Alamo Schulte 2500 Giant Troubleshooting guide

2500 GIANT
REEL TYPE ROCK PICKER
Published 07/03 Effective S/N R10000328303 - R100000382308 Part No. R100-03-1
OPERATOR’S MANUAL
with PARTS LISTING
Schulte Industries Ltd.
P.O. Box 70
Englefeld Saskatchewan
Canada S0K 1N0
Tel. [phone]
Fax. [phone]
Parts Fax. [phone]
Email: [email protected] ©2003 Alamo Group Inc.
73747 130TH ST
ZEARING IA 50276
641-487-7608
[email protected]
WWW.NESSAINC.COM

To The Owner/Operator/Dealer
This manual hasbeen compiled to assistyou in operating and servicing your new SCHULTERock
Picker. READ and UNDERSTAND this manual BEFOREoperating theRock Picker. Pay special
attention to the safety instructions.
In addition to the design and configuration of equipment, hazard control and accident prevention
aredependent upon the awareness, concern, prudenceand proper training ofpersonnel involved
in the operation, transport, maintenance and storage of equipment.
WARRANTY INFORMATION:
Read and understand the complete Warranty Statement found at the back of this Manual. Fill out
the Warranty Validation Form in full and return it within thirty (30) days of the date of purchase.
Make certain the Serial Number andModelNumber is recordedon theallthree copiesof theform.
The use of non-genuine SCHULTE replacement parts could result in voiding of warranty.

Schulte 2500 Giant July, 2003 SCHULTE is a registered trademark of Alamo Group Inc.
DEALER'S PREDELIVERY SERVICE GUIDE ..................................... i
SAFETY SECTION ........................................................ 1-1
Decals ............................................................ 1-9
INTRODUCTION SECTION ................................................. 2-1
General Data ....................................................... 2-3
OPERATION SECTION .................................................... 3-1
Preparation for Operation ............................................. 3-2
Motor Valve Kit ..................................................... 3-3
Solenoid Open Center Valve Kit ........................................3-3
Field Operation ..................................................... 3-3
Transportation ...................................................... 3-5
Transport Light Kit ................................................... 3-6
Troubleshooting ..................................................... 3-7
MAINTENANCE SECTION .................................................. 4-1
Drive Chain ........................................................ 4-2
Nuts And Bolts ...................................................... 4-2
Hubs And Spindles ..................................................4-3
Tires ............................................................. 4-4
Batt Springs ........................................................ 4-5
Hydraulics ......................................................... 4-5
LUBRICATION ..................................................... 4-5
Grease Schedule .............................................. 4-5
Rock Picker Grease Points ...................................... 4-5
PARTS SECTION ......................................................... 5-1
Main Frame & Bucket ................................................ 5-2
Reel and Grate ..................................................... 5-4
Hub and Axle Assembly .............................................. 5-6
Hitch Jack, Side Wind 10" Crown (232-500) ............................... 5-8
Tow Clevis ......................................................... 5-9
Rock Deflector Kit (73-00) ............................................ 5-10
Hydraulic Circuit ................................................... 5-11
Hydraulic Drive Assembly ............................................ 5-12
Hydraulic Motor, Char Lynn, 14.9 in3(116-006) ............................ 5-14
Motor Valve Kit, Main Assembly (R100-200) .............................. 5-16
Hydraulic Cylinder, 3 x 36 TC Monarch (100-3271) ......................... 5-18
Transport Kits ..................................................... 5-19
Safety Chain (S000-010) ....................................... 5-19
Transport Light Kit (S000-035) ................................... 5-19
Parts Index ....................................................... 5-20
TABLE OF CONTENTS

iSchulte 2500 Giant July, 2003
DEALER'S PREDELIVERY SERVICE GUIDE
for SCHULTE ROCK PICKERS and ACCESSORIES
DETAILS OF ITEMS LISTED BELOW ARE COVERED IN THIS OPERATOR'S MANUAL
____ Shipping damage corrected
____ Set up machine as outlined in the Assembly Instructions and Operator’s Manual.
____ Check that all safety decals are in good condition, replace if necessary.
____ Lubricate all grease fittings.
DEALER'S DELIVERY GUIDE
for SCHULTE ROCK PICKERS and ACCESSORIES
____ Mounting and removal from tractor
____ Operation
____ Adjustments
____ Lubrication
____ Maintenance
____ Storage
____ Operator's safety precautions
____ User's responsibility and warranty
____ Operator's Manual delivered to owner
____ Operator instructed on contents of Operator’s Manual
PREDELIVERY SERVICE IS REQUIRED BY DEALER OR END USER

