Page 1 Model Hurricane RS Model Hurricane TRX Machine Serial # _____________ Engine Model & Spec # _____________ Engine Serial # _____________ HPTO/Clutch Model & Spec # _____________ Clutch Serial # _____________ Purchase Date _____________ Dealer _____________ Carlton J.P.Carlton Company Div. D.A.F. Inc.
Page 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.
Page 5 HURRICANE TRACK SAFETY ALERT...
Page 7 HURRICANE TRACK SAFETY ALERT...
Page 9 HURRICANE TRACK SAFETY ALERT...
Page 11 HURRICANE TRACK SAFETY ALERT...
Page 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.
Page 15: Important Notice
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.
Page 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.
Page 19: Table Of Contents
Hurricane Track TABLE OF CONTENTS INTRODUCTION FOREWORD GENERAL INFORMATION MACHINE FEATURES MACHINE SPECIFICATIONS OPERATION SAFETY PRECAUTIONS DAILY CHECKLIST MACHINE CONTROLS TRANSPORT MACHINE MACHINE OPERATION MAINTENANCE MACHINE MAINTENANCE LUBRICATION CHART TROUBLESHOOTING GUIDE SERVICING BELTS SERVICING BEARINGS SERVICING CUTTER WHEEL SERVICING HYDRAULICS WIRING DIAGRAM PARTS ENGINE BELT ASSEMBLY...
Page 21: Foreword
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 ®...
Page 22: General Information
Any reference made to right, left, front or rear in relationship to the stump cutter 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.
Page 23: Machine Features
Hurricane Track MACHINE FEATURES Available Machine Features: Proportional wireless Oil cooler with electric 1 1/2” thick Blanchard • • • remote control with ground cutter wheel tether back-up Hydraulic oil and fuel Low maintenance drive • • filters belts Continuous 360° •...
Page 24: Machine Specifications
Hurricane Track MACHINE SPECIFICATION Hurricane RS General: Hydraulic System: Weight: ------------------ 8500 Pounds Hyd Pump Displcmnt: -Variable Displacement Pressure Length:------------------- 170” Comp. Height: ------------------- 83” Hyd Pump Drive Sys: --Direct Drive off Engine Mount Width:-------------------- 65” Flow: ---------------------Variable Controls: ----------------- Wireless Remote w/ Tether...
Page 25 Hurricane Track MACHINE SPECIFICATION Hurricane TRX General: Hydraulic System: Weight: ------------------ 12500 Pounds Hyd Pump Displcmnt: -Variable Displacement Pressure Length:------------------- 185” Comp. Height: ------------------- 83” Hyd Pump Drive Sys: --Direct Drive off Engine Mount Width:-------------------- 78” Flow: ---------------------Variable Controls: ----------------- Wireless Remote w/ Tether System Relief:-----------2750 PSI Back Up Oil Tank Capacity: -----42 Gallons...
Page 26: Safety Precautions
Hurricane Track SAFETY PRECAUTIONS Before operating the stump cutter, read this manual, the engine manual, and all the safety decals on the machine. Know all parts of the machine and their functions, especially the shut down procedures in case of emergency. No inexperienced person may operate machine.
Page 27 (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.
Page 28 Hurricane Track SAFETY PRECAUTIONS • Battery fumes are explosive. Recharge battery in an open area away from fire, sparks, or other sources of ignition. • Battery acid can cause severe burns. Keep away from eyes, skin, and clothing. • Always remove battery before welding on equipment. •...
Page 29 • Keep all chip guards in place and secured properly. • 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.
Page 30: Daily Checklist
Hurricane Track DAILY CHECKLIST DAILY CHECKS SHOULD BE PERFORMED BEFORE STARTING ENGINE FOR THE DAY. DO NOT INSERT KEY INTO ENGINE UNTIL ALL CHECKS HAVE BEEN COMPLETED. • Check engine oil at dipstick, located inside the cover of the engine. Engine must be level.
