Operation, Parts and Service Manual

Transcription

1 Operation, Parts and Service Manual DIAMOND PRODUCTS PC6004EC Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher Rd Nampa ID, Phone Toll Free Fax

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3 Foreword: Operators and maintenance personnel must carefully read and understand this manual before using the machine or performing maintenance operations. Diamond Products cannot reasonably predict every circumstance that might involve a potential hazard during the operation or maintenance of the machine; for this reason, the safety messages included in this manual and applied into the machine may not include all possible safety precautions. DOCUMENT #: Page 3 of 110 LAST UPDATE: 3/26/18

4 Table of Contents Owner s Manual Warranty Section 1 Placing Parts Orders Section 2 Safety Section 3 Operator Orientation Section 4 Daily Equipment Inspection Section 5 Lubrication and Maintenance Section 6 Controls Overview Section 7 Basic Operation Instructions Section 8 Blade Shaft Speeds Section 9 Blade Shaft Removal & Installation Section 10 Hydraulic and Electrical Schematics Section 11 Reference Material Section 12 Machine Serial Numbers Section 13 Origional Instructions Please Note: The information provided is subject to change. Diamond Products has provided this information in good faith and is not liable for how this information is interpreted or applied. DOCUMENT #: Page 4 of 110 LAST UPDATE: 3/26/18

5 Section 1 Warranty DOCUMENT #: Page 5 of 110 LAST UPDATE: 3/26/18

6 DOCUMENT #: Page 6 of 110 LAST UPDATE: 3/26/18

7 DOCUMENT #: Page 7 of 110 LAST UPDATE: 3/26/18

8 Section 2 Placing Parts Orders DOCUMENT #: Page 8 of 110 LAST UPDATE: 3/26/18

9 PLACING PARTS ORDERS FOR: Diamond Products Grinding & Grooving Equipment CALL: Our Customer Service Representative Will Need: Company Name and Ship to Address Your Purchase Order and/or name Your Diamond Products Customer Number Any Special Instructions i.e Next Day Air, 2 nd Day etc. Return for Repair: Items returned for repair should be carefully packaged and accompanied by a Packing Slip with the following information: (RGA) number obtained from our Customer Service Representative. Your Company Name, address, phone and address, list of items for repair, RGA#, Explanation of repair(s) needed, Original Invoice (Warranty Only) DOCUMENT #: Page 9 of 110 LAST UPDATE: 3/26/18

10 Replacement/Refund: All items returned to stock are subject to a 15% restocking fee. Special Order items, i.e: parts for out of production equipment and any item beyond two (2) years from original invoice date are subject to a mandatory 50% restocking fee. Discontinued items and/or items purchased four (4) years from original invoice date cannot be returned. Items returned for replacement or refund should be in the original cartons and must be accompanied by a packing slip with the following information: Return goods authorization number (RGA) obtained from our Customer Service Representative. List of items returned Reason(s) for return(s) Copy of original invoice(s) Please ship items to: Diamond Products,LTD Heavy & Specialty Equipment Operations 2016 E. Karcher Rd. Nampa, Idaho /7/17 jka DOCUMENT #: Page 10 of 110 LAST UPDATE: 3/26/18