1-1Schulte 2500 Giant July, 2003
SAFETY
SECTION

1-2Schulte 2500 Giant July, 2003
CAUTION!
WARNING!
DANGER!
Asafe and careful operator is the best operator. Safety is of primary importance to the
manufacturerandshouldbetotheowner/operator. Mostaccidentscanbeavoidedbybeingaware
of your equipment, your surroundings, and observing certainprecautions. The first section of this
Manual includes a list of Safety Messages that, if followed, will help protect the operator and
bystandersfrominjuryordeath. ReadandunderstandtheseSafetyMessagesbeforeassembling,
operatingorservicingthisRockPicker. Thisequipmentshouldonly be operated by thosepersons
who have read the Manual, who are responsible and trained, and who know how to do so safely
and responsibly.
The Safety Alert Symbol combined with a Signal Word, as seen below, is used throughout this
Manual and on decals which are attached to the equipment. The Safety Alert Symbol means:
“ATTENTION! BECOMEALERT! YOURSAFETY IS INVOLVED!” TheSymbolandSignalWord
are intended to warn the owner/operator of impending hazards and the degree of possible injury
faced when operating this equipment.
The lowest level of Safety Message; warns of possible injury. Decals located on the
Equipment with this Signal Word are Black and Yellow.
Serious injury or possible death! Decals are Black and Orange.
Imminent death/critical injury. Decals are Red and White. (SG-1)
SAFETYSAFETYSAFETY
Practice all usual and customary safe working precautions and
above all---remember safety is up to YOU. Only YOU can
prevent serious injury or death from unsafe practices.

1-3Schulte 2500 Giant July, 2003
PELIGRO!
¡LEA EL
INSTRUCTIVO!
DANGER!
WARNING!
WARNING!
WARNING!
WARNING!
DANGER!
READ,UNDERSTAND,andFOLLOWthefollowingSafetyMessages.
Serious injury or death may occur unless care is taken to follow the
warnings and instructions stated in the Safety Messages. Always
use good common sense to avoid hazards. (SG-2)
Si no lee Ingles, pida ayuda a alguien que si lo lea para
que le traduzca las medidas de seguridad. (SG-3)
NeveroperatetheTractororImplement untilyouhaveread andcompletely
understand this Manual, the Tractor Operator's Manual, and each of the
Safety Messages found in the Manual or on the Tractor and Implement.
Learn how to stop the Tractor engine suddenly in an emergency. Never
allow inexperienced or untrained personnel too operate the Tractor and
Implementwithout supervision. Make sure the operator has fully read and
understood the Manuals prior to operation. (SG-4)
Always maintain the safety decals in good readable condition. If the decals are missing,
damaged, or unreadable, obtain and install replacement decals immediately. (SG-5)
Make certain that the "Slow Moving Vehicle" (SMV) sign is installed in such
away as to be clearly visible and legible. When transporting the Equipment
use the Tractor flashing warning lights and follow all local traffic regulations.
(SG-6)
roll-over-protectivesystem(ROPS).Alwayswearseatbelts.Seriousinjury
or even death could result from falling off the Tractor--particularly during
a turnover when the operator could be pinned under the ROPS. (SG-7)
Do not modify or alter this Implement. Do not permit anyone to modify or alter this Implement,
any of its components or any Implement function. (SG-8)
BEFORE leaving the Tractor seat,always engage the brake and/or set the
Tractor transmission in parking gear, disengage the PTO, stop the engine,
remove the key, and wait for all moving parts to stop.Place the Tractor shift
lever into a low range or parking gear to prevent the Tractor from rolling.
Never dismount a Tractor that is moving or while the engine is running.
Operate the Tractor controls from the Tractor seat only. (SG-9)
SAFETY