Page 31: Machine Controls
Hurricane Track MACHINE CONTROLS ENGINE CONTROLS – Refer to the engine manufacturer’s operating manual for controls, operation and service. Never weld on a machine without disconnecting the ECU on the engine. DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR.
Page 32 Hurricane Track MACHINE CONTROLS HYDRAULIC CONTROLS • A series of hydraulic controls are located on the radio control transmitter and are clearly marked for operation. All machine controls are operated from the radio control transmitter. SWITCH FUNCTIONS RIGHT TRACK – LEFT TRACK •...
Page 33 Hurricane Track MACHINE CONTROLS SWING PADDLE • The swing paddle controls the rotation and moves the machine back and forth in a right and left direction as well as a continuous 360° rotation. • The swing knob controls how fast the SWING BRAKE SWITCH SWING SPEED machine moves back and forth when...
Page 34 Hurricane Track MACHINE CONTROLS THROTTLE • The radio control transmitter has a throttle switch for the operator to control the engine speed. Push the switch away from the operator to increase the engine THROTTLE SWITCH CLUTCH SWITCH speed and pull the switch toward the operator to decrease engine speed.
Page 35 Hurricane Track MACHINE CONTROLS MACHINE HYDRAULIC CONTROLS • A series of hydraulic controls are located on the radio control transmitter and the machine and are clearly marked for operation. DO NOT USE THE MACHINE MOUNTED CONTROLS TO GRIND STUMPS. The machine mounted control levers are to be used only for positioning the machine at slow speeds and to check hydraulic operation.
Page 36 Hurricane Track MACHINE CONTROLS SWING ROTATION • The third lever, in the middle, is the swing rotation and moves the machine back and forth in a right and left rotation as well as a continuous 360° rotation. DO NOT GRIND STUMPS USING THE MACHINE MOUNTED SWING ROTATION LEVER.
Page 37 Hurricane Track MACHINE CONTROLS PT TECH CLUTCH CONTROL • The PT TECH Clutch control console is located at the operators’ station. The engine must be at idle to engage or disengage the PT TECH clutch. With the engine at idle hold the ENGAGE/DISENGAGE BUTTON engage/disengage button until the green...
Page 38 Hurricane Track MACHINE CONTROLS SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE.
Page 39: Troubleshooting
FOR ANY OPERATING PROBLEMS WITH THE RADIO RECEIVER & TRANSMITTER (Included in the back of this manual) • Contact your Carlton dealer if you need assistance not the radio control manufacturer. • Check the batteries to make sure they are providing enough power to operate the transmitter.
Page 40: Transport Machine
DOWN RINGS ON THE SIDE OF THE MACHINE. The Hurricane TRX requires a lowboy trailer that will support and carry 12000 pounds. The Hurricane RS requires a trailer rated for at least 10000 lbs. THE TRAILER MUST BE SECURELY ATTACHED TO THE TOW •...
Page 41 Hurricane Track TRANSPORT MACHINE • THE TRAILER MUST BE SECURELY ATTACHED TO THE TOW VEHICLE BEFORE LOADING OR UNLOADING THE STUMP GRINDER. • DO NOT LOAD OR UNLOAD ON ANYTHING OTHER THAN LEVEL GROUND. LOADING • Start the machine using the key-switch on the machine control panel and turn on the radio control and push the ON button.
Page 42: Machine Operation
Hurricane Track MACHINE OPERATION STARTING – ALL OPERATORS MUST READ THIS MANUAL, ALL MACHINE DECALS, AND THE ENGINE AND OTHER COMPONENT MANUALS BEFORE STARTING. • ALWAYS PERFORM DAILY CHECKLIST BEFORE STARTING MACHINE FOR THE DAY. REPLENISH FUEL AND OIL DAILY. •...
