check hydraulic oil level daily. This Carlton stump grinder is equipped with a gauge that shows the level of oil and the temperature of the oil. When filling the tank with oil, the window of the gauge will also fill with oil, as the level gets higher in the tank. Never fill the oil tank above the BLACK line at the top of the gauge. Do not run the machine with the oil level below the RED line at the bottom of the gauge. The machine is equipped with Citgo AW32 hydraulic oil at the time of manufacture. Use the same or equivalent. 57

78 SERVICING HYDRAULICS For a new machine, change the hydraulic oil filter when the stump grinder has been operating for 10 hours. Replace with the same type of in-tank filter element supplied originally, available through Carlton or Carlton dealers. From this point on, change the filter every 200 hours of operation. Change hydraulic oil every 500 hours of operation or at least once a year depending on use. Flush the hydraulic tank when changing the hydraulic oil. Replace oil if it has a burnt odor or if it is contaminated. Replace oil if the stump grinder has been stored for a long period of time (all winter). Drain the hydraulic tank using the drain plug located on the bottom of the tank. Dispose of used oil according to state regulations. HYDRAULIC OIL COOLER (only on remote control machines) There is a hydraulic oil cooler on all remote control machines to keep the hydraulic oil from over heating. There is a temp sensor in the bottom of the oil cooler and if the oil temperature rises to 140 or higher the fan comes on to cool the oil. The fan may go on and off as the temperature of the oil changes depending on the environment and the operation of the grinder. Keep the fins clean. Use a garden hose and a mild detergent. Do not use a power washer as it may cause the fins to bend. Do not use an industrial strength detergent that may cause the metal to deteriorate. Inspect all connections and hoses for leaks and wear. Replace if necessary. Use extra care when inspecting hoses with fluid under pressure. DO NOT use your finger or hand to inspect for leaks, use a board or cardboard. Follow all safety procedures at the beginning of the Servicing Hydraulics section. 58

79 SERVICING HYDRAULICS REPLACING HYDRAULIC PUMP Engine must be shut off. Disconnect hydraulic lines from pump and cap them. Remove bolts holding mounting plate to machine (located at 6 & 12 o clock position) Remove plate/pump assembly by pulling assembly straight out. Drive coupling will separate and make removal possible. Make sure to set aside fiber spacer for later reinstallation. Remove drive coupling half from pump shaft by loosening Allen screw. It may be necessary to pry apart coupling by inserting screwdriver into coupling split and relieving pressure on pump shaft. Set aside key-way for later re-installation. Remove pump from backing plate by removing mounting bolts. To install new pump, reverse this process. Making sure to replace fiber spacer in coupling. Recheck oil supply in reservoir. REPLACING HARDENED BUSHINGS Hardened bushings have been incorporated into the machine to protect the frame from wear and damage. Should a bushing need replacing, disconnect the rod end from the frame and swing cylinder out of the way. Position the new bushing directly above the old bushing and gently tap new bushing down into position thus removing the old bushing. Swing cylinder back into position. Use new pin assemblies to re-install rod end to frame. 59

80 MACHINE WIRING STANDARD WIRING DIAGRAM 60

81 MACHINE WIRING REMOTE WIRING DIAGRAM 61

82 MACHINE WIRING REMOTE BOX WIRING DIAGRAM 62

83 MACHINE WIRING RADIO WIRING DIAGRAM SEE RADIO CONTROL MANUAL, INCLUDED IN THIS MANUAL, FOR MORE INFORMATION. 63

84 HYDRAULIC ASSEMBLY HYDRAULIC INLET ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section G Hyd Pump 4012 Bucher J1 3/4 Hose - 3/4 FJ45T- Dayco /4 JIC - 5/8 ORB /2 JIC - 1/2 ORB /2 JIC-1/2 ORB H Hose Assembly 1 8 H Hose Assembly 1 64

85 HYDRAULIC ASSEMBLY STEERING HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section A Hydraulic Cylinder - 2x /8 JIC- 1/2 ORB /8JIC-1/2ORB H Hose Assembly 1 6 H Hose Assembly 1 65

86 HYDRAULIC ASSEMBLY TRACTION HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section Vickers Needle Cartridge C Deltroll Freewheel Valve Ctg Series-Parallel Module A C/B Cartridge Valve - CBCG-LKN A1 Hyd Mtr Drv w/ 2 Mtrs RH A11 Hyd Mtr Drv w/ 2 Mtrs LH A 2500 Flow Divider Cartridge B W 2P Cartridge C W 2P Cartridge D 2500 Solenoid /8 JIC- 1/2 ORB /8 JIC-5/8 ORB /8 JIC-3/8 ORB H Hose Assembly 1 16 H Hose Assembly 1 17 H Hose Assembly 2 18 H Hose Assembly 2 66

87 HYDRAULIC ASSEMBLY LIFT HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section Lift Valve Body - ECB C/B Cartrdige Valve - CBCA-LHN F Hydraulic Cylinder - 3x /8 JIC- 1/2 ORB /2FP-1/2FP-1/2MPTee /2MP-3/8MP Nipple /8 MP - 3/8 JIC /8 JIC - 1/4 MP H Hose Assembly 1 11 H Hose Assembly 1 12 H Hose Assembly 1 67

88 HYDRAULIC ASSEMBLY TONGUE HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section B Hydraulic Cylinder - 2 1/2 x /8 JIC- 1/2 ORB /8JIC-1/2MP H Hose Assembly 1 6 H Hose Assembly 1 68

89 HYDRAULIC ASSEMBLY SWING HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section Vickers Needle Cartridge A 25-4 Swg Mnfld with Ndle Cvty A C/B Cartridge Valve - CBCG-LKN Hydraulic Cylinder - 2x /8 JIC- 1/2 ORB /2 JIC - 1/2 ORB H Hose Assembly 1 9 H Hose Assembly 1 10 H Hose Assembly 1 11 H Hose Assembly 1 12 H Hose Assembly 1 13 H Hose Assembly 1 69

90 HYDRAULIC ASSEMBLY HYDRAULIC RETURN ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section E Hydraulic In Tank Filter STF F Hydraulic In Tank Filter Eleme A Hydraulic Site Gauge w/temp /2 JIC-1/2 ORB A 1/2 JIC- 3/4 ORB H 7/16-14 x 1 1/2" SHC /16 Lock Washer B 7/16 Flat Washer 2 10 H Hose Assembly 1 70

91 HYDRAULIC ASSEMBLY CONTROL VALVE ASSEMBLY ITEM NO PART NO DESCRIPTION QTY F Work Section - SVS1GA1AA G Valve Section - SVH1BA1AA H Prince Inlet Section - SVI I Outlet Section SVE Relief Valve Steel Plug, 1/2 SAE O-Ring Back-Up Washer O-Ring O-Ring O-Ring Relief Plug L Valve Spool End Cap Handle Flange M Prince Handle Linkage N Prince Valve Spool Extension Valve Handle Kit O-Ring Spool Back-Up Washer O-Ring O-Ring Load Check Poppet Spring Load Check Plug Back-Up Washer O-Ring 10 NOTES: 1. SVS work section seal kit - P/N ZA - Includes items 11,18,20,21, SVH work section seal kit - P/N ZB - Includes items 10,11,20,21, SVI inlet section seal kit - P/N ZC - Includes items 10,11. 71