1-4Schulte 2500 Giant July, 2003
DANGER!
DANGER!
WARNING!
DANGER!
DANGER!
DANGER!
Never allow children or other persons to ride on the Tractor or Implement.
Falling off can result in serious injury or death. (SG-10)
Never allow children to operate or ride on the Tractor or Implement.
(SGM-11)
Donotmountthe Tractorwhile the Tractoris moving. MounttheTractor only
when the Tractor and all moving parts are completely stopped. (SG-12)
Start Tractor only when properly seated in the Tractorseat.Starting a Tractor
in gear can result in injury or death. Read the Tractor Operators Manual for
proper starting instructions. (SG-13)
Never work under the Implement, the framework, orany lifted component unless the Implement
is securely supported or blocked up to prevent sudden or inadvertent falling which could cause
serious injury or even death. (SG-14)
Do not operate this Equipment with hydraulic oil leaking. Oil is expensive
and its presence could present a hazard. Do not check for leaks with your
hand! Use a piece of heavy paper or cardboard. High-pressure oil streams
from breaks in the line could penetrate the skin and cause tissue damage
including gangrene. If oil does penetrate the skin, have the injury treated
immediately by a physician knowledgeable and skilled in this procedure.
(SG-15)
SAFETY

1-5Schulte 2500 Giant July, 2003
WARNING!
CAUTION!
WARNING!
Theoperator and all support personnel should wear hard hats, safety
shoes, safety glasses, and proper hearing protection at all timesfor
protectionfrom injury includinginjury fromitemsthrownbythe Equipment.
(SG-16)
PROLONGEDEXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT
HEARING LOSS! Tractors with or without an Implement attached can often
be noisy enough to cause permanent hearing loss. We recommend that you
always wear hearing protection if the noise in the Operator's position exceeds
80db. Noise over 85db over an extended period of time will cause severe
hearing loss. Noise over 90db adjacent to the Operator over an extended
period of time will cause permanent or total hearing loss. Note: Hearing loss
from loud noise [from Tractors, chainsaws, radios, and other such sources
closeto the ear] is cumulative over a lifetime without hopeof natural recovery.
(SG-I7)
Transport only at safe speeds. Serious accidents and injuries can result
from operating this Equipment at unsafe speeds. Understand the Tractor
and Implement and how it handles before transporting on streets and
highways. Make sure the Tractor steering and brakes are in good
condition and operate properly.
Before transporting the Tractor and Implement, determine the safe
transport speeds foryou and the Equipment. Make sure youabideby the
following rules:
1. Test the Tractor ata slow speed and increase the speed slowly. Apply
the Brakes smoothly to determine the stopping characteristics of the
Tractor and Implement.
Asyou increase the speed oftheTractorthe stoppingdistance increases.
Determinethemaximumsafetransportspeedforyouand thisEquipment.
2. Test the Equipment at a slow speed in turns. Increase the speed
through the turn only after you determine that it is safe to operate at a
higher speed. Use extreme care and reduce your speed when turning
sharply to prevent the Tractor and Implement from turning over.
Determine the maximum safe turning speed for you and this Equipment
before operating on roads or uneven ground.
3. Only transportthe Tractorand Implement at the speeds thatyou have
determined are safe and which allow you to properly control the
Equipment.
Be aware of the operating conditions. Do not operate the Tractor with
weak or faulty brakes. When operating down a hill or on wet or rain slick
roads,thebrakingdistanceincreases:use extremecare and reduce your
speed.When operatingintraffic always use the Tractor'sflashingwarning
lights and reduce your speed. Be aware of traffic around you and watch
out for the other guy. (SG-19)
SAFETY

1-6Schulte 2500 Giant July, 2003
WARNING!
WARNING!
WARNING!
DANGER!
DANGER!
DANGER!
SAFETY
Never attempt to lubricate, adjust, or remove material from the Implement while it is in motion
or while Tractor engine is running. Make sure the Tractor engine is off before working on the
Implement. (SG-20)
Periodically inspect all moving parts for wear and replace when necessary
with authorized service parts. Look for loose fasteners, worn or broken
parts, and leaky or loose fittings. Make sure all pins have washers with
cotter pins or roll pins. Serious injury may occur from not maintaining this
machine in good working order (SG-21)
Always read carefully and comply fully with the manufacturers instructions
when handling oil, solvents, cleansers, and any other chemical
agent.(SG-22)
Never run the Tractor engine in a closed building or without adequate ventilation. The exhaust
fumes can be hazardous to your health. (SG-23)
Never allow children to play on or around Tractor or Implement. Children can slip or fall off the
Equipment and be injured or killed. Children can cause the Implement to shift or fall crushing
themselves or others. (SG-25)
There are obvious and hidden potential hazards in the operation of this
Implement. REMEMBER! This machine isoften operated inareas with heavy
rocks and the teeth of this Implement can throw objects. Serious injury or
evendeath may occur unless care is taken to insure the safety of the operator,
bystanders,or passerby inthe area. Do not operate this machine with anyone
in the area. (SGR-1)