Page 43 Hurricane Track MACHINE OPERATION • The E-STOP light will flash red quickly. LIGHT PANEL • Release the E-STOP button by twisting it clockwise. Release the E-STOP button within 10 seconds or the unit will power down. • The Active light will flash yellow. •...
Page 44 Hurricane Track MACHINE OPERATION • Release the swing brake by pressing the switch down and test cutter wheel swing SWING LOCK SWING SPEED controls for proper operation. DO NOT ALLOW ANYONE TO BE NEAR THE MACHINE WHEN THE SWING IS BEING OPERATED.
Page 45 Hurricane Track MACHINE OPERATION • Continue cutting the stump by adjusting the cutting head progressively lower until the stump is cut well below ground level. • Raise and swing cutter wheel clear of stump and position machine closer to stump for next series of passes. Lower and continue cutting.
Page 46: Machine Maintenance
Hurricane Track MACHINE MAINTENANCE SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE.
Page 47: Maintenance
Hurricane Track MACHINE MAINTENANCE • The Hurricane track machine may come with an inline fuel filter. This filter must be changed every 50 hours of operation. Clamp the hoses on both sides of the filter and remove and replace with a new filter.
Page 48: Maintenance
Hurricane Track MACHINE MAINTENANCE • Check hydraulic oil daily and replenish as necessary. A site glass is provided for easy viewing. If oil can be seen in glass, there is enough oil in the tank. Do not fill the tank more than 7/8 full; operating at high temperature will cause oil to expand and spill over if tank is full.
Page 49 Hurricane Track MACHINE MAINTENANCE SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE.
Page 50 Hurricane Track MACHINE MAINTENANCE • The Hurricane track machine may come with an inline fuel filter. This filter must be changed every 50 hours of operation. Clamp the hoses on both sides of the filter and remove and replace with a new filter.
Page 51 Hurricane Track MACHINE MAINTENANCE • Check hydraulic oil daily and replenish as necessary. A site glass is provided for easy viewing. If oil can be seen in glass, there is enough oil in the tank. Do not fill the tank more than 7/8 full; operating at high temperature will cause oil to expand and spill over if tank is full.
Page 52: Lubrication Chart
Hurricane Track LUBRICATION CHART • The Hurricane track model, as well as all • A regularly scheduled maintenance of our machines, is built to be a rugged program will pay big dividends in performer. Your new machine is sturdy machine life, performance, and avoided and our design goals are simplicity and downtime.
Page 53: Troubleshooting Guide
TROUBLESHOOTING GUIDE Hurricane Track COMPLAINT CAUSE CORRECTION • Loose ground wire. • Clean and tighten. Engine will not start. (See Engine Manufacturer • Loose hot wire. • Clean and tighten. Manual for further • Dead battery. • Recharge or replace. information.) •...
Page 54 TRACKS WILL BOW Traction loss of power. • Hydraulic motor worn. • See Track Maintenance section in this manual. for information or contact your Carlton dealer. ONLY USE QUALIFIED PERSONNEL TO WORK ON HYDRAULIC SYSTEMS FOR REPAIRS OR REPLACEMENT OF PARTS!!
Page 55: Servicing Belts
Hurricane Track SERVICING BELTS Servicing Engine Belt SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE.
Page 56 Hurricane Track SERVICING BELTS Servicing Engine Belt • There is a dust protection plate, in two sections, that goes behind the engine sheave and bolts to the engine belt guard using four 1/4” bolts and nuts. Loosen all four bolts enough to be able to move the engine to loosen the belt and remove it.
Page 57 Hurricane Track SERVICING BELTS Servicing Engine Belt • When the belt is loose enough, remove the belt by pulling it off the engine sheave and then the jackshaft sheave. Removing the ENGINE SHEAVE SHOWN ABOVE AND JACKSHAFT SHEAVE SHOWN BELOW. belt from the engine sheave first should be easier because of the size of the sheave.