11 Section 3 Safety DOCUMENT #: Page 11 of 110 LAST UPDATE: 3/26/18

12 Safety Precautions Operate the equipment and all of its components according to this manual. Failure to comply with and understand the following safety, operations, and maintenance instructions can result in serious injuries and/or death. All operators must be properly trained or supervised prior to using this equipment and should understand the risks and hazards involved. Improper or unintended equipment usage is discouraged and Diamond Products cannot be held liable for any resulting damages. Equipment modifications should be made by Diamond Products to ensure proper safety and accuracy. Modifications made to this equipment by the owner are not the responsibility of Diamond Products and void all equipment warranties if a problem arises as a result of the modification. Refer to the Diamond Products Parts Lists for additional information and part diagrams. Prior to operating the equipment, record the serial number, and the engine s model and serial numbers in the Serial Tags section in the Index for future reference. The information in this manual may be updated at any time! Safety Alerts DANGER Serious injuries and/or death will occur if these instructions are not followed. WARNING Serious injuries and/or death could occur if these instructions are not followed. Proposition 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and/or other reproductive harm. Spark Arrester Requirement WARNING In the State of California it is a violation of Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective, working order or the engine is constructed, equipped, and maintained for the prevention of fire pursuant to Section 4443 Respiratory Hazards WARNING Concrete cutting produces dusts and fumes known to cause illness, death, cancer, respiratory disease, birth defects, and/or other reproductive harm. Safety protection techniques include, but are not limited to: Wearing gloves. Wearing safety goggles or a face shield. Using approved respirators. Washing work clothes daily. Using water when wet cutting to minimize dust. Washing the hands and face prior to eating/drinking. For additional safety and self-protection information contact your employer, the Occupational Safety and Health Administration (OSHA), and/or The National Institute for Occupational Safety and Health (NIOSH). CAUTION Mild and/or moderate injuries could occur if these instructions are not followed. DOCUMENT #: Page 12 of 110 LAST UPDATE: 3/26/18

13 General Safety Read and understand all of the safety, operations, and maintenance instructions provided in this manual prior to operating or servicing the equipment. Keep equipment components clean and free of slurry, concrete dust, and debris. Inspect water hoses prior to operating the equipment. Clean, repair, or replace damaged components. Raise the equipment to a proper height for access when working underneath the equipment. Use frame pin ups and chocks to block the wheels, and fit blocks or jacks under the frame edges at the front and back of the frame for additional support. When using a jack to raise the equipment, place the jack against a solid, flat area under the frame to properly support the equipment while lifting. Repair the equipment immediately when a problem arises. Replace equipment decals if unreadable. Dispose of all hazardous waste materials according to city, state, and federal regulations. Always have a phone nearby, and locate the nearest fire extinguisher and first aid kit prior to operating the equipment. Operate the equipment wearing flame resistant clothing. Always wear safety glasses when removing retaining rings. Persons under the statutory age limit should not operate the equipment. Keep all body parts away from rotating machinery. Replace all guards and access panels (unless stated otherwise) prior to operating the equipment. When servicing equipment always remove guards fully to avoid serious injuries. DO NOT assume the equipment will remain stopped when in Neutral or when parking/stopping the equipment on a slope. Chock the tires to help prevent unnecessary movement. All non-routine maintenance tasks should be performed by a factory authorized service technician or at the factory. Always shut off engine, lower the equipment and engage parking brake when equipment is parked. DO NOT: Drop parts, supplies, tools, etc., when handling to help prevent injuries. Operate the equipment around combustible materials or fumes to prevent fires/explosions. Lift and carry equipment, supplies, tools, etc., that are too heavy and/or cannot be lifted easily. Operate the equipment without using the appropriate safety equipment required for the work task. Operate or service the equipment with clothing, hair, or accessories that can snag in the machinery, which could lead to serious injuries or death! Operate the equipment with anyone near the work area. Operate the equipment until unnecessary materials have been removed from the work area. Operate the equipment using attachments not associated with or recommended for the equipment. Operate the equipment around combustible materials or fumes to prevent fires/explosions. Operate the equipment with anyone near the work area or within the direct line of the blade. Operate the equipment until all unnecessary materials have been removed from the work area. Operate the equipment with loose nuts, screws, and bolts. Operate the equipment when ill or fatigued. Operate the equipment under the influence of drugs and/or alcohol. Operate the equipment on steep slopes. Operate the equipment with guards and access panels removed. DOCUMENT #: Page 13 of 110 LAST UPDATE: 3/26/18