1-7Schulte 2500 Giant July, 2003
DANGER!
DANGER!
WARNING!
WARNING!
WARNING!
WARNING!
WARNING!
NEVER use drugs or alcohol immediately before or while operating the
Tractor and Implement. Drugs and alcohol will affect an operator's alertness
and coordination and therefore affect the operator's ability to operate the
Equipmentsafely. Before operating the Tractor or Implement, an operator on
prescription or over-the-counter medication must consult a medical
professional regarding any side effects of the medication that would hinder
their ability to operate the Equipment safely. NEVERknowingly allow anyone
to operate this Equipment when their alertness or coordination is impaired.
Serious injury or death to the operator or others could result if the operator is
under the influence of drugs or alcohol. (SG-27)
Operate the Tractor and/orImplementcontrols onlywhile properly seatedin theTractorseatwith
the seat belt securely fastened around you. Inadvertentmovement of the Tractor or Implement
may cause serious injury or death. (SG-29)
Operate at the speed that you can safely operate and control the Tractor and Implement. Safe
operating speed depends on terrain condition, rock density, rock size, and working depth.
Normal ground speed range is from 0 to 5 mph. Use slow speeds when operating on or near
steepslopes,drop-offs, overhead obstructions, powerlines, orwhen debris and foreign objects
are to be avoided. (SGR-3)
Keep hands, feet, hairand clothing away from moving parts. Contact
with moving parts can result in serious injury or even death. Stay
away until all motion has stopped. (SGR-5)
NeverleaveTractorandImplementunattended while theGrate is in theliftedposition.Accidental
operation of lifting lever or a hydraulic failure may cause sudden drop of Grate with injury or
death by crushing. To properly park the Implement when disconnecting itfrom the Tractor,raise
theGrate and putthe transportpinssecurely in place,or lower the Grate carefully to the ground.
Do not put hands or feet under lifted components. (SGR-6a)
Never stand between the Tractor and Implement when Tractor is being backed up to hitch, or
when the Implement is being prepared for transportation. (SGR-7)
Relieve hydraulic pressure prior to doing any maintenance or repair work
on the Implement.Place the Implement on the ground or securely blocked
up,disengage the PTO, and turn offthe Tractorengine. Push and pullthe
Remote Cylinder lever in and out several times prior to starting any
maintenance or repair work. (S3PT-9)
SAFETY

1-8Schulte 2500 Giant July, 2003
DANGER!
DANGER!
DANGER!
This Implement is wider than the Tractor. Be careful when operating or transporting this
Equipmentto preventthe Implementfromrunning into orstrikingsignposts,guardrails,concrete
abutments or other solid objects. Such an impact could cause the Implement and Tractor to
pivotviolently resulting in loss of steering control, serious injury, or even death. Never allow the
Implement to contact obstacles. (3PT-12)
Be particularly careful when transporting the Implement using the Tractor. Turn curves or go up
or down hills only at a low speed and at a gradual steering angle. Make certain thatat least 20%
of the Tractor's weight is on the front wheels to maintain safe steerage. Slow down on rough or
uneven surfaces. (STI-1)
Always keep a careful lookout and use extreme care when working around overhead
obstructions. Never allow the Bucket within 10 feet of any power line. When working close to
power lines consult your electric company for a safe code of operation. (SGR-8)
PARTS INFORMATION
Schulte Industries Ltd. RockPickers use matched system components forroller chain, drivetrain components
and bearings. These parts are made and tested to Schulte specifications. Non-genuine “will fit” parts do not
consistently meet these specifications. The use of “will fit” parts may reduce Rock Picker performance, void
Rock Picker warranties, and present a safety hazard. Use genuine Schulte Rock Picker parts for economy
and safety. (SPRM-1a)
SEE YOUR SCHULTE DEALER
In addition to the design and configuration of this Implement, including Safety Signs and Safety Equipment,
hazard control and accident prevention are dependent upon the awareness, concern,prudence, and proper
trainingofpersonnelinvolvedintheoperation,transport,maintenance,andstorageofthemachine.Refer also
toSafety Messagesand operationinstructionineachoftheappropriatesections oftheTractorandEquipment
Manuals. Pay close attention to the Safety Signs affixed to the Tractor and Equipment. (SG-18)
SAFETY