Page 58 Hurricane Track SERVICING BELTS Servicing Engine Belt • When the belt is tightened slightly, check the alignment of the sheaves using a straight edge. If sheaves are out of line, use the adjustment nuts to align the sheaves. You will need to loosen one adjustment bolt’s jam nut and tighten the other, making only slight adjustments until the sheaves are aligned.
Page 59 Hurricane Track SERVICING BELTS Servicing Engine Belt ENGINE MOUNTING BOLTS • When belt tension is adjusted properly, tighten all four engine bolts (3/4”) and torque bolts to 300 ft-lb. Next make sure all jam nuts on the adjustment bolts are tightened. •...
Page 60 Hurricane Track SERVICING BELTS Servicing Poly Chain Belt ® SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. •...
Page 61 Hurricane Track SERVICING BELTS Servicing Poly Chain Belt ® • Loosen the Poly Chain belt by ® loosening the cutter wheel bearing bolts; DO NOT remove the bolts. There are two lock nuts on each bolt that have to be loosened to loosen the bearing bolts. MARK THE LOCATION OF EACH BEARING TO MAKE ADJUSTMENTS EASIER WHEN...
Page 62 Hurricane Track SERVICING BELTS Servicing Poly Chain Belt ® • Remove the belt. • Place the new belt on the jackshaft sprocket first and then put the cutter wheel sprocket in the belt and put it on the cutter wheel shaft. Replace the bushing in the sprocket and position it as close to the mark made earlier as possible.
Page 63 Hurricane Track SERVICING BELTS Servicing Poly Chain Belt ® • Check the Poly Chain belt tension. See ® the chart that follows for tensioning specifications. If belt tension needs adjustment, use the jam bolts to move the cutter wheel to get the proper tension.
Page 64 Hurricane Track SERVICING BELTS Servicing Poly Chain Belt ® • Retighten all the bolts and nuts in the belt guard. The nuts are easily accessible on the back of the guard. • Replace all 14 bolts with flat and lock washers.
Page 65: Servicing Bearings
Hurricane Track SERVICING BEARINGS Always clean tip of grease gun fitting and grease fitting on machine before attaching hose to prevent dirt from being forced into machine parts. After applying grease, remove excess grease from the grease fitting to prevent dirt build up. There are four (4) bearings on the jackshaft;...
Page 66 Hurricane Track SERVICING BEARINGS TURNTABLE BEARING While turntable bearings require almost no attention, what little they are given will pay big dividends in long life, high performance, and trouble free service. Lubricate the bearing every 100 operating hours. When greasing the turntable bearing, lower the cutter wheel to the ground.
Page 67: Servicing Cutter Wheel
SERVICING CUTTER WHEEL Hurricane Track 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.
Page 68 SERVICING CUTTER WHEEL Hurricane Track TOOTH ARRANGEMENT • Inspect pockets, teeth and bolts for damage • Use anti-seize on threads to prevent bolts and replace as required. from “freezing up” in cutter wheel pockets. • • When replacing pockets, always replace When replacing complete set of teeth, be new pockets across form each other in order sure to duplicate original factory tooth...
Page 69 Dura Disk II Cutter Wheel THE PICTURES SHOWN BELOW ARE FOR A DIFFERENT MACHINE BUT THE WHEEL CONFIGURATION IS THE SAME. • If the Hurricane RS is supplied with the optional Dura Disk II cutter wheel, there are sixty-eight (68) teeth to a complete set.
Page 70 SERVICING CUTTER WHEEL Hurricane Track TOOTH ARRANGEMENT • • Inspect pockets, teeth and bolts for damage and Outside pocket teeth are Short Plow Bolt Bits. replace as required. These pockets are angled and welded in place. • You can switch teeth from one outside pocket When replacing a cutter wheel tooth, replace to a pocket that is the opposite direction to the tooth and nut as a set and use anti-seize on...