14 Grease the equipment with the engine running (unless stated otherwise). Touch hot components when operating the equipment. Leave the equipment unattended until the engine is off and the blade has stopped spinning. Place the equipment into storage until it has cooled down. Service the equipment until it has cooled down. Service the equipment with the engine running (unless stated otherwise). Perform maintenance, repair or install components on machine until the machine and engine are stopped and secured Battery and Electrical Safety Ignitable explosive gases are emitted from the battery. DO NOT expose the battery to sparks or open flames. Keep the area around the battery wellventilated. Keep the battery level when handling it. Use protective eyewear or a face shield, and avoid contact with the skin when handling/servicing the battery. Use a proper battery tester when testing the battery strength. Always be sure to connect the battery cables to the proper terminal when reconnecting the cables. Regularly inspect the battery, cables, clamps, and terminals for damages. Clean, replace, tighten and grease components as necessary. Always keep the battery cable clamps away from the battery terminals when the battery is disconnected to avoid accidental connections while servicing. Immediately rinse your clothing, skin, or eyes with water if exposed to battery acid. Seek medical attention immediately! Disconnect the battery prior to servicing all equipment components (unless stated otherwise). Remove the battery when storing the equipment for longer periods. Always use the correct size fuses (amps) to prevent fires. Blade Safety Never use a wet cutting blade without an adequate water supply to properly cool and lubricate the blade. Inspect all blades prior to usage and discard damaged blades. Clean dirty blades as necessary. DO NOT install or remove grinding head with the engine/motor running. Unless stated otherwise. Keep all body parts away from rotating blades. Inspect the blade flanges for damage, wear, and cleanliness. Clean or replace dirty/damaged components immediately. DO NOT expose yourself or anyone else to the direct line of the cutting head when operating the equipment. Always use an appropriate size blade and the correct blade type based on the cutting task and the type of material being cut. The blades must always fit snug on the blade shaft and/or outer flange. Wear gloves and be alert to the surrounding environment when handling blades. When installing the blade, always point the arrow printed on the blade in the direction of the blade shaft s rotation. DO NOT exceed the blade s maximum recommended speed when cutting. Excessive blade speeds can cause blade breakage, resulting in serious injuries and/or death! DO NOT use damaged blades when cutting to avoid harming yourself, others, or the equipment. DO NOT use a blade for cutting that requires a lower speed than the blade shaft speed. Tighten the blade shaft bolts/nuts as directed to properly secure the outer flange and blades. Failure to properly secure the outer flange and blade may cause parts to loosen or fall off. Always install the correct blade shaft sheave, blade drive belts, and flanges when changing the blade size. Changing the blade shaft sheave requires assistance from technical support. Contact technical support prior to running the equipment DOCUMENT #: Page 14 of 110 LAST UPDATE: 3/26/18