92 HYDRAULIC ASSEMBLY CONTROL VALVE ASSEMBLY 72

93 HYDRAULIC ASSEMBLY OPTIONAL: STEERING HYDRAULIC ASSEMBLY (ALL WHEEL DRIVE) ITEM NO PART NO DESCRIPTION QTY Work Section W Hydraulic Cylinder 2 x /8 JIC- 1/2 ORB /2" O-Ring - 3/8 JIC H Hose Assembly 1 6 H Hose Assembly 2 73

94 HYDRAULIC ASSEMBLY OPTIONAL: TRACTION HYDRAULIC ASSEMBLY (ALL WHEEL DRIVE) ITEM NO PART NO DESCRIPTION QTY Work Section Vickers Needle Cartridge C Deltroll Freewheel Valve Ctg Series-Parallel Module A C/B Cartridge Valve - CBCG-LKN A1 Hyd Mtr Drv w/ 2 Mtrs RH A11 Hyd Mtr Drv w/ 2 Mtrs LH A 2500 Flow Divider Cartridge B W 2P Cartridge C W 2P Cartridge D 2500 Solenoid /8 JIC- 1/2 ORB /8 JIC-5/8 ORB /8 JIC-3/8 ORB E SPC Hose Assembly 1 17 Hose Assembly 1 18 Hose Assembly 1 19 Hose Assembly 1 20 Hose Assembly 1 21 Hose Assembly 1 22 Hose Assembly 1 23 Hose Assembly 1 74

95 HYDRAULIC ASSEMBLY OPTIONAL: TRACTION HYDRAULIC ASSEMBLY (ALL WHEEL DRIVE) 75

96 HYDRAULIC ASSEMBLY OPTIONAL: BLADE HYDRAULIC ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Work Section A Hydraulic Cylinder 2x /8 JIC- 1/2 ORB /2" O-Ring - 3/8 JIC Hose Assembly 1 6 Hose Assembly 1 76

97 FRONT AXLE ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Tire Assembly Lug Lug Nut - 1/ R/H Steering Frame L/H Steering Frame E/Z Lube Grease Seal Inner Bearing # Inner Bearing Race # H Hub w/cups & Studs Outer Bearing Race 3500# Outer Bearing 3500# Spindle Washer Spindle Jam Nut Tang Washer Grease Cap for E/Z Lube 3500# Rubber Plug for EZ Lube Cap Steering Linkage Weld-on Seal Ring G-1010 Shoulder Bolt, 5/8 x 1 1/4" (1/2-13) /8 Flat Washer Hydraulic Cylinder - 2x Hardened Spring Bushing N Prince Cyl. Pin - Short /4-28 x 2 HHCS Ground Stake Rod Lock Pin - 3/8 x 2 3/ Hardened Spring Bushing - 5/8" /2" Flat Washer Grease Seal End Cap 3500# /2-13 Lock Nut 2 77

98 FRONT AXLE ASSEMBLY Part # 8 comes complete with parts # 9, 10, 11, 12, 13, 28, & 29 as shown for front wheel. All parts can be purchased separately also. 78

99 FRONT AXLE ASSEMBLY OPTIONAL: ALL WHEEL DRIVE ITEM NO PART NO DESCRIPTION QTY Tire Assembly Lug Lug Nut 1/ Weldment, Mount, AWD Motor, RH Weldment, Mount, AWD Motor, LH E/Z Lube Grease Seal Inner Bearing # Inner Bearing Race # H Rear Tapered Hub Outer Bearing Race # Outer Bearing # Spindle Washer Spindle Jam Nut Tang Washer Grease Cap E/Z Lube # Rubber Plug for EZ Lube Cap Assy, Steering Linkage, AWD G-1010 Shoulder Bolt, 5/8 x 1 1/4 (1/2-13) /8 Flat Washer /2 Flat Washer /2-13 Lock Nut A11 Hyd Mtr Drv w/ 2 Mtrs, LH A1 Hyd Mtr Drv w/ 2 Mtrs, RH W Hydraulic Cylinder 2 x O Prince Cyl. Pin - Long 2 25 Hitch Pin Clip (with O) Hardened Spring Bushing Hardened Spring Bushing 5/ G 1/2-13 x 2 3/4 HHCS 8 29 Woodruff Key 1/4 x 1 (with motor) /2 Flat Washer 8 31 Axle Nut 1 Slotted Hex (with motor) Cotter Pin 3/16 x Weld-on Seal Ring 2 79

100 FRONT AXLE ASSEMBLY OPTIONAL: ALL WHEEL DRIVE 80

101 REAR WHEEL ASSEMBLY ITEM NO PART NO DESCRIPTION QTY A1 Hyd Mtr Drv w/ 2 Mtrs RH A11 Hyd Mtr Drv w/ 2 Mtrs LH /2 Flat Washer G 1/2"-13 x 2 3/4" HHCS /2-13 Lock Nut H Rear Tapered Hub Tire Assembly Lug Lug Nut 1/ E Axle Nut - 1" Slotted Hex Cotter Pin - 3/16 x SP4012K-RWHLASY_a.doc 81

102 REAR WHEEL ASSEMBLY DUAL WHEEL ASSEMBLY (Parts List For Two Assemblies, Only One Shown.) ITEM NO PART NO DESCRIPTION QTY Dual Wheel Hub 5 Bolt Dual Wheel Spacer 5 Bolt Tire Assembly Lug Lug Nut 1/ SAE Flat Washer Lock Washer A 1-8 x 7 HHCS 2 ASSEMBLY INSTRUCTIONS 1. Remove lug nuts and install inner hub. 2. Replace lug nuts and tighten. 3. Bolt wheel spacer to dual wheel and tighten with new lug nuts. 4. Place dual wheel up to rear wheel and bolt through center of wheel to inner hub. 5. Tighten. 6. Repeat for other side. 28-SP4012K-RWHLASY_a.doc 82

103 PIVOT ASSEMBLY LOWER PIVOT ASSEMBLY TWO WHEEL DRIVE WITH TONGUE EXTENSION ITEM NO PART NO DESCRIPTION QTY Lift Pivot Shaft Hardened Spring Bushing - 1" " SAE Flat Washer Hex Castle Nut Cotter Pin - 3/16" x 2" F Hydraulic Cylinder - 3x O Prince Cyl. Pin - Long 2 8 Hitch Pin Clip (with O) Side Pivot Tube Side Pivot Gusset Pivot Shaft Tube Grease Fitting 1/4 NPT 3 13 H Grease Hose Assembly H Grease Hose Assembly H Grease Hose Assembly /4 MJIC - 1/8 NPT PARTS # 9 & 10 ARE WELDED TO THE PIVOT ASSEMBLY AFTER THE BOOM IS LEVEL #11 IS WELDED IN THE FRAME ASSEMBLY 29-SP4012K-PVTASY_B.doc 83

104 PIVOT ASSEMBLY UPPER PIVOT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Swing Pivot Shaft - 1" - 23/ Hardened Spring Bushing - 1" Race - 23/25 # Bearing - 1" - 23/25 # Seal - 23/ Top Pivot Inner Bushing Bottom Pivot Bushing Hex Jam Nut Hex Castle Nut Cotter Pin - 3/16" x 2" /16-18 x 3/4 SHCP /16-18 x 3/4 FHSCP Top Pivot Bushing N Prince Cyl. Pin Short /4"-28 x 2" HHCS Snap Ring for 2500 Pivot " SAE Flat Washer Grease Fitting 1/4 NPT 1 19 Pop-Out Valve Boom Pivot Tube 1 PART #20 IS WELDED IN THE PIVOT ASSEMBLY 29-SP4012K-PVTASY_B.doc 84