1-9Schulte 2500 Giant July, 2003
Decals
Ref. Part No. Description Qty.
1226-146 Decal "Warning Read Manual..." 1
2226-144 Decal "Danger Moving Part..." 2
3226-148 Decal "Warning High Pressure" 1
4226-150 Decal "Warning Jammed Batt..." 2
5226-151 Decal "Danger Thrown Rock..." 2
6226-153 Decal Red Reflector 2
7226-154 Decal Amber Reflector 3
8226-013 Decal SMV Emblem 1
9226-020 Decal "Important Remove Pins." 2
0226-084 Decal "Made In..." 1
11 226-100 Serial # plate 1
12 226-118 Decal "SCHULTE", 5 x 19-5/16 3
13 226-152 Decal "2500 Giant" 2
14 226-180 Decal “Grease interval, 4 hr” 10
15 226-181 Decal “Grease interval, 8 hr” 2
16 226-182 Decal “Grease interval, 50 hr” 3
17 226-183 Decal “Oil interval, 8 hr” 1
18 226-193 Decal “Danger Guard Missing” 1
19 226-191 Decal “Peligro...” 1
20 226-197 Decal “Operator’s Manual Inside 1
21 226-050 Decal “Fasten Lynch Pin...” 1
22 226-004 Decal “FEMA Member” 1
23 226-049 Decal “Use Genuine Schulte Parts...” 1
24 226-048 Decal “Do Not Transport” 1
SAFETY

1-10Schulte 2500 Giant July, 2003
Decal # 226-146
Location: Hitch pole
Decal # 226-148
Location: Hitch pole
Decal # 226-151
Location: Bucket, left and right side
Decal # 226-144
Location: Right grate panel and left frame
SAFETY

1-11Schulte 2500 Giant July, 2003
Decal # 226-150
Location: Right grate panel and left frame
Decal # 226-191
Location: Hitch pole
Decal # 226-193
Location: Inside chain case
SAFETY

1-12Schulte 2500 Giant July, 2003

2-1Schulte 2500 Giant July, 2003
INTRODUCTION
SECTION

2-2Schulte 2500 Giant July, 2003
The 2500 Giant Rock Picker is a reel type rock picking implement designed primarily for picking
surfacerock 2" [51mm]to 27"[686mm]in diameter. Withproper maintenance as described in this
manual, your Rock Picker will provide you with years of dependable service with a minimum of
repairs.
It is recommended that all operators of this implement read this manual or be instructed of its
contents as to safety, proper operation, and maintenance before beginning operation.
When ordering replacement parts for this rock picker, be sure to specify the serial number. The
serial number is located on the rear, left upright on the main frame.
The place warranty into effect, fill out the warranty validation form in full and return it within thirty
(30) days of the date of purchase.
For the purpose of this Schulte equipment, the following definitions apply.
Left-handside: Side which is to theleft when theoperator is facingin the normalforward direction
of the tractor.
Right-hand side: Side which is to the right when the operator is facing in the normal forward
direction of the tractor.
INTRODUCTION

2-3Schulte 2500 Giant July, 2003
General Data 2500 Giant
Weight (approx.) 4970 lbs. (2254 kg)
Overall length 205" (5.207 m)
Overall width 114" (2.896 m)
Height w/ rock deflector 81" (2.057 m)
Hopper capacity 2.5 cubic yards (1.94 m3)
Dumping height 49" (1.245 m)
Tire size 16.5L x 16.1SL
Power requirement 75 HP (56 kW)
Maximum ground speed 4 mph (6.4 km/h)
Hydraulic Drive Kit
Motor displacement 14.9 in3/ rev. (244 cm3/rev)
2000 psi (13.8 MPa) peak pressure
Final drive ratio 4:1 reduction
Drive sprockets 11T and 45T #80
Cross over relief valve set at 1750 psi (12.1 MPa) cracking pressure
Flow control, variable 0-15 gpm (0-57 l/min)
Options
R100-200 Motor valve kit
S000-035 Safety Light Kit
INTRODUCTION

2-4Schulte 2500 Giant July, 2003