15 .Refer to the RPM Chart posted on the equipment or in the Parts List for additional information. Blade Shroud Safety DO NOT operate the equipment with the blade shroud raised or removed. When pivoting the front of the blade shroud, raise/lower it cautiously and slowly to avoid serious injuries. Always pivot the front of the blade shroud (fully upward) so the guard does not swing down unexpectedly, causing serious injury. Loosen bolts to pivot up tighten bolts to hold in place. DO NOT install or remove the blade shroud with the engine running. Always use a blade guard that corresponds with the blade size. Inspect the blade shroud, vacuum skirting and water spray nozzles prior to starting the equipment. Clean or replace dirty/damaged components immediately. When lowering the front part of the blade shroud, pivot it cautiously and slowly to avoid serious injuries. Fuel Safety Always use caution when refueling. Store all fuel in appropriate safety containers. DO NOT operate the equipment with a fuel leak. DO NOT fuel the equipment with the engine running. Let the engine cool prior to adding fuel. Refer to the engine manual for recommended fuels. Always use appropriate fuels in cold weather. Move the equipment away from the refueling area prior to starting the engine. DO NOT smoke or expose fuel to open flames when filling the fuel tank or working with fuel. Clean up any spilled fuel prior to starting the engine. Drain the fuel tank and fuel lines when storing the equipment for longer periods of time. Refer to the engine manual for additional recommendations. Fuel may seep out from the fuel cap vent (applicable models) when raising the equipment if the fuel tank has been overfilled. Engine Safety Refer to the engine manual as the primary source for engine safety. Refer to the engine manual for recommended oil. Know how to turn off the engine quickly for emergency purposes. Make sure the speed control lever is at Neutral when starting the engine. Fill the fuel tank and check the oil level prior to starting the engine. Keep all body parts away from rotating parts with the engine running. DO NOT start the engine without the air filter(s) installed. DO NOT allow dust to enter the air intake tube when cleaning/replacing air filter(s). Immediately replace damaged equipment components that may allow dust to enter the engine. DO NOT leave the engine/motor running unattended. Always operate the equipment in well-ventilated areas. Concentrated engine exhaust can cause loss of consciousness and/or death. DO NOT operate the equipment around combustible materials or fumes to prevent fires/explosions. DO NOT leave the equipment unattended until the engine is off and the blade has stopped spinning. DO NOT touch the engine/muffler assembly with the engine running, and always let them cool down prior to touching or servicing the equipment. Handle hot oil carefully when changing the oil. Wipe down the engine/motor exterior and guards daily or regularly to prevent high operating temperatures. DOCUMENT #: Page 15 of 110 LAST UPDATE: 3/26/18

16 DO NOT spray the engine/motor with water to prevent engine/motor damage. Let the engine cool prior to removing pressurized caps. Clean the engine cooling system regularly to prevent high operating temperatures. DO NOT use any starter substances or starter fluids (e.g., starter fluid sprayed into the air filter) when starting the engine using a glow plug (applicable models). These materials are extremely flammable and explosive, and can melt parts or possibly explode when used to help start the engine. Cutting Safety The direct work area should not contain buried or embedded electrical, gas, or water lines that could be damaged and/or cause personal injury while cutting. Turn off all electricity, gas, and water around the direct work area prior to cutting. DO NOT expose yourself or anyone else to the direct line of the blade when operating the equipment. DO NOT allow any person, animal, and/or object in and around the work area while cutting. DO NOT assume the equipment will remain stopped while in Neutral when stopping and/or parking the equipment on a slope. Chock the wheels to prevent unnecessary movement. Hydraulic Safety Turn off the engine prior to servicing and/or disconnecting hydraulic components. Lower the equipment completely to relieve some hydraulic fluid pressure prior to servicing the equipment. Always place a piece of cardboard or paper up against hydraulic components, or use a leak detection fluid to check for hydraulic fluid leaks. Keep all body parts away from leaks and/or areas that may eject hydraulic fluid. Pressurized hydraulic fluid can penetrate the skin, causing serious injuries. Seek medical attention immediately. Belt Safety Turn off the engine and let the belts cool down prior to servicing them. Regularly inspect the belts for fraying, stress cracks, and/or breakage and replace immediately when damaged. Always check belt alignment prior to operating the equipment. Over-tensioning the belts may damage the power take-off (PTO). Under-tensioning the belts may cause slippage, shorter belt life, and/or poor equipment performance. Squealing belts indicate looseness. DO NOT use old and new belts together. Transporting Safety Make sure the truck/trailer is in good, working condition and sufficient to transport the load. DO NOT tow the equipment behind a vehicle. See specifications page for equipment weight and dimensions for planning purposes prior to transporting. Close the fuel shutoff valve when transporting. Drain the fuel tank when transporting long distances. Use ramps of the proper load rating that will support the weight of the equipment when loading or unloading. Raise the equipment only to avoid damaging components while moving up and down ramps. Use extreme caution when guiding the equipment up and down ramps. Slowly drive the equipment forward up the ramp. Slowly back the equipment down the ramp. Avoid standing directly behind the equipment to avoid serious injuries. Lower the equipment when loaded. Failure to lower the equipment before securing for transport may result in damage to the equipment. Set brake and secure equipment with chain and binders of proper load capacity prior to transport. Turn off the engine once the equipment is loaded into the truck/trailer. Place the speed control lever at Neutral. DOCUMENT #: Page 16 of 110 LAST UPDATE: 3/26/18