105 PIVOT ASSEMBLY LOWER PIVOT ASSEMBLY (OPTION: ALL WHEEL DRIVE) ITEM NO PART NO DESCRIPTION QTY Lift Pivot Shaft Hardened Spring Bushing - 1" SAE Flat Washer Hex Castle Nut Cotter Pin - 3/16 x F Hydraulic Cylinder - 3x O Prince Cyl. Pin - Long 2 8 Hitch Pin Clip (with O) Side Pivot Tube Side Pivot Gusset Pivot Shaft Tube Grease Fitting 1/4 NPT 3 13 H Grease Hose Assembly H Grease Hose Assembly H Grease Hose Assembly /4 MJIC - 1/8 NPT PARTS # 9 & 10 ARE WELDED TO THE PIVOT ASSEMBLY AFTER THE BOOM IS LEVEL #11 IS WELDED IN THE FRAME ASSEMBLY 29-SP4012K-PVTASY_B.doc 85

106 BOOM ASSEMBLY ENGINE BELT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY AA Engine - 27 HP Kohler /2-13 x 2" Hex Cap Screw /2 Flat Washer /2-13 Lock Nut Bee Hive Belt Keeper - Top 1 6 7/16"-14 x 1 3/4" HHCS 1 7 7/16" Lock Washer Bee Hive- Kohler Bee Hive Belt Keeper - Bottom /8-16 x 1" Hex Cap Screw /8 Lock Washer Bushing - 25 Engine -SH 1 7/ Sheave 2500 SP4012 4/3V Key - 3/8" x 5/16" x 1 1/4" /16-18 x 1" HSHCS Coupling - 23/25 Engine Spider Insert - 23/ Coupling - 23/25 Pump Pump Mounting Plate /8"-16 x 1 1/2" HHCS /8-16 Lock Nut G Hyd Pump Bucher (w/key) 1 24 SP Motor Plate - SP Belt 23/25/SP4012Khlr 4/3V Engine V-Belt Guard Engine Belt Guard Cover 1 30-SP4012K-BOOMASY_c.doc 86

107 BOOM ASSEMBLY ENGINE BELT ASSEMBLY 30-SP4012K-BOOMASY_c.doc 87

108 BOOM ASSEMBLY BELT ENGAGEMENT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Engagement Handle Handle Grip 3/4" Cotter pin - 3/16" x 2" /4" Flat Washer Linkage Assembly Clevis Pin - 1/2 x 1 3/ Bridge Pin - 1/8" #4 Zinc Collar Weldment 1 9 1/4"-20 x 1/2" HSHCS Split Lock Collar - 1" Grease Fitting 1/4-28 Str Idler Arm /4"-16 Hex Nut Idler Shaft - 23/ Idler Bushing - Long Bearing 1" - Idler Idler Pulley Pulley Rework Idler Complete Idler Bushing - Short Belt Keeper-- Idler Pulley /2 Flat Washer /2 Lock Washer B 1/2-13 x 1 1/4" Hex Cap Screw 1 30-SP4012K-BOOMASY_c.doc 88

109 BOOM ASSEMBLY 30-SP4012K-BOOMASY_c.doc 89

110 BOOM ASSEMBLY JACKSHAFT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY A Jack Shaft TL - 1 7/16" 23/ A160T01 Key - 3/8 sq. x1 1/ Bearing - 1 7/16" - Link Belt F 1/2-13 X 2 1/4 HCS /2 Flat Washer /2-13 Lock Nut Sheave 25 JS 4/3V Bushing - 25 JS,CW - SK 1 7/16" F /16" Taper Lock Bshn A PC Sprkt 8M-40S-62 Taper Lock /16"-14 x 1 1/2" SHCS /2-13 x 3" Square Head Screw /2-13 Hex Nut /2 Lock Washer /2-13 x 4" Square Head Screw 2 30-SP4012K-BOOMASY_c.doc 90

111 BOOM ASSEMBLY POLY CHAIN BELT ASSEMBLY ITEM NO PART NO DESCRIPTION QTY PC Belt Guard /8-16 x 1" Carriage Bolt /8 Flat Washer /8-16 Lock Nut F /16" Taper Lock Bshn A PC Sprkt 8M-40S-62 Taper Lock 2 7 7/16"-14 x 1 1/2" SHCS PC SP4012 8M PC Guard Bottom /16-18 x 1" Hex Cap Screw /16-18 Lock Nut PC Guard Cover /8-16 x 1" Hex Cap Screw /8 Lock Washer 8 30-SP4012K-BOOMASY_c.doc 91

112 BOOM ASSEMBLY CUTTER WHEEL ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Bearing - 1 7/16" - Link Belt A Cutter Wheel Shaft 23/25 TL 1 3 A160T01 Key - 3/8 sq. x1 1/ Cutter Wheel 23/ Cutter Wheel Hub SK600A Bushing JS, CW - SK 1 7/ /2 CW Shaft Washer - 1 7/ A PC Sprkt - 8M-40S-62 Taper Lock Shaft Washer 1 7/ B 1/2-13 x 1 1/4" Hex Cap Screw Round Pocket - C/S Round Pocket - Thd Tooth - Straight Tooth - Right 45 Degree Tooth - Left 45 Degree Tooth Bolt - 5/8-18 x 2 1/8" F 1/2-13 x 2 1/4" HCS /2 Flat Washer /2-13 Lock Nut F /16" Taper Lock Bshn /16"-14 x 1 1/2" SHCS /2 CW Shaft Washer - 1 7/ SP4012K-BOOMASY_c.doc 92

113 BOOM ASSEMBLY 30-SP4012K-BOOMASY_c.doc 93

114 BOOM ASSEMBLY CUTTER WHEEL ASSEMBLY (SANDVIK WHEEL OPTION) ITEM NO PART NO DESCRIPTION QTY D184 Cutter Wheel Shaft 1 11/ Bearing 1 11/16 Link Belt B 5/8-11 x 2 3/4" HHCS /8 Flat Washer /8-11 Lock Nut 4 6 A160T013 Key - 3/8 sq.x1 7/8 1 7 A160T014 Key - 3/8 sq. x Bushing 35/44 JS -SK 1 11/ Sandvik Dura Disk SP Cutter Wheel Hub - SK600A A Cutter Wheel Spacers-Diesel Sm B Cutter Wheel Spacers-Diesel Lg A PC Sprkt 8M-40S-62 Taper Lock F /16 Taper Lock Bshn /16-14 x 1 1/2 SHCS Shaft Washer 1 7/ /2-13 x 1 1/4 Hex Cap Screw JP Sandvik Plow Bolt Tooth JP Sandvik Short P/B Tooth JP Sandvik Plow Bolt Holder Sandvik Stover Jam Nut SP4012K-BOOMASY_c.doc 94

115 BOOM ASSEMBLY CUTTER WHEEL ASSEMBLY (SANDVIK WHEEL OPTION) 30-SP4012K-BOOMASY_c.doc 95

116 CHIP GUARD ASSEMBLY ITEM NO PART NO DESCRIPTION QTY Deck Plate - R/H Deck Plate - L/H /8-16 x 3/4 Carriage Bolt /8 Flat Washer /8-16 Lock Nut Front Rubber Chip Guard Side Rubber Chip Guard H 3/4-10 x 6 Hex Head Bolt Chip Guard Front Bracket Chip Guard Side Bracket Pan Guard B 1/2-13 x 1 1/4" Hex Cap Screw /2-13 Lock Nut Boom Chip Guard Deck /8-16 x 1 Carriage Bolt Front Boom Rubber Chip Guard Side Boom Rubber Chip Guard Chip Guard Bracket Cutter Wheel Flap /4-10 Lock Nut /16-18 x 1 Hex Cap Screw /16-18 Lock Nut 1 31-SP4012K-CGASY_a.doc 96

