Carlton 900H User manual

Carlton
J.P.Carlton Company
Div. D.A.F. Inc.
121 John Dodd Road
Spartanburg, SC 29303
Ph. [phone]
Fax [phone]
www.stumpcutters.com
CONTROLS AND
MAINTANENCE FOR
TRACK CHIPPERS
TRACK OPERATIONS SUPPLEMENT

TRACK CHIPPER TABLE OF CONTENTS
GENERAL INFORMATION
FOREWORD 1
GENERAL SAFETY ALERTS 2
OPERATION
SAFETY PRECAUTIONS 8
DAILY CHECKLIST 13
MACHINE CONTROLS 14
TRANSPORTING GUIDE 19
MACHINE OPERATION 21
TRACK OPERATIONS & MAINTENANCE GUIDE .
MISCELLANEOUS
BOLT TORQUE REFERENCE CHART
CONTACT INFORMATION
BACK

TRACK CHIPPER FOREWORD
Congratulations on your purchase of a new Carlton®Professional Chipper! Carlton®has built
its reputation on the superior performance and reliability of their stump grinders and you can be
assured your new chipper has the same 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®track chipper functions and performs the same as a standard tow-behind machine
but with a different mode of transport. This machine is designed to access those difficult-to-reach
jobs and includes wireless remote control. From the ground up, the components and weldments
are the strongest on the market.
Read the machine owner’s manual and this track operations supplement 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®
track chipper is a durable and profitable professional chipper. Read the chipper manual, the
safety and operational decals on the chipper, and all other operation and safety materials
provided for the engine and other components. 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®Chipper.
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 chipper.
Please feel free to write to us with any comments. We’ll enjoy hearing from you!
1

ENGINE EXHAUST WARNING
WARNING
This product and the fuels used to operate this product
(Gasoline or Diesel), and the products of combustion of
such fuels, can expose you to chemicals including
benzene, which is known to the State of California to
cause cancer, birth defects, or other reproductive harm.
For more information go to www.p65Warnings.ca.gov
!
2

TRACK CHIPPER SAFETY ALERT
3

TRACK CHIPPER SAFETY ALERT
4

TRACK CHIPPER SAFETY ALERT
5

TRACK CHIPPER SAFETY ALERT
6

TRACK CHIPPER SAFETY ALERT
7

TRACK CHIPPER SAFETY PRECAUTIONS
Before operating the chipper, read the machine owner’s manual, this supplement, 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 the chipper. Inexperience may cause injury. It is the
owner’s responsibility to ensure all operators are trained and fully understand all safety
and operational aspects of the chipper.
This machine was built with safety in mind. The guards and other safety devices only work
when kept in place and secured properly. Safety decals are placed on the machine as
reminders of how to operate the machine safely, pay attention to the instructions.
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.
P/N 070000A
P/N 0700008
P/N 0700010
PERSONAL PROTECTION:
❖All personnel must wear eye and
ear protection, hard hat, short
fitted gloves without cuffs, long
sleeve shirt, long pants without
cuffs, and over the ankle work
boots with skid resistant soles
❖Do not wear loose-fitting clothing
❖Tie long hair back
❖Do not wear jewelry or long
dangling clothing; i.e. neckties,
long belts, or chains
❖Stay away from feed wheels
❖Keep away from moving parts
❖Only run in a well ventilated area
because of carbon monoxide
poisoning
8