17 Make sure ramp and deck surfaces are clear and there are no traces of grease, oil, or ice before loading. Load equipment on flat ground only. Refer to the Department of Transportation (DOT) for additional information on proper transportation techniques and truck/trailer requirements. Lifting Safety Move yourself and all others away from the lifting area when hoisting the equipment to prevent being crushed. Secure the appropriate hoisting cables, straps, and/or chains to the equipment s designated lift points prior to hoisting. DO NOT attempt to lift the equipment irresponsibly and/or improperly. See Specification page for equipment weight prior to lifting. Secure the appropriately rated hoisting cables, straps and/or chains to the equipments designated lift points prior to lifting. DOCUMENT #: Page 17 of 110 LAST UPDATE: 3/26/18

18 DOCUMENT #: Page 18 of 110 LAST UPDATE: 3/26/18

19 Section 4 Operator Orientation DOCUMENT #: Page 19 of 110 LAST UPDATE: 3/26/18

20 Grinder/Groover Operator Orientation Operator orientation is required for every start up whether the operator is new or experienced. For SAFETY reasons equipment orientation should be conducted in a location such as a shop or yard. Equipment operational training is conducted at work sight. At any point in this process YOU are uncomfortable or DO NOT understand the instructions, STOP and ask for clarification or demonstration of a process or procedure. Prior to running equipment: 1. Review Manual with all personnel that are involved with the operation and maintenance of the equipment. Review items include but not limited to all Safety instructions, Warnings, Daily equipment inspection, Equipment Warranty, Maintenance and operator interface screens ( PLUS One and engine). The PC 1500 DOES NOT have a Plus One screen. 2. Perform walk around inspection (also see Daily Equipment Inspection List in Manual) with operator to assure equipment is in good working order and all guards are in place. 3. During walk around instruct operator as to locations and functions of, including but not limited to: fuel shut off, master switch, hydraulic pumps and systems, vacuum system, hose connections, clutch engagement lever, fluid level check, safety pin up NOTE: safety pin ups are to be used when replacing cutting head and when any repair work is to be done under the equipment. Equipment models PC1500, PC4500 and PC4504 are not to be driven, loaded on or unloaded from trailer with the equipment (PC1500) or engine frame (PC4500, PC4504, PC6000) PINNED UP. Equipment may tip due to high center of gravity. 4. CAUTION: The Loading or unloading of all equipment models must be done on a level pavement surface. The PC1500, PC4500, PC4504 are transported on trailers. When loading or unloading trailer deck must be clean, dry and level. The PC6000 is transported by connecting via fifth wheel to a semi tractor. Operator must be familiar with hooking up air and electrical connections, fifth wheel, PC6000 landing leg and front bogey slide operation. CAUTION: All models due to their weight should not be driven or parked on dirt, gravel or thin asphalt. Equipment will sink into any SOFT surface become stuck and may tip. 5. Operator station instruction: review control panels, (engine(s) and PLUS ONE), functions of switches, screens, joystick function, E Stop etc. NOTE: PC1500 has one operator station located on the right side of the equipment. PC4500, PC4504, PC6000 can be operated from either the right or left side of the equipment. WARNING: Never operate the equipment with the operator adjacent to LIVE TRAFFIC. DOCUMENT #: Page 20 of 110 LAST UPDATE: 3/26/18