117 STUMP CUTTERS MODEL TYPE ENGINE HP FUEL CUTTING DEPTH CUTTING HEIGHT CUT SWING NO. TEETH WHEEL DIA. WHEEL THICKNESS TONGUE EXTENSION WEIGHT (lbs.) 900H SP2000 Walk- Behind Walk- Behind Honda 13 Gas 9" 21" N/A ".5" N/A 220 Kohler 27 Gas 24" 27" N/A 16 19".5" N/A 695 Self- Propelled Kohler 27 Gas 13" 34" 40" arc 20 21" 1" 30" 1,550 SP4012 Self- Propelled Briggs- Vanguard 35 Gas 13" 34" 40" arc 20 21" 1" 30" 1,650 Self- Propelled Kubota 33 Diesel 13" 34" 40" arc 20 21" 1" 30" 1,650 SP7015 SP7015TRX SP8018 TRX Self- Propelled Track- Mounted Track- Mounted Deutz Turbo 60 Diesel 15" 43" 70" arc " 1" N/A 3,500 Deutz Turbo 60 Diesel 15" 43" 70" arc " 1" N/A 4,300 Deutz Turbo 78 Diesel 18" 43" 80" arc " 1" N/A 5,420 HURRICANE RS Track- Mounted John Deere Turbo 140 Diesel 25" 53" " 1.5" N/A 8,500 Track- Mounted John Deere Turbo 140 Diesel 25" 72" " 1.5" N/A 12,000 HURRICANE TRX Track- Mounted John Deere Turbo 175 Diesel 25" 72" " 1.5" N/A 12,000 Track- Mounted John Deere Turbo 250 Diesel 25" 72" " 1.5" N/A 12, D 7500 Tow- Behind Tow- Behind Deutz Turbo 60 Diesel 15" 40" 80" arc " 1" 48" 2,900 Deutz Turbo 78 Diesel 24" 46" 92" arc 48 31" 1.5" 60" 4,400 Call and ask about Carlton s line of Chippers or visit our website: CARLTON QUALITY PRODUCTS AND EXCEPTIONAL SERVICE Carlton Owner s Manual SP4012 Revised: 09/ SP4012K-Back.doc

118 COMMAND CH18-26, CH HORIZONTAL CRANKSHAFT OWNER'S MANUAL

119 Safety Precautions To ensure safe operations please read the following statements and understand their meaning. Also refer to your equipment owner's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. For Your Safety! These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others. WARNING WARNING WARNING Explosive Fuel can cause fires and severe burns. Do not fill the fuel tank while the engine is hot or running. Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. 2 Rotating Parts can cause severe injury. Stay away while engine is in operation. Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed. California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

120 WARNING Safety Precautions (Cont.) WARNING WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug leads before servicing. Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sources of ignition away. Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. Congratulations You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you can count on. Here are some reasons why: Efficient overhead valve design and full pressure lubrication provide maximum power, torque, and reliability under all operating conditions. Dependable, maintenance-free electronic ignition ensures fast, easy starts time after time. Kohler engines are easy to service. All routine service areas like the dipstick, oil fill, air cleaner, and spark plugs are easily and quickly accessible. Parts subject to the most wear and tear (like the cylinder liner* and camshaft) are made from precision formulated cast iron. Because the cylinder liner* can be rebored, these engines can last even longer. *Some CH25/26 engines have POWER-BORE Cylinders. These cylinders are plated with nickel-silicon to give increased power, virtually permanent cylinder life, superior oil control, and reduced exhaust emissions. These cylinders cannot be rebored. Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service support is just a phone call away. Call (U.S. & Canada) for Sales & Service assistance. To keep your engine in top operating condition, follow the maintenance procedures in this manual. 3

121 Oil Fill Air Cleaner Dipstick Fuel Pump Oil Filter Electric Starter Oil Drain Plug (Each Side) Rectifier-Regulator Figure 1. Typical Command Horizontal Shaft Carbureted Engine. Throttle Body Intake Manifold Ignition Coil Fuel Injectors Ignition Coil Oil Filter Oil Cooler Figure 2. Typical Command Horizontal Shaft EFI Engine. Rectifier-Regulator 4

122 Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high quality detergent oil of API (American Petroleum Institute) service class SG, SH, SJ, or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table. Refer to Maintenance Instructions beginning on page 8 for detailed oil check, oil change, and oil filter change procedures. Fuel Recommendations WARNING: Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. ** * General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling. *Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4 C (40 F). **Synthetic oils will provide better starting in extreme cold below -23 C (-10 F). Figure 3. Viscosity Grades Table. NOTE: NOTE: Using other than service class SG, SH, SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals. However to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil. A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 4. Figure 4. Oil Container Logo. Do not use gasoline left over from the previous season, to minimize gum deposits in fuel system and to ensure easy starting. Do not add oil to the gasoline. Do not overfill the fuel tank. Leave room for the fuel to expand. Fuel Type For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must not be used on EFI engines, or on other models where exhaust emissions are regulated. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. 5

123 Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on a decal affixed to the engine shrouding. Include letter suffixes, if there are any. Record your engine identification numbers on the identification label below (Figure 5) for future reference. For Models CH IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA AND CA 2005 AND LATER AND EC STAGE II (SN:4) EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY TYPE APP DISPL. (CC) MODEL NO. N11236 SPEC. NO. SERIAL NO. BUILD DATE OEM PROD. NO. EMISSION COMPLIANCE PERIOD: EPA: CARB: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY, MAINTENANCE AND ADJUSTMENTS KOHLER CO. KOHLER, WISCONSIN USA For Model CH750 IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA 2005 AND LATER AND EC STAGE II (SN:4) SI SMALL OFF-ROAD ENGINES AND CA 2005 AND LATER LSI ENGINES FAMILY TYPE APP DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DATE OEM PROD. NO. EMISSION COMPLIANCE PERIOD: EPA: CARB: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY, MAINTENANCE AND ADJUSTMENTS KOHLER CO. KOHLER, WISCONSIN USA The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements. The following table provides the Engine Compliance Period (in hours) associated with the category descriptor found on the certification label. Emission Compliance Period (Hours) EPA CARB Category C 250 hours Moderate 125 hours Category B 500 hours Intermediate 250 hours *Extended hours for Model CH750 is Category A 1000 hours Extended 500* hours Refer to certification label for engine displacement. Exhaust Emission Control System for models CH18,20,22,23,730,740,750 is EM. Exhaust Emission Control System for models CH26 and CH745 are EM, O2S, ECM, MFI. Model Designation Model CH20S for example: C designates Command engine, H designates horizontal crankshaft, and 20 designates horsepower. Some model numbers (CH730) use a numerical designation rather than horsepower. A letter suffix designates a specific version as follows: Suffix S ST QS EP CS Designates Electric Start Electric Start/Retractable Start Quiet Model/Electric Start Electric Plant Clutch Model/Electric Start Operating Instructions Also read the operating instructions of the equipment this engine powers. Pre-Start Checklist Check oil level. Add oil if low. Do not overfill. Check fuel level. Add fuel if low. Check cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed. Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened. Figure 5. Engine Identification Label. 6

