Carlton 2400-4 User manual

Model 2400-4
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 S.C. 29303
Ph. [phone]
Fax [phone]
www.stumpcutters.biz

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.

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:
Kohler Engines . . . . . . . . . . . . 1-800-544-2444
Onan Engines . . . . . . . . . . . . . 1-800-343-7357
Kawasaki Engines . . . . . . . . . 1-877-529-7697
Wisconsin Engines . . . . . . . . . 1-800-932-2858
Deutz Engines . . . . . . . . . . . . . 1-800-241-9886
John Deere Engines . . . . . . . . 1-800-533-4463
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

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 unless prior
approval has been obtained from the manufacturer. 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.

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: JP Carlton Company Div. D.A.F. Inc.
121 John Dodd Road
Spartanburg, SC 29303
Phone: [phone]
Purchaser Information:
Company Name:_______________________ Street Address:_____________________________
City:_________________________ State:__________ Zip Code:__________________________
Telephone:_______________________Contact:________________________________________
Machine Information:
Model Number :_______________________ Engine Model :________________________
Serial Number :________________________ 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.
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

TABLE OF CONTENTS
INTRODUCTION
FOREWORD 1
GENERAL INFORMATION 2
MACHINE FEATURES 3
MACHINE SPECIFICATIONS 4
OPERATION
SAFETY PRECAUTIONS 5
DAILY CHECKLIST 9
MACHINE CONTROLS 10
TRANSPORTING 14
MACHINE OPERATION 16
MAINTENANCE
MACHINE MAINTENANCE 19
LUBRICATION CHART 24
TROUBLE SHOOTING GUIDE 25
SERVICING BELTS 27
SERVICING BEARINGS 35
SERVICING FRONT AXLE 44
SERVICING REAR AXLE 45
SERVICING BOOM PIVOT 47
SERVICING CUTTER WHEEL 48
SERVICING HYDRAULICS 51
PARTS
HYDRAULIC ASSEMBLY 55
FRONT AXLE ASSEMBLY 65
REAR AXLE ASSEMBLY 67
PIVOT ASSEMBLY 70
BOOM ASSEMBLY 72
CHIP GUARD ASSEMBLY 77

FOREWORD
1
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 2400-4 is designed and intended to be used in unique situations where size
and maneuverability are foremost. As a result, the Model 2400-4 has it's 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 2400-4 is a safe and profitable professional stump grinder. Read this
manual. Use proper safety precautions 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!

GENERAL INFORMATION
2
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 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.
Front
Left Right
Rear Front

MACHINE FEATURES
3
• Gas Power
• Direct drive hydraulic
pump
• 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
• Adjustable Timken
tapered roller bearings in
the pivot head with
hardened shafts
• Tapered roller bearings
on cutter wheel & jack
shaft
• 1” thick Blanchard
ground cutter wheel
• Low maintenance,
multiple drive belt
• 20 carbide tipped cutter
teeth
• Enclosed drive chain
• 35” width to clear narrow
fence gates
• 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
• Marine battery box
• Premium tires
• Heavy duty rubber and
metal chip guards
• Hour meter
• Large hydraulic tank
• Hydraulic and fuel filters
• Removable chip flap
• PolyChain® to cutter
wheel
• Easy engine belt
adjustment
We Pride Ourselves
in the strength and quality of each and every machine

MACHINE SPECIFICATIONS
4
Engine . . . . . . . . . . Onan 24 HP – 224 Performer
Weight . . . . . . . . . . 1550 lbs.
Length . . . . . . . . . . 103”
Height . . . . . . . . . . 46”
Width . . . . . . . . . . 35”
Cutting Depth
Below Ground . . . . . . . 12”
Cutting Height
Above Ground . . . . . . . 34”
Cutterhead Swing . . . . . . 39” arc
Number of Teeth
on Cutter Wheel . . . . . . .20
Cutter Wheel
Diameter W/Teeth . . . . . . 21”
Cutter Wheel
Thickness . . . . . . . . . 1” Blanchard Ground
Cutter Wheel RPM . . . . . .1350 RPM
Fuel Tank Capacity . . . . . .6.5 Gallons
Hydraulic Tank Capacity . . . .4.5 Gallons