21 Prior to Start up Instruction: 1. Appropriate safety gear including but not limited to: Hearing protection, Safety glasses, Hard hat and Safety Vest are required. Check with Equipment Owner if there are specific requirements. 2. Adjust operator seat and panel to comfortable location. WARNING: Never operate the equipment with the operator adjacent to live traffic. 3. Verify: clutch lever (PC1500) is disengaged, clutch ON/OFF switch (PC4500, PC4504, PC6000) is in OFF position, brake switch (all models) is in ON position, E STOP is in OUT position, NOTE: engine will not start if brake switch is off or E STOP is pushed IN, joystick is in neutral locked position, two speed switch is in LOW and water on/off valve in off position. Battery master switch is ON. 4. Check all other operator panel switches. Verify that they are in OFF or NEUTRAL position. Engine Starting instruction: 1. Refer to Manual for engine panel legend. 2. A single diesel engine powers the grinding head and all systems on the PC 1500, 4500 and Two diesel engines are used on the PC6000. A small diesel engine is used to power all systems and a large diesel engine is used to power the grinding head. 3. Starting PC1500, 4500, Operator MUST be in seat. NOTE: refer to engine manual for specific starting instructions. Turn key to ON position. Panels will light and will take a moment to cycle, when cycle complete start engine. Once started check engine screen for, oil pressure, temp etc. Allow engine to warm up at low idle. Once warm do E STOP test. If OK restart engine and increase RPM to NOTE: if E STOP does not shut down engine, shut engine OFF with key, trouble shoot and repair the E STOP system prior to operation. DO NOT proceed with operations if E STOP is not functioning properly. 4. Starting PC6000, the front engine is started first. The engine panel is located on the engine at the front of the equipment. NOTE: refer to engine manual for specific starting instructions. Turn key to ON, panel will light and take a moment to cycle. When cycle complete start engine and allow engine to warm up. Once warm do E STOP test. If OK restart engine, SEE NOTE ABOVE IF E STOP is not functioning properly, and increase engine RPM to Return to operator seat and start main engine. Follow same starting procedure as above for front engine including E Stop test. DOCUMENT #: Page 21 of 110 LAST UPDATE: 3/26/18

22 Systems Check: 1. Equipment/engine frame safety pins removed and engine running. 2. CAUTION: Safety Pins are used to safely hold the equipment in the fully raised position. The Pins are to be used when changing the cutting head or when performing equipment maintenance only. Never work under the equipment without the pins installed. Always set brake and chock wheels to prevent equipment from moving. Never travel the equipment in the fully raised position or in the fully raised position with safety pins installed. Keep equipment low when travelling. When fully raised equipment has high center of gravity which when traveling may cause the machine to tip. 3. Operator MUST be in seat when running system checks. 4. IF any failure occurs during systems check STOP. Locate and repair prior to operation. 5. Work area must be free of debris and persons. Be aware that due to the size and shape of the equipment line of sight/area of vision may be obscured. NOTE: PC4500, 4504 and PC6000 are equipped with the PLUS ONE cruise control system. All maneuvering of the equipment is done in the MANUAL setting of the PLUS ONE system. 6. Raise or lower equipment (PC1500) or engine frame (PC4500, PC4504) until vacuum skirt touches pavement. 7. To check equipment brake, (PC1500, 4500, 4504) move joystick slowly forward and reverse. Equipment should not move. 8. To check equipment brake (PC6000) Raise or lower engine and traction frame. When vacuum skirt touches pavement STOP, then continue to lower TRACTION FRAME until drive tires are in contact with pavement. 9. Water alarm will activate when lowering when no water present. 10. Check forward/neutral/reverse control: Two speed switch in LOW, Release brake and slowly move joystick forward and reverse. Equipment will move forward/reverse and slow to stop when brought back to neutral from either forward or reverse. BACK UP alarm MUST sound when in reverse. Joystick must lock in neutral. Check two speed by moving switch to high while equipment is moving. Equipment speed will increase when switch is activated to HIGH. NOTE: All grinding operations are done in LOW speed setting. High setting is used for travel only. Check steering function while equipment is moving. Be aware that the equipment has large turning radius and area of vision may be obscured. Check the area around the equipment prior to moving the equipment. 11. Stop, set brake and reduce engine RPM to LOW idle. 12. Vacuum System check PC 1500: Blower on PC1500 is driven by belts from the gearbox that drives the grinding head. Operator will have to get out of seat and engage clutch to run blower. Disengage clutch after test. 13. Vacuum System check PC4500, PC4504, PC6000: Blower is hydraulically driven on these models. Operator to stay in seat. Switch blower switch to ON. Blower may take several seconds to start. 14. Slurry Pump check: Switch slurry pump switch to ON. On PC6000 the blower and slurry DOCUMENT #: Page 22 of 110 LAST UPDATE: 3/26/18