124 Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting. WARNING: Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. c. If the engine fails to start, repeat steps a and b. If the engine does not start after two priming intervals, contact your Kohler Engine Service Dealer for further assistance. NOTE: Do not crank the engine continuously for more than 10 seconds at a time. If the engine does not start, allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out, or permanently damage, the starter motor. Cold Weather Starting Hints 1. Be sure to use the proper oil for the temperature expected. See Figure 3 on page Disengage all possible external loads. 3. Be sure the battery is in good condition. A warm battery has much more starting capacity than a cold battery. NOTE: Upon start-up, a metallic ticking may occur. This is caused by hydraulic lifter leakdown during storage. Run the engine for 5 minutes. The noise will normally cease in the first minute. If noise continues, run the engine at midthrottle for 20 minutes. If noise persists, take the engine to your local authorized Kohler Engine Service Dealer. 4. Use fresh winter grade fuel. NOTE: Winter grade gasoline has higher volatility to improve starting. Do not use gasoline left over from summer. Starting 1. Place the throttle control midway between the slow and fast positions. Place the choke control (non-efi engines only) into the on position. See Figure 6. Figure 6. Optional Engine Mounted Throttle and Choke Controls (Carbureted Engines). 2. Start the engine by activating the key switch. Release the switch as soon as the engine starts. EFI Engines Only Initial Starting or After Running out of Fuel (Dry System) a. Turn the key switch to the on position for one minute. Allow the fuel pump to cycle and prime the system. Turn the key switch off. NOTE: If the engine develops sufficient speed to disengage the starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart the engine. If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash resulting in damage to the starter. If the starter does not turn the engine over, shut off starter immediately. Do not make further attempts to start the engine until the condition is corrected. Do not jump start using another battery (refer to Battery on page 8). See your Kohler Engine Service Dealer for service assistance. Carbureted Engines Only: 3. For a Cold Engine Gradually return the choke control to the off position after the engine starts and warms up. The engine/equipment may be operated during the warm-up period, but it may be necessary to leave the choke partially on until the engine warms up. 4. For a Warm Engine Return choke to off position as soon as engine starts. b. Turn the key switch to the start position, crank and start engine. 7

125 Stopping 1. Remove the load by disengaging all PTO driven attachments. 2. For Carbureted Engines Without A Shutdown Solenoid: Move the throttle to the slow or low idle position. Allow the engine to run at idle for seconds; then stop the engine. For Carbureted Engines Equipped With A Shutdown Solenoid: Position the throttle control somewhere between half and full throttle; then stop the engine. For EFI Engines: Move the throttle to the slow or idle position; turn key off to stop engine. Battery A 12 volt battery is normally used. Refer to the operating instructions of the equipment this engine powers for specific battery requirements. If the battery charge is not sufficient to crank the engine, recharge the battery (see page 13). Operating Angle of Operation This engine will operate continuously at angles up to 25. Check oil level to assure crankcase oil level is at the F mark on the dipstick. Refer to the operating instructions of the equipment this engine powers. Because of equipment design or application, there may be more stringent restrictions regarding the angle of operation. Cooling NOTE: If debris builds up on the grass screen or other cooling air intake areas, stop the engine immediately and clean. Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating. WARNING: Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed. Engine Speed NOTE: Do not tamper with the governor setting to increase the maximum engine speed. Overspeed is hazardous and will void the engine warranty. The maximum allowable high idle speed for these engines is 3750 RPM, no load. Maintenance Instructions Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized Kohler service outlet. WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. NOTE: Do not operate this engine continuously at angles exceeding 25 in any direction. Engine damage could result from insufficient lubrication. 8

126 Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. Frequency Daily or Before Starting Engine Every 25 Hours Every 100 Hours Every 200 Hours Annually or Every 500 Hours Maintenance Required Fill fuel tank. Check oil level. Check air cleaner for dirty 1, loose, or damaged parts. Check air intake and cooling areas, clean as necessary 1. Service precleaner element 1. Replace air cleaner element 1. Change oil. (More frequently under severe conditions.) Remove cooling shrouds and clean cooling areas 1,3. Check oil cooler fins, clean as necessary (if equipped). Check spark plug condition and gap. Change oil filter. Replace fuel filter (carbureted engines). Every 250 Hours Replace heavy-duty air cleaner element and check inner element 1. Every 500 Hours Every 1500 Hours Have bendix starter drive serviced 2,4. Have solenoid shift starter disassembled and cleaned 2,4. Have crankshaft spline lubricated 2. Replace fuel filter 1 (EFI engines). 1 Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. 2 Have a Kohler Engine Service Dealer perform this service. 3 Cleanout Kits S (black) or S (gold) allow cooling areas to be cleaned without removing shrouds. 4 Only required for Denso starters. Not necessary on Delco starters. Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EACH USE as follows: 1. Make sure the engine is stopped, level, and is cool so the oil has had time to drain into the sump. 2. To keep dirt, debris, etc., out of the engine, clean the area around the dipstick before removing it. 3. Remove the dipstick; wipe oil off. Reinsert the dipstick into the tube and press all the way down. 4. Remove the dipstick and check the oil level. The oil level should be up to, but not over, the F mark on the dipstick. See Figure 7. Operating Range F Mark 5. If the level is low, add oil of the proper type, up to the F mark on the dipstick. (Refer to Oil Type on page 5.) Always check the level with the dipstick before adding more oil. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the L mark or over the F mark on the dipstick. Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure switch. If the oil pressure decreases below an acceptable level, the Oil Sentry will either shut off the engine or activate a warning signal, depending on the application. NOTE: Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick. This includes engines equipped with Oil Sentry. Figure 7. Oil Level Dipstick. 9

127 Change Oil and Filter, Service Oil Cooler Change Oil Change oil after every 100 hours of operation (more frequently under severe conditions). Refill with service class SG, SH, SJ or higher oil as specified in the Viscosity Grades table (Figure 3) on page 5. Change the oil while the engine is still warm. The oil will flow more freely and carry away more impurities. Make sure the engine is level when filling, checking, and changing the oil. Change the oil as follows (see Figures 8 and 9): 1. To keep dirt, debris, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it. 2. Remove one of the oil drain plugs, oil fill cap, and dipstick. Be sure to allow ample time for complete drainage. 3. Reinstall the drain plug. Make sure it is tightened to 13.6 N m (10 ft. lb.) torque. 4. Fill the crankcase, with new oil of the proper type, to the F mark on the dipstick. Refer to Oil Type on page 5. Always check the level with the dipstick before adding more oil. 5. Reinstall the oil fill cap and tighten securely. Reinstall dipstick. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the L mark or over the F mark on the dipstick. Oil Filter Oil Drain Plug Oil Cooler Figure 9. Oil Drain Plugs, Oil Filter, and Oil Cooler (Blower Housing Mounted). Change Oil Filter Replace the oil filter at least every other oil change (every 200 hours of operation). Always use a genuine Kohler oil filter. Use chart below to determine part number to order. Oil Filter Part No S S Replace the oil filter as follows: 1. Drain the oil from the engine crankcase. 2. Allow the oil filter to drain. Length 2-1/2" 3-3/8" 3. Before removing the oil filter, clean the area around the oil filter to keep dirt and debris out of the engine. Remove the old filter. Wipe off the surface where the oil filter mounts. 4. Place a new replacement filter in a shallow pan with the open end up. Pour new oil, of the proper type, in through the threaded center hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by the filter material. 5. Apply a thin film of clean oil to the rubber gasket on the new filter. 6. Install the replacement oil filter to the filter adapter or oil cooler. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter or oil cooler, then tighten the filter an additional 3/4 to 1 turn. Oil Filter Oil Cooler Oil Drain Plug 7. Reinstall the drain plug. Make sure it is tightened to 13.6 N m (10 ft. lb.) torque. Figure 8. Oil Drain Plugs, Oil Filter, and Oil Cooler (Crankcase Mounted). 8. Fill the crankcase with new oil of the proper type to the F mark on the dipstick. 10