SAFETY PRECAUTIONS
5
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 0700008
P/N 070000A
P/N 0700010 P/N 0700027

SAFETY PRECAUTIONS
6
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 and all safety decals on machine.
• DO NOT permit children to operate machinery
or to play near machinery during operation.
• 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 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 refuel gas tank while engine is hot,
running, or indoors. Danger of fire or explosion
exists.
• Gasoline and its vapors are highly flammable
and explosive. Handle with care. Only use
approved (red) gasoline containers for storage.
• Do not store equipment with gas in tank or
gasoline containers near any open flames or
sparks.
• 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.
• Remove battery before welding on equipment.
• Never allow spectators to stand and watch
machine in operation without proper hearing
and eye protection and standing at a safe
distance.
• 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.).
California
Proposition 65 Warning
Engine exhaust from this
p
roduct contains chemicals
known to the State of
California to cause cancer,
birth defects, or other
reproductive harm.

SAFETY PRECAUTIONS
7
• 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.
• Allow all machine parts to cool sufficiently
before servicing or making adjustments. Hot
machine parts can cause severe burns.
• Do not touch engine while running or hot
(serious burns may result).
• 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.
• 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.
• Always wear eye and ear protection.

SAFETY PRECAUTIONS
8
ATTENTION:
The Carlton®Model 2700-4 Stump Grinder CAN be overturned on steep inclines.
This can cause serious injury to operator and machine. DO NOT OVERTURN!
Avoid steep side inclines when operating this
machine! The narrow design width required in
operating the model 2700-4 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 and as possible while in transit will minimize
the danger of tipping over and maximize the
steadiness of the Model 2700-4.
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.
P/N 0700024

DAILY CHECKLIST
9
• 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).
• 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.
A sight glass is located on
the tank. Add oil if required.
In hot weather do not fill
window full, oil will expand
and spill out.
• Check condition of tires.
Inflate to proper pressure.
INCORRECT POSITION
CORRECT POSITION

MACHINE CONTROLS
10
ENGINE CONTROLS - Refer to engine manufacturers owners’ manual for controls, operation,
and service.
HYDRAULIC CONTROLS
A series of hydraulic controls are located on the
machine and clearly marked.
STEERING CONTROL (lever 1)
Push or pull control lever to control steering,
right or left.
TRACTION CONTROL (lever 2)
Push or pull control lever to control travel,
forward or reverse. Engine RPM determines
machine speed.

MACHINE CONTROLS
11
CUTTERHEAD may be moved in any
of three directions.
• LIFT (Lever 3)
(Up & Down)
• EXTENSION (Lever 4)
(Tongue In & Out)
• SWING (Lever 5)
(Left & Right)

MACHINE CONTROLS
12
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
With engine idling, slowly move lever towards
cutting 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.

MACHINE CONTROLS
13
TRAVEL SPEED ADJUSTMENT
Adjust travel speed for smooth operation.
Turn valve counter-clockwise to decrease
travel speed at high RPM.
FREE-WHEELING VALVE
Releases wheels from the drive system by
overriding the hydraulics. To engage, push
knob in and turn a quarter turn counter-clockwise.
Tongue extension can be accomplished by simply
setting the lever to free-wheeling position. Always
make sure that the ground stake is in the ground
before placing machine in free-wheel. To
disengage free-wheel, push knob in and turn
clockwise back to original position.
SWING SPEED ADJUSTMENT
Adjust swing speed for smooth operation.
Turn valve counter-clockwise to slow cutter
head swing at high RPM. Close valve by turning
clockwise to allow head to move side to side at low
RPM.
SWING SPEED
ADJUSTMENT
TRAVEL SPEED
ADJUSTMENT
FREE-WHEELING
VALVE

TRANSPORTING
14
DO NOT TOW! THE MODEL 2400 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 2400 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.
• LOADING RAMPS MUST BE STURDY AND ATTACHED TO
THE TRANSPORT VEHICLE BEFORE ATTEMPTING TO
LOAD\UNLOAD THIS MACHINE.
• Check trailer for security and
make sure chains and properly
installed.
• Check tire inflation.
• Check towing lights for proper
operation
• Never transport with motor
running.
• Towing will affect handling.
Allow for extra stopping
distances.
• Start and stop gradually.
• Tow at a safe reasonable
speed.