TRACK CHIPPER SAFETY PRECAUTIONS
Be Safe and Practice Safe Operation using the following guidelines.
•No one should ever reach, lean, or kick
into the feed intake chute when the
chipper or the engine is running. Feed
wheels will pull in anything in the path
of operation and will cause severe
personal injury if a person is pulled
into feed intake wheels.
•Always load shorter pieces of wood or
brush on top of longer pieces or use
push paddle, never reach into the feed
intake chute to load these pieces.
•Stay clear of discharge zone when
running chipper. Never allow anyone
to stand near or to walk close to the
discharge zone, even if being
discharged into a bin or truck.
•Airborne debris may cause severe
injury. If inspection of chipped
material is required, shut down the
chipper and the engine first.
•Discharge spout should not be pointed
toward people, buildings, or other
personal property that may be injured
or damaged. Airborne debris is as
dangerous as any powerful projectile.
•Never position, adjust, or move the
discharge chute while the chipper or
the cutter drum are running
•Any individual operating this chipper
must first read and understand this
manual, the engine and other
component manuals supplied with the
chipper, and all safety and operational
decals on machine.
•DO NOT permit children to operate
machinery or to play near machinery
during operation.
•DO NOT allow spectators to stand and
watch chipper in operation.
•DO NOT allow people to pass by
discharge zone while chipper is in
operation.
•Keep hands, feet, legs, clothing, hair
and all other body parts away from
feed intake wheels, chipper knives, and
other moving parts.
•Do not hang from, ride, sit, stand, lay,
or climb anywhere on this chipper
while it is in operation, running, or
being transported.
•Do not move, position, or transport
this chipper with the engine running.
•Keep away from pressurized leaks.
Never check for leaks using hand or
finger, use cardboard or wood.
Pressurized fluid can penetrate the skin
and cause injury or even death. Seek
immediate medical attention if
penetration occurs. Always wear eye
protection.
•DO NOT operate any machinery while
under the influence of alcohol or drugs
(prescription, over the counter, or
otherwise).
•DO NOT modify or change any part
without written approval from J. P.
Carlton Company.
9

TRACK CHIPPER SAFETY PRECAUTIONS
•KEEP CUTTER DRUM DOOR
CLOSED WHILE CHIPPER IS
RUNNING. Always make sure the
cutter drum door latch pin is in place
and locked securely using a padlock
before starting chipper. The cutter
drum door must be locked using the
factory issued lock pin and padlock.
•Never open the cutter drum door while
engine is running. After the engine is
turned off, allow the cutter drum to
come to a complete stop before
opening the cutter drum door. This
will take several minutes
•Never run the chipper or the engine
with the cutter drum door open or
unlocked at any time or for any reason.
•If the cutter drum door or hinge is
damaged, replace immediately.
CUTTER DRUM
DOOR
•Always have at least 2 operators at the
job site running the chipper. One to
load the brush into the feed wheels and
the other to maintain the feed control
bar in case of an accident.
•Always feed trees and brush butt end
first and walking to the right side of
the chipper, material being fed should
be to the operator’s left side. The
material being fed tends to kick to the
left and could injure anyone on that
side.
•Never lean over material being loaded
into the feed wheels; especially small
diameter, short length material that is
still long enough to be fed into the feed
wheels alone. The material is not
heavy enough to hold down when the
feed wheels first grab it and will kick
up hitting the operator in the chin or
head causing injury.
•Operator must be tethered to safety switch
while machine is feeding.
•Never lay vine type material in front of feed
intake chute.
•Never allow yourself or your clothing to
become tangled in or tripped by vine type
material. SEVERE INJURY COULD
OCCUR.
•Always cut vine type material into shorter,
easier to handle pieces, approximately 4 to 5
feet.
•Don’t feed the vines into the chipper unless
they have been cut!!!
•STOP automatic feed system and run vine type
material through using manual start/stop
controls and a wooden push paddle.
•Always have the trees and brush cut to
size for the chipper before the chipper
arrives at the job site.
•It is very dangerous to run a chain saw
and the chipper at the same time.
•If a tree gets jammed and has to be
trimmed, shut down the chipper first.
10