128 9. Start the engine and check for oil leaks. Correct any leaks before placing the engine into service. Check oil level to be sure it is up to but not over the F mark. Service Oil Cooler Some engines are equipped with an oil cooler. One style of oil cooler mounts on the engine crankcase and has the oil filter on it (See Figure 8). The other style of oil cooler is mounted on the blower housing (see Figure 9), separate from the oil filter. Air Cleaner Cover Element Cover Element Cover Knob Element Cover Nut Precleaner Inspect and clean the oil cooler every 100 hours of operation (more frequently under severe conditions). Oil cooler must be kept free of debris. To service the crankcase mounted oil cooler clean off the outside fins with a brush or with compressed air. To service the blower housing mounted oil cooler, clean the outside of fins with a brush. Remove the two screws holding the cooler unit to the blower housing. Tilt the cooler downward as shown in Figure 10. Clean the inside of cooler with a brush as shown in Figure 10 or with compressed air. After cleaning, reinstall oil cooler to blower housing with two mounting screws. Figure 11. Air Cleaner System Components. Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components. NOTE: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure. Service Precleaner If so equipped, wash and reoil the precleaner every 25 hours of operation (more often under extremely dusty or dirty conditions). 1. Loosen the cover retaining knob and remove the cover. 2. Remove the precleaner from the paper element. Figure 10. Cleaning Oil Cooler. Service Precleaner and Air Cleaner Element This engine is equipped with a replaceable, high density paper air cleaner element. Most engines are also equipped with an oiled, foam precleaner which surrounds the paper element. See Figure 11. Some engines use the heavy-duty air cleaner system. See Figure Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry. 4. Saturate the precleaner with new engine oil. Squeeze out all excess oil. 5. Reinstall the precleaner over the paper element. 6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob. 7. When precleaner replacement is necessary, order genuine Kohler parts S S 61 mm (2.40 in.) high x 173 mm (6.81 in.) O.D. 71 mm (2.79 in.) high x 173 mm (6.81 in.) O.D. 11

129 Service Paper Element Every 100 hours of operation (more often under extremely dusty or dirty conditions) replace the paper element. 1. Loosen the cover retaining knob and remove the cover. 2. Pull the air cleaner element out of the housing. See Figure 12. Main Element Inner Element 2. Remove the element cover nut, element cover, and paper element with precleaner. 3. Remove the precleaner (if so equipped) from the paper element. Service the precleaner as described above. 4. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged. 5. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components. NOTE: If any loose dirt or debris fell on the air cleaner base when the element was removed, carefully remove it and wipe the base clean. Be careful that none of it drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud. If the condition is questionable in any way, replace it with the new seal packaged with the replacement element. 6. Reinstall the paper element, precleaner, element cover, element cover nut, and air cleaner cover. Secure cover with the cover retaining knob. 7. When element replacement is necessary, order genuine Kohler parts. Figure 12. Removing Elements. 3. After the main element is removed, check the condition of the inner element. It should be replaced whenever it appears dirty, typically every other time the main element is replaced. Clean the area around the base of the inner element before removing it, so dirt does not get into the engine. 4. Do not wash the paper element and inner element or use pressurized air, this will damage the elements. Replace dirty, bent or damaged elements with new genuine Kohler elements as required. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged. 5. Check all parts for wear, cracks, or damage. Replace any damaged components. 6. Install the new inner element, Kohler Part No S followed by the outer element, Kohler Part No S. Slide each fully into place in the air cleaner housing. 7. Reinstall the end cap so the dust ejector valve is down and secure with the two retaining clips. See Figure S S 65 mm (2.55 in.) high x 178 mm (7.00 in.) O.D. 74 mm (2.91 in.) high x 178 mm (7.00 in.) O.D. Heavy-Duty Air Cleaner To Service Every 250 hours of operation (more often under extremely dusty or dirty conditions), replace the paper element and check inner element. Follow these steps Unhook the two retaining clips and remove the end cap from the air cleaner housing. Dust Ejector Valve Figure 13. Heavy-Duty Air Cleaner Assembly.

130 Clean Air Intake/Cooling Areas To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Every 100 hours of operation (more often under extremely dusty, dirty conditions), remove the blower housing* and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. 3. Check the gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 in.) by carefully bending the ground electrode. See Figure 14. Wire Gauge Spark Plug NOTE: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating. *Cleanout kits S (black) or S (gold) allow inspection and cleanout of the cooling fins, without removing the blower housing. Ignition System Ground Electrode Figure 14. Servicing Spark Plug mm (0.030 in.) Gap Carbureted Engines - Use an electronic Capacitive Discharge (CD) ignition system. Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system. EFI Engines - Incorporate a computer-controlled battery ignition system with individual coils. Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system. Check Spark Plugs Every 200 hours of operation, remove the spark plugs, check condition, and reset the gap or replace with new plugs as necessary. The standard spark plug is a Champion RC12YC (Kohler Part No S). RFI complaint engines use a Champion XC12YC (Kohler Part No S) spark plug. A high-performance spark plug, Champion Platinum 3071 (used on Pro Series engines, Kohler Part No S) is also available. Equivalent alternate brand plugs can also be used. 1. Before removing the spark plug, clean the area around the base of the plug to keep dirt and debris out of the engine. 2. Remove the plug and check its condition. Replace the plug if worn or reuse is questionable. NOTE: Do not clean the spark plug in a machine using abrasive grit. Some grit could remain in the spark plug and enter the engine causing extensive wear and damage. 4. Reinstall the spark plug into the cylinder head. Torque the spark plug to N m (18-22 ft. lb.). Battery Charging WARNING: Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. NOTE: Fuel System Do not apply 12 volt DC to kill terminal of ignition module. WARNING: Fuel System Under Pressure! The EFI fuel system operates under high pressure, and the fuel filter and fuel line used must be approved system components only. Use of substitute parts can result in system failure, gasoline leakage and possible explosion. Fuel Filter Carbureted Engines: Most engines are equipped with an in-line fuel filter. Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours. 13