Page 71 Dura Disk II cutter wheel, there are one hundred four (104) teeth to a complete set. There are sixteen (16) Short Plow Bolt Bits (Carlton part #0450121) and eighty-eight (88) Plow Bolt Bits (Carlton part #0450120). • DO NOT OPERATE A MACHINE...
Page 72 SERVICING CUTTER WHEEL Hurricane Track TOOTH ARRANGEMENT • • Inspect pockets, teeth and bolts for damage and Outside pocket teeth are Short Plow Bolt Bits. replace as required. These pockets are angled and welded in place. • You can switch teeth from one outside pocket When replacing a cutter wheel tooth, replace to a pocket that is the opposite direction to the tooth and nut as a set and use anti-seize on...
Page 73 SERVICING CUTTER WHEEL Hurricane Track 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.
Page 74: Servicing Hydraulics
Hurricane Track SERVICING HYDRAULICS SAFETY • NEVER SERVICE A MACHINE WITH THE ENGINE RUNNING, SEVERE PERSONAL INJURY COULD OCCUR. TURN ENGINE OFF THEN REMOVE IGNITION KEY AND DISCONNECT POSITIVE BATTERY CABLE TO AVOID STARTING MACHINE ACCIDENTALLY. • CUTTER WHEEL MUST BE DISENGAGED BEFORE TURNING ENGINE ON/OFF AND BEFORE SERVICING A MACHINE.
Page 75 This design will eliminate most of the oil spilling but some may drip from the filter. Clean up any spilled oil to prevent fire hazard. • Replace with new filter, use only manufacturer recommended filter. Contact JP Carlton or your local dealer...
Page 76 Hurricane Track SERVICING HYDRAULICS • Inspect hydraulic hoses and fittings daily for leaks, tightness, wear, or damage. Repair or replace as needed. • FLUID UNDER PRESSURE CAN PENETRATE THE SKIN AND CAUSE SEVERE INJURY. CHECK HOSES AND FITTINGS USING A BOARD OR CARDBOARD;...
Page 77 Hurricane Track MACHINE WIRING...
Page 78: Engine Belt Assembly
Hurricane Track ENGINE BELT ASSEMBLY Hurricane RS ITEM NO PART NO DESCRIPTION 19040079 Weldment, Engine Belt Base 1/2”-13 x 1 1/2” Carriage Bolt 0150304 1/2” Flat Washer 0150206 1/2”-13 Lock Nut 0400121B V-Belt – 6/B173 0250109 Engine Sheave – 6B8.0 SF 0250182B Tapered Bushing –...
Page 79 Hurricane Track ENGINE BELT ASSEMBLY Hurricane TRX ITEM NO PART NO DESCRIPTION 19040073 Weldment, Engine Belt Base 1/2”-13 x 1 1/2” Carriage Bolt 0150304 1/2” Flat Washer 0150206 1/2”-13 Lock Nut 0400121A V-Belt – 8RB195 0250185 Engine Sheave – 8B6.8 SF 0250182A Tapered Bushing –...
Page 80 Hurricane Track POLY CHAIN ® ASSEMBLY Hurricane RS ITEM NO PART NO DESCRIPTION 19040078 Weldment, Poly Chain Base ® 1/2”-13 x 1 1/2” Carriage Bolt 0150304 1/2” Flat Washer 0150206 1/2”-13 Lock Nut 0250151 Cutter Wheel Sprocket – 14M-56S-125 0250151A Tapered Bushing –...
Page 81 Hurricane Track POLY CHAIN ® ASSEMBLY Hurricane TRX ITEM NO PART NO DESCRIPTION 19040034 Weldment, Poly Chain Base ® 1/2”-13 x 1 1/2” Carriage Bolt 0150304 1/2” Flat Washer 0150206 1/2”-13 Lock Nut 0250151 Cutter Wheel Sprocket – 14M-56S-125 0250151A Tapered Bushing –...