TRACK CHIPPER SAFETY PRECAUTIONS
DO NOT PERFORM MAINTENANCE
OF ANY KIND ON THIS MACHINE
UNLESS:
The engine is turned off
The ignition key is removed
Positive battery cable is
disconnected
The clutch is disengaged
Feed control bar is in neutral
All machine parts have come to a
complete stop –NOTE: The cutter
drum takes several minutes to
come to a complete stop
All machine parts have had
sufficient time to cool down
The cutter drum lock pin is
installed in the drum lock tube
No operator is in position at the
controls to accidentally start
machine
At least 2 people are at the site
where maintenance is performed
More accidents occur while performing
maintenance than any other time! Use
extra caution.
Never perform maintenance with the
engine running, not even with the clutch
disengaged. The pilot bearing could seize
or freeze to the clutch shaft and permit the
clutch to engage even though the operator
thought the clutch had been disengaged.
ALWAYS REPLACE GUARDS AND
OTHER PROTECTIVE EQUIPMENT
BEFORE STARTING CHIPPER AFTER
PERFORMING MAINTENANCE.
•YOKE LOCK PIN MUST BE IN
POSITION before performing
maintenance between the feed wheels.
Use the hydraulic lift to raise upper
feed wheel high enough to insert yoke
lock pin as shown above.
•After the upper feed wheel has been
raised and the lock pin is in position,
place a block of wood 4” x 18” x 16”
between feed wheels to keep wheel
from coming down. See Maintenance
Section for further instruction.
•Stop engine, remove key, and
disconnect battery cable 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.
•Keep a well-stocked First Aid Kit with
the chipper at all times.
•Keep a full Fire Extinguisher with the
chipper at all times.
11

TRACK CHIPPER SAFETY PRECAUTIONS
•During operation of the chipper, all people
within a 100-foot radius should wear
protective equipment, including eye and
ear protection and hard hats.
•If unusual noise or vibration occurs, stop
engine immediately and correct the
problem before continuing operation,
consult authorized dealer if necessary.
•Keep all guards in place and properly
secured during operation. Never operate
the chipper with guards missing or loose.
•Keep all safety devices working properly
and all other machine parts in good
condition.
•Never leave the controls unattended while
in operation. Be sure machine is not
capable of operation when left unattended.
Remove key and disconnect battery, if
necessary.
•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.)
•Gasoline, diesel fuel and their vapors
are highly flammable and explosive.
Handle with care. Only use approved
fuel containers for storage.
•Do not store machine with fuel inside
tank or fuel containers near any open
flames, sparks, or other sources of
ignition.
•Do not store equipment with fuel in the
tank for long periods.
•Battery fumes are explosive. Recharge
battery in an open area away from fire,
sparks, or other sources of ignition.
•Use caution in extreme cold! Frozen
battery will explode! Allow battery to
thaw in heated area away from fire or
sparks.
•Battery acid can cause severe burns.
Keep away from eyes, skin, and
clothing.
•Remove battery before welding on
equipment.
•If operating chipper uncoupled from
tow vehicle, the tires and tongue must
be blocked. Use but do not depend on
jack stands to hold machine steady.
•Always store tools safely away from
moving machine parts, especially the
feed intake wheels.
•There should be no obstacles in the
path of operation behind the chipper or
around the chipper to allow trip free
movement of all personnel.
•Keep unauthorized persons away from
the chipper operation area.
•Do not operate chipper in dim lit, dark, or
concealed areas. Do not operate or run
machine or engine in enclosed area due to
carbon monoxide poisoning hazard.
•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 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.
•Remove all foreign objects from the chipper
before starting, i.e. jackets, gloves, tools, etc.
12

TRACK CHIPPER DAILY CHECKLIST
REFERENCE MACHINE OWNER’S MANUAL &
TRACK OPERATIONS GUIDE IN THIS SUPPLEMENT
13

TRACK CHIPPER MACHINE CONTROLS
HYDRAULIC CONTROLS
Your track machine has a series of hydraulic controls located on the machine control panel
and radio transmitter, which are clearly marked for use. To operate, push levers/toggle
switches in the direction of the command you want to perform. See illustrations and details
below.
•RIGHT TRACK (FWD/REV)
(Shown as R. TRACK-FORWARD /
REVERSE on Remote.) This switch
operates only the right track drive motor.
•LEFT TRACK (FWD/REV)
(Shown as L. TRACK-FORWARD /
REVERSE on Remote.) This switch
operates only the left track drive motor.
➢Use both controls in the same direction
(FWD/FWD or REV/REV) to move machine
forward or reverse. The radio transmitter also
has a single switch (BOTH TRACKS) that will
move both tracks at the same time in the forward
or reverse directions.
➢Use controls opposite (REV/FWD or FWD/REV)
of each other to turn machine either right or left.
When rotating the machine, try not to leave one
track stationary while rotating the other one
around as this could cause the machine to jump a
track. If it is desired to spin the machine,
counter-rotate the tracks.
•CHUTE ROTATION (LEFT/RIGHT)
(Shown as CHUTE-LEFT/RIGHT on
Remote.)
This switch operates the chute rotation
function, which swings the chute left or
right, 360 degrees.
14