131 EFI Engines: A special, high volume, high pressure filter with greater filtration capabilities and internal surface area is used. See Figure 15. Fuel Filter Fuel Line Figure 15. EFI Fuel Filter and Line. Replacement is recommended every 1500 hours, or more frequently under extremely dusty or dirty conditions. When replacement is necessary, always use genuine Kohler parts. Fuel Line Carbureted Engines: In compliance with CARB Tier III Emission Regulations, carbureted engines with a Family identification number beginning with 6 or greater (see Figure 16), must use Low Permeation SAE 30 R7 rated fuel line; certified to meet CARB requirements. Standard fuel line may not be used. Order replacement hose by part number through a Kohler Engine Service Dealer. Carburetor Troubleshooting and Adjustments Engines in this series use either a one- or two-barrel carburetor depending on model, and may also be equipped with a Governed Idle System. Specific adjustment procedures are provided based on the model and carburetor involved. If the engine is equipped with a Governed Idle System, refer to Models with Governed Idle System on page 15 when performing any carburetor adjustment, as an additional step to the listed adjustment procedure(s) is required. NOTE: Carburetor adjustments should be made only after the engine has warmed up. The carburetor is designed to deliver the correct fuel-to-air mixture to the engine under all operating conditions. To comply with current emission regulations, the fuel mixture settings are made at the factory and cannot be adjusted. NOTE: To ensure correct engine operation at altitudes above 1525 meters (5000 ft.), it may be necessary to have an authorized Kohler dealer install a special high-altitude jet kit in the carburetor. If a high-altitude kit has been installed, the engine must be reconverted to the original jet size, before it is operated at lower altitudes, or overheating and engine damage can result. 14 IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA AND CA 2005 AND LATER AND EC STAGE II (SN:4) EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY 6 KHXS.7252 PH TYPE APP DISPL. (CC) MODEL NO. N11236 SPEC. NO. SERIAL NO. BUILD DATE OEM PROD. NO. EMISSION COMPLIANCE PERIOD: EPA: CARB: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY, MAINTENANCE AND ADJUSTMENTS KOHLER CO. KOHLER, WISCONSIN USA Figure 16. Family Number Location. EFI Engines: A special fuel line, capable of withstanding the high pressure of the EFI fuel system, is used (must meet SAE R9 specifications). See Figure 15. If fuel line must be replaced, see your Kohler Engine Service Dealer. Low Idle Speed Adj. Low Idle Fuel Adj. Needle & Fixed Main Jet (under optional Figure 17. Carburetor (CH18-25,CH730,740). Troubleshooting If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting the carburetor. Make sure the fuel tank is filled with clean, fresh gasoline. Make sure the fuel tank cap vent is not blocked and that it is operating properly.

132 If the fuel tank is equipped with a shut-off valve, make sure it is open. If the engine is equipped with an in-line fuel filter, make sure it is clean and unobstructed. Replace the filter if necessary. Make sure fuel is reaching the carburetor. This includes checking the fuel lines and fuel pump for restrictions or faulty components, replace as necessary. Make sure the air cleaner element is clean and all air cleaner element components are fastened securely. If, after checking the items listed above, the engine is hard to start, runs roughly, or stalls at low idle speed, it may be necessary to adjust or service the carburetor. Adjust Carburetor Models CH There are no accessible mixture adjustment screws on the carburetor. The only setting which can be changed is the low idle speed. 1. Start the engine and run at half throttle for 5 to 10 minutes to warm up. The engine must be warm before making final settings (steps 2 and 3). The system requires an additional procedure for setting the idle speed. If speed adjustments are required proceed as follows. 1. Make any necessary speed or control adjustments following the appropriate instructions covered in this section. 2. Move the throttle control to the idle position. Hold the governor lever away from the carburetor, or hold the throttle lever so it is tight against the idle speed adjusting screw, to negate the governor activation. See Figure 19. Check the speed with a tachometer and adjust it to 1500 RPM. 3. Release the governor lever and allow the engine to return to the governed idle speed. Check it with a tachometer against the equipment manufacturers recommended idle speed. Governed Idle Speed (RPM) is typically 300 RPM (approximate) higher than the low idle speed. If adjustment is necessary, bend the adjusting tab on the speed control assembly to set. See Figure 18. Governed Idle Spring Tab 2. Low Idle Speed Setting: Place the throttle control into the idle or slow position. Set the low idle speed to 1200 RPM* (± 75 RPM) by turning the low idle speed adjusting screw in or out. Check the speed using a tachometer. *NOTE: The actual low idle speed depends on the application refer to equipment manufacturers recommendations. The standard low idle speed is 1200 RPM. Figure 18. Governed Idle Spring Location. 3. If proper operation is not restored after adjusting the low idle speed, carburetor servicing by an authorized Kohler Engine Service Dealer may be required. Models with Governed Idle System An optional governed idle control system is supplied on some CH engines. The purpose of this system is to maintain a desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. Engines with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket. See Figure 18. Hold Throttle Lever Against Screw Figure 19. Holding Throttle Lever Against Idle Stop Screw. 15

133 Model CH750 CH750 engines use a Keihin BK two-barrel carburetor with fixed main jets and fixed or limiter-equipped low idle fuel adjusting needles. See Figure 20. Adjustments are made as follows. Low Idle Fuel Adjusters (with limiters) Low Idle Speed (RPM) Adjustment Screw adjusting needle in (clockwise). The engine speed may increase, then it will decrease as the needle is turned in (lean). Note the position of the needle. Set the adjusting needle midway between the rich and lean settings. See Figure 21. b. Repeat the procedure on the other low idle adjustment needle. 4. Recheck/adjust the Low Idle Speed (RPM), to the specified setting. Fuel Solenoid Adjust to Midpoint Lean Adjust to Midpoint Lean Figure 20. Keihin Two-Barrel Carburetor. Low Idle Speed (RPM) Adjustment 1. Low Idle Speed (RPM) Setting: Place the throttle control into the idle or slow position. Set the low idle speed to 1200 RPM* (± 75 RPM) by turning the low idle speed adjusting screw in or out. Check the speed using a tachometer. *NOTE: The actual low idle speed depends on the application. Refer to the equipment manufacturer s recommendations. The low idle speed for basic engines is 1200 RPM. To ensure best results when setting the low idle fuel needle, the low idle speed should be 1200 RPM (± 75 RPM). Low Idle Fuel Adjustment NOTE: Engines will have fixed low idle or limiter caps on the two idle fuel adjusting needles. Step 3 can only be performed within the limits allowed by the cap. Do not attempt to remove the limiter caps. 1. Start the engine and run at half throttle for 5 to 10 minutes to warm up. The engine must be warm before doing steps 2, 3, and Place the throttle control into the idle or slow position. Adjust the low idle speed to 1200 RPM* Follow the Adjusting the Low Idle Speed (RPM) procedure. 3. Low Idle Fuel Needle(s) Setting: Place the throttle into the idle or slow position. a. Turn one of the low idle fuel adjusting needles out (counterclockwise) from the preliminary setting until the engine speed decreases (rich). Note the position of the needle. Now turn the Rich Left Side Rich Right Side Figure 21. Optimum Low Idle Fuel Settings. Models with Governed Idle System An optional governed idle control system is supplied on some CH750 engines. The purpose of this system is to maintain a desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. Engines with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket. See Figure 18. Refer to the same adjustment procedure covered in Models with Governed Idle System for the CH models on page 15, when adjustments are required. Electronic Fuel Injection (EFI) System The EFI system is a complete, electronically-controlled fuel management system, designed to deliver a precisely controlled fuel flow under all operating conditions. The electronic control unit (ECU), the brain of the system, automatically adjusts fuel delivery and ignition timing based upon load, speed, operating temperature, and exhaust emission levels. The low idle speed is the only manual adjustment possible. The ECU continuously monitors operation of the EFI system. If it detects a problem or fault within the system, it will illuminate the malfunction indicator light (MIL), which is mounted in view of the operator. This is a signal that normal, programmed operation has been affected, and service by an authorized Kohler Engine Dealer is required. 16