Page 82 TRACK MAINTENANCE RUBBER TRACK ON HURRICANE TRX...
Page 83 TRACK MAINTENANCE...
Page 84 TRACK MAINTENANCE...
Page 85 TRACK MAINTENANCE...
Page 86 TRACK MAINTENANCE...
Page 87 TRACK MAINTENANCE...
Page 88 TRACK PARTS LIST...
Page 89 TRACK PARTS LIST...
Page 90 TRACK PARTS LIST...
Page 91 TRACK PARTS LIST...
Page 92 TRACK PARTS LIST...
Page 93 TRACK PARTS LIST...
Page 94 TRACK PARTS LIST...
Page 95 TRACK PARTS LIST...
Page 96 TRACK PARTS LIST...
Page 97 TRACK PARTS LIST...
Page 98 Behind Tow- 7500 Deutz Turbo Diesel 24" 46" 92" arc 31" 1.5" 60" 4,400 Behind Call and ask about Carlton’s line of Chippers or visit our website: www.stumpcutters.com CARLTON—QUALITY PRODUCTS AND EXCEPTIONAL SERVICE Carlton Owner’s Manual HURRICANE TRACK Revised: 10/2007...
Page 99 Installation and Maintenance Bulletin HPTO8TD-100 January 10, 2002 Hydraulic Power Take-off Rotating equipment is potentially dangerous and should be properly guarded. The user should check all applicable safety codes and provide suitable guards. The HPTO™ Hydraulic Power Take-off is MOUNTING AND ORIENTATION The HPTO is manufactured to mount to a hydraulically actuated, enclosed dry clutch...
Page 100 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 4. Check that the oil return line from the 4. Install flywheel ring gear to engine clutch manifold will be isolated from any flywheel using the “Flywheel Mounting return line that pressurized. Bolts”.
Page 101 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 17. Insure that there is a clean 15-micron 8. Once the HPTO housing is piloted and minimum oil filter in the hydraulic flush with the engine housing, you can system. remove the crane support. 9.
Page 102 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF MAINTENANCE INSTRUCTIONS SERVICE INSTRUCTIONS HPTO requires simple routine The HPTO can be reconditioned in the field maintenance by maintaining the proper oil or sent back to PT Tech. Contact PT Tech level hydraulic reservoir if any portions of these service instructions...
Page 103 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Remove all seals from piston, shaft and backplate (Items 25,17 & 18). 21. Remove two seals from endcover (Items 12 & 13). 10. Remove quantity of three springs (Item 21). 22. Clean area around manifold and endcover.
Page 104 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REBUILD INSTRUCTIONS SHAFT Refer to exploded view drawing SHOULDER HPTO8TD-100 sheet 2 of 2. Endcover Assembly 1. Apply Loctite 620 to steel cage of seals (Items 12 &13). 2. Install qty of 2, seals (Items 12 &13) into bore in endcover (Item 6).
Page 105 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF orientation of the dimpled side of the removed from the manufacturers rings are extremely important. package. Lightly lube ID and OD of bearing with Mobilifluid 424 or similar oil. Thread ½-13 rod into shaft. Use a bearing Endcover Sub-assembly ATTENTION: Check for burrs or debris press fixture that contacts the inner...
Page 106 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Note: do not use any washers. Note: orientation of housing to endcover as shown on assembly drawing. 8 of 8 9/11/2007...
Page 107 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Clutch Sub-assembly Press qty. of 3, dowel pins (Item 3) 10. Install backplate (Item 10) over shaft into endplate (Item 8). Apply Loctite into piston cavity. 609 to dowel pins before installing. ATTENTION: do not pinch o-ring in Dowel pins should be 1-1/4”...
Page 108 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 10 of 10 9/11/2007...
Page 109 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 11 of 11 9/11/2007...