TRACK CHIPPER MACHINE CONTROLS
HYDRAULIC CONTROLS (cont.)
•GEAR (HIGH/ LOW) (Same on Remote)
Gear control affects both the travel speed
and track motor torque. In high gear the
machine moves faster with less track motor
torque. In low gear the machine will travel
slower with more track motor torque. Use
low gear in situations where more climbing
power and track motor torque are needed.
(Note: to control the gear selection
functionality with the wireless remote, the
gear switch on the machine control panel
must be in the LOW position.
REMOTE CONTROLS
Note: we use multiple remote manufacturers.
* Refer to the remote manufacturer’s manual for specific controls, operation, and service.
•Emergency Stop Button (E-STOP)
On a HATOX remote: Twist E-stop to
activate remote.
On an OMNEX remote: Press button then
toggle any switch on the remote to activate
transmitter. Within 10 seconds, twist E-Stop
button clockwise and release to turn on the
transmitter for use. To turn off the
transmitter and immediately shut off the
engine, Press E-Stop button.
•Toggle Switches
Push toggle switches in the direction of the
command you want to perform. See
previous section under Hydraulic Controls
for details on function of each switch.
•Low Battery/Fault Light
Light will indicate when battery is low or if
a fault exists. (Refer to manufacturer manual
for troubleshooting)
•Active Light
Light will flash on power up and during
normal operation.
15

TRACK CHIPPER MACHINE CONTROLS
PROGRAMMING OMNEX WIRELESS REMOTE
If there is a problem with the receiver or the transmitter and either must 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. (Refer to the provided radio control manual for detailed programming instructions.)
•To access the receiver, open the cover to the
machine control box.
•Locate the radio receiver unit then remove
the circuit panel by unlatching the plastic
tabs on either side of the receiver housing.
The receiver panel will now slide out of the
cap. Note: you may need to unplug the
wiring harness before removing the circuit
panel. Be sure to plug harness back in before
attempting to program remote.
•Follow the instructions in the radio control
manual to download the ID Code.
•Push the receiver panel back up into the cap
until the tabs snap back into place.
•Replace control box lid and tighten bolts.
CAUTION
Do Not Run Machine Without All Guards and
Covers in Place and Secure.
Do Not Weld on the Machine Without First
Disconnecting the Battery and Wireless
Receiver Wire Harness.
CONTROL BOX COVER
16

TRACK CHIPPER MACHINE CONTROLS
PROGRAMMING HATOX WIRELESS REMOTE
To pair the handheld transmitter and the machine
receiver, follow the below steps.
•Stand within 3 feet of the machine receiver
with no obstruction between the two devices.
•Activate the transmitter into pairing mode by
holding the Chute Left/Right switch in the
LEFT position and the Right Track
Reverse/Forward switch in the Forward
position then twisting the E-STOP button
clockwise to turn remote on, then release. Both
indicator lights should be on.
•Turn the machine key switch to the on/run
position to activate the transmitter. This begins
the pairing process.
•Stay within the 3 feet range for a minimum of
10 seconds to allow pairing to complete.
•Pairing is successful once the remote
transmitter fault light goes out and the green
Active light is flashing.
CAUTION
Do Not Run Machine Without All Guards and
Covers in Place and Secure.
Do Not Weld on the Machine Without First
Disconnecting the Battery and Wireless Receiver
Wire Harness.
17