134 NOTE: The EFI system requires a rather complex wiring harness to carry the electrical signals between the sensors and the ECU. Do not spray water at the wiring harness or any of the electrical components, especially the ECU, as it could cause malfunction, damage, or failure. Troubleshooting If the MIL comes on, or the engine becomes hard to start, runs roughly, or stalls at low idle speed, initial checks should be made in the following areas: Make sure the fuel tank is filled with clean, fresh gasoline, and shut-off valve (if so equipped) is opened completely. Make sure fuel tank vent cap is not blocked and it is operating properly. Make sure the air cleaner element and precleaner are clean and all components are properly secured. Clean or replace as necessary. Make sure the proper fuel filter is being used, and it is clean and unobstructed. Replace filter only with genuine Kohler parts. Make sure all connections to sensors, ECU, and fuel injectors are properly secured. Make sure a good 12 volt battery is being used and is fully charged. If these checks do not correct the problem, or the MIL remains on, further diagnosis and servicing by an authorized Kohler Engine Dealer is necessary. Adjustment EFI Throttle Body Low Idle Speed (RPM) is the only adjustment that can be made. All other fuel calibrations are permanently preset and controlled by the ECU. The standard low idle speed is 1500 RPM* (+ 75 RPM). *NOTE: The actual low idle speed depends on the application -- refer to equipment manufacturer's recommendations. When an EFI engine is started cold, the ECU will be using internal programming for cold running, and the idle speed may vary from the manual setting. Do not attempt to perform any readjustment during this warm-up period. If adjustment is to be made, the engine must be at operating temperature, air cleaner in place, and check engine light must be off (no fault codes present). 1. Start the engine and run at half throttle for 5 to 10 minutes to warm up. 2. Place the throttle control into the idle or slow position. 3. Turn the low idle speed adjusting screw in or out and check RPM with a tachometer. See Figure 22. Low Idle Speed Adjusting Screw Fuel Rail Figure 22. EFI Throttle Body Manifold. Throttle Body Intake Manifold Troubleshooting When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles are listed in the following table. Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. Have your Kohler Engine Service Dealer do this work. Possible Cause No Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line/System Grass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start Hard Starting Stops Suddenly Lacks Power Operates Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Consumption 17

135 Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the engine. On EFI engines, avoid spraying water at the wiring harness or any of the electrical components. 2. Change the oil and filter while the engine is still warm from operation. See Change Oil and Filter on page The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturers recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2-3 minutes to get stabilized fuel into the rest of the system. Close fuel shut-off valve when unit is being stored or transported. To empty the system, run the engine until the tank and fuel system are empty. 4. Remove the spark plugs. Add one tablespoon of engine oil into each spark plug hole. Install the plugs, but do not connect the plug leads. Crank the engine two or three revolutions. 5. On units with EFI engines, disconnect the negative (-) battery cable or use a battery minder trickle charger while the unit is in storage. 6. Store the engine in a clean, dry place. Parts Ordering The engine Specification, Model, and Serial Numbers are required when ordering replacement parts from your Kohler Engine Service Dealer. These numbers are found on the identification plate which is affixed to the engine shrouding. Include letter suffixes if there are any. See Engine Identification Numbers on page 6. Always insist on genuine Kohler parts. All genuine Kohler parts meet strict standards for fit, reliability, and performance. Major Repair Major repair information is available in Kohler Engine Service Manuals. This type of repair generally requires the services of a trained mechanic and the use of special tools and equipment. Kohler Engine Service Dealers have the facilities, training, and genuine Kohler replacement parts necessary to perform this service. For the nearest Sales & Service location: visit our website call (U.S. & Canada) look in the yellow pages under Engines-Gasoline Specifications Model:... CH18,20... CH22,23... CH730,26,740, CH750 Bore:... mm (in.) (3.03) (3.2) (3.27) (3.27) Stroke:... mm (in.) (2.64) (2.64) (2.64) (2.72) Displacement:... cm 3 (in 3 ) (38.1) (41) (44.0) (45.6) Power (@ 3600 RPM):... kw (HP) (18*)/14.9 (20*) (22*)/17.2 (23*) (25*)/19.4 (26*) (30*) 20.1 (27*)/20.9(28*) Max. Peak Torque (@ RPM):.. N m (ft. lb.) Compression Ratio: : : : :1 Weight:... kg (lb.) (90) (90) (94) (105) Oil Capacity (w/filter) - approximate, determined by oil filter and oil cooler used: L ( U.S. qt.) Lubrication: Full Pressure w/full Flow Filter Exhaust Emission Control System for models CH18,20,22,23,730,740,750 is EM. Exhaust Emission Control System for models CH26 and CH745 are EM, O2S, ECM, MFI. *Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940. Actual engine horsepower is lower and affected by, but not limited to, accessories (air cleaner, exhaust, charging, cooling, fuel pump, etc.), application, engine speed and ambient operating conditions (temperature, humidity, and altitude). Kohler reserves the right to change product specifications, designs and equipment without notice and without incurring obligation. 18

136 LIMITED 2 YEAR COMMAND ENGINE WARRANTY Kohler Co. warrants to the original consumer that each new COMMAND engine sold by Kohler Co. will be free from manufacturing defects in materials or workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated and maintained in accordance with Kohler Co. s instructions and manuals. Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective. EXCLUSIONS: Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are warranted for two (2) years. This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary maintenance. The following items are not covered by this warranty: Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by Kohler Co. These are subject to the warranties, if any, of their manufacturers. KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts. IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any on our behalf. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. TO OBTAIN WARRANTY SERVICE: Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, and click on SALES AND SERVICES to use the locator function, consult your Yellow Pages or telephone ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN KOHLER CO. FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF-ROAD AND CLASS 1 LSI ENGINES The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the Federal and California Emission Control Systems Warranty on your off-road equipment engine. For California, small offroad engines produced in 1995 and later, and Class 1 LSI (Large Spark Ignited engines at or below 1.0 liter) produced in 2005 and later, must be designed, built and equipped to meet the state s stringent anti-smog standards. In other states, 1997 and later model year engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must be free from defects in materials and workmanship, which cause it to fail to conform with U.S. EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, provided there has been no abuse, neglect or improper maintenance. The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included are the hoses, belts and connectors and other emission related assemblies. Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at an authorized dealer), parts and labor. MANUFACTURER S WARRANTY COVERAGE Small off-road engines produced in 1995 or later, and Class 1 LSI engines produced in 2005 and later, are warranted for two years in California. In other states, 1997 and later model year engines are warranted for two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge. OWNER S WARRANTY RESPONSIBILITIES (a) The engine owner is responsible for the performance of the required maintenance listed in the owner s manual. Kohler Co. recommends that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed. (b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Continued on next page. 19

137 (c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call or access our website at: for the names of the nearest service centers. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at and ask for an Engine Service representative. COVERAGE Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years. Small off-road engines produced in 1995 or later, and Class 1 LSI engines produced in 2005 and later, are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser. If any emission related part on the engine is defective, Kohler Co. will replace the part at no cost to the owner. Kohler Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty. Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective. Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are: Oxygen sensor (if equipped) Intake manifold (if equipped) Exhaust manifold (if equipped) Catalytic muffler (if equipped) Fuel metering valve (if equipped) Spark advance module (if equipped) Ignition module(s) with high tension lead Gaseous fuel regulator (if equipped) Electronic control unit (if equipped) Carburetor or fuel injection system Fuel lines (if equipped) Air filter, fuel filter, and spark plugs (only to first scheduled replacement point) LIMITATIONS This Emission Control Systems Warranty shall not cover any of the following: (a) (b) (c) (d) (e) repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not recommended or approved in writing by Kohler Co., replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point, consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc., diagnosis and inspection fees that do not result in eligible warranty service being performed, and any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts. MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep maintenance records. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of the engine manufacturer. FORM NO.: A ISSUED: 11/04 REVISED: 6/07 LITHO IN U.S.A. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

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