Page 110 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REVISION LOG SHEET DATE INITIALS CHANGES MADE 1/10/02 MC/glj Newly created in word. 2/26/02 Added Wiring Schematic and Hydraulic Schematic to end of file. 4/5/02 Added Controller Functions section and updated troubleshooting section.
Page 111 Installation and Maintenance Bulletin HPTO10TD-100 May 7, 2003 Hydraulic Power Take-off Rotating equipment is potentially dangerous and should be properly guarded. The user should check all applicable safety codes and provide suitable guards. The HPTO™ Hydraulic Power Take-off is MOUNTING AND ORIENTATION a hydraulically actuated, enclosed dry The HPTO is manufactured to mount to clutch...
Page 112 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 4. Check that the oil return line from the 4. Install flywheel ring gear to engine clutch manifold will be isolated from any flywheel using the “Flywheel Mounting return line that pressurized. Bolts”.
Page 113 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 8. Once the HPTO housing is piloted and 17. Insure that there is a clean 15-micron flush with the engine housing, you can minimum oil filter in the hydraulic remove the crane support. system.
Page 114 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF SERVICE INSTRUCTIONS Remove all seals from piston, shaft The HPTO can be reconditioned in the field or sent back to PT Tech. Contact PT Tech and backplate (Items 10, 18 & 19). if any portions of these service instructions 10.
Page 115 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REBUILD INSTRUCTIONS 22. Remove two seals from endcover Refer to exploded view drawing (Items 16 & 12). HPTO10TD-100 sheet 2 of 2. 23. Clean area around manifold and Endcover Assembly 1. Apply Loctite 620 to steel cage of seals endcover.
Page 116 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 5. Lube shaft diameter and hook piston Shaft Assembly 1. Using bearing heater, heat I.D. of rings with Mobilfluid 424 or similar oil. bearing (Item 13) to 250 °F. Using protective gloves, slide bearing onto 6.
Page 117 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Endcover Sub-assembly Pack end of endcover with MOBILITH ATTENTION: Check for burrs or debris SHC 220 grease only. Pack to 20% in bore of endcover at oil inlet and capacity on outer diameter. outlet holes.
Page 118 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 10. Install housing (Item 1) into endcover Install die springs (Item 41) qty 3 into (Item 2). Install hex head bolts (Item end plate (Item 3). 32) qty 9 and torque to PT Tech specification.
Page 119 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF 15. Install backplate (Item 14) over shaft into piston cavity. ATTENTION: do not pinch o-ring in O.D. groove of fixed end plate and o-ring on shaft while installing. 16. Install piston (Item 9) into dowel pins of endplate (Item 3).
Page 120 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Page 10 of 10...
Page 121 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF Page 11 of 11...
Page 122 I & M BULLETIN HPTO8TD-100 HYDRAULIC POWER TAKE-OFF REVISION LOG SHEET DATE INITIALS CHANGES MADE 5/7/03 Newly created 9/4/03 Updated controller callouts to match that of controller decal. 11/25/03 Updated hydraulic schematic to callout ¾” hose for HPTO12 unit. 12/29/03 Removed controller documentation and created a separate controller I&M Bulletin.
Page 123 Installation and Maintenance Bulletin CMCCU-004 Basic Controller December 29, 2003 TABLE OF CONTENTS INSTALLATION INSTRUCTIONS ..................2 CONTROLLER FUNCTIONS....................4 Power LED Indicator ......................... 4 Engine Speed Detected LED Indicator ..................... 4 Clutch Engagement........................... 4 Clutch Disengagement........................5 FAULT – RPM TOO HIGH, while attempting to engage ..............5 FAULT –...
Page 124: Installation Instructions
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Electronic equipment is potentially dangerous and should be installed by a trained professional. To avoid any electrical malfunction, the user should disconnect the wiring harness from the controller when welding on the equipment. Failure to do so may result in loss of controller warranty.
Page 125 I & M BULLETIN CMCCU-004 BASIC CONTROLLER For 072 teeth, set the dials as follows: 6. Install the Microprocessor Controller in a location in the customer’s control panel that will provide visual accessibility. The customer’s control panel opening cutout, thru hole diameters and depth dimensions can be found on the controller mounting...
Page 126: Controller Functions
I & M BULLETIN CMCCU-004 BASIC CONTROLLER WARNING: The controller has been Power LED pre-programmed at PT Tech per the customer’s specifications. Failure to understand specified operating parameters and conditions prior to initial startup and operation may result in unexpected results and/or possible damage to vital HPTO components.
Page 127: Clutch Disengagement
I & M BULLETIN CMCCU-004 BASIC CONTROLLER During this time the “CLUTCH ENGAGED” aborted startup attempt). symbol will illuminate to indicate that the clutch is engaging. See sketch below. If the operator keeps the speed above 1100 re-attempts clutch Clutch Engaged Symbol engagement, then the “RPM TOO HIGH”...
Page 128: Fault - Oil Presssure Loss
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Once the lockout timer has expired, the light will turn off and the clutch can be TIMED LOCKOUT symbol engaged. ATTENTION: If engine ignition switched power is removed from the controller the lockout timer will continue to count down.
Page 129: Fault - Safety Switch
I & M BULLETIN CMCCU-004 BASIC CONTROLLER SAFETY SWITCH Symbol OIL PRESSURE symbol FAULT – SAFETY SWITCH The Equipment Safety Switch (customer supplied) must be a FAULT – COIL FAULT normally closed switch (opens when Attached to the hydraulic manifold safety hazard exists).
Page 130 I & M BULLETIN CMCCU-004 BASIC CONTROLLER cause the controller to function similarly to pushing the “Engage/Disengage Button” on the front of the controller. This remote switch must be a momentary switch only. The controller will draw the following amps when the remote button is pushed: @ 5volts the draw will be 10mA @ 12volts the draw will be 24mA...
Page 131: Operating Instructions
I & M BULLETIN CMCCU-004 BASIC CONTROLLER Once “CLUTCH ENGAGED” OPERATING INSTRUCTIONS symbol illuminates, the button can be Once all of the installation instructions have been completed and the functionality released. Note: The controller will of the controller has been understood, the begin the engagement of the clutch and perform a series of “bumps”...
Page 132: Troubleshooting Instructions
I & M BULLETIN CMCCU-004 BASIC CONTROLLER TROUBLESHOOTING INSTRUCTIONS Check that the 3-dials on the back The following items may be helpful in determining what caused the various of the controller are set correctly to symbols to illuminate on the controller match the tooth count of the flywheel ring gear.
Page 133: Clutch Will Not Engage
I & M BULLETIN CMCCU-004 BASIC CONTROLLER probe end to make certain it is not Check reservoir fluid level. damaged. Check oil filter. Replace speed pickup with a new Check cooler for a leak. one. Check pressure switch wires for a cut wire.
Page 134: Coil Fault
I & M BULLETIN CMCCU-004 BASIC CONTROLLER If a safety switch is present, insure TOO HIGH” symbol is illuminated when the that it is receiving power and in “Engage/Disengage Button” is pressed, good working order. then refer to the Troubleshooting section titled, “Engine Speed Detected”...
Page 135 I & M BULLETIN CMCCU-004 BASIC CONTROLLER Page 13 of 13...
Page 136 I & M BULLETIN CMCCU-004 BASIC CONTROLLER Page 14 of 14...
Page 137 I & M BULLETIN CMCCU-004 BASIC CONTROLLER REVISION LOG SHEET DATE INITIALS CHANGES MADE 12/29/03 Newly created in word. 3/7/04 Updated wiring harness schematic per ECN# 144. 3/12/04 Added coil ohm measurement to coil fault troubleshooting section. 4/26/04 Updated wiring harness schematic. 4/27/04 Updated controller images to black face style.

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