23 pump must both be on for system to operate. 15. Check work lights, safety beacons and flashers. 16. Check equipment/engine frame/traction frame raise/lower and hold down pressure functions (PC4500, PC4504, PC6000) and adjustments. Discuss/demonstrate adjustment and purpose. 17. Check profile wheel raise/lower function and purpose. Discuss/demonstrate setting the grinding head to ZERO and matching adjacent passes. 18. Check clutch engagement function. 19. PC1500 and PC 6000: Check front bogey slide operation and discuss purpose of same. 20. PC6000: Check load leg operation and discuss use and purpose. 21. With brakes set, clutch disengaged check engine throttle adjustment function. Run engine(s) up to full RPM and back to low idle. 22. When checks completed, Adjust Engine(s) RPM to LOW idle. Allow engine(s) to cool down then shut down engine. Review all the steps prior to proceeding to grinding. After completing the above orientation and prior to starting grinding or grooving operations, the equipment Operator must have an understanding of and be comfortable with the operation and functions of the equipment. Operator should show proficiency in: working safely, maneuvering the equipment, equipment controls and their functions and daily equipment inspection. Everyone present during the operator orientation must sign and date next page. DOCUMENT #: Page 23 of 110 LAST UPDATE: 3/26/18

24 Grinder/Groover Operator Orientation: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Signature: Print Name: Date: Diamond Products Representative: Diamond Products Representative: Diamond Products Representative: Diamond Products Representative: Print Name: Date: Print Name: Date: Print Name: Date: Print Name: Date: DOCUMENT #: Page 24 of 110 LAST UPDATE: 3/26/18

25 Section 5 Daily Equipment Inspection DOCUMENT #: Page 25 of 110 LAST UPDATE: 3/26/18

26 Daily Equipment Inspection Prior to start of work the Operator should inspect the equipment for the following: 1. Any leaks of, engine oil, engine coolant, hydraulic oil, fuel and gear oil. Repair prior to operation. 2. Any loose or missing nuts and bolts. Repair/replace as necessary. 3. That all guards are in place and not damaged. Repair or replace. Do not operate machine unless all guards are in place. 4. All instructional or safety decals are in place and legible. Replace if necessary. 5. Check engine coolant, engine oil, hydraulic oil and gear oil levels. Add if necessary. 6. Drain fuel/water separator. 7. Check air cleaner indicator. Replace air cleaner element if necessary. 8. Inspect head drive, hydraulic pump drive, blower drive, and Alternator belts for fraying or cracking. Replace if necessary. 9. Clean water filter screen. Before Starting: 1. Clutch must be disengaged. 2. Joystick in locked Neutral position 3. Brake switch ON 4. All other switches OFF or NEUTRAL position. 5. Start Engine, leave at low idle. 6. Test E STOP. When pushed in engine will shut off. PULL E STOP out to restart. If engine does not shut down when E STOP pushed turn off key to shut down engine. Find/fix cause. DO NOT OPERATE EQUIPMENT IF E STOP IS NOT FUNCTIONING. DOCUMENT #: Page 26 of 110 LAST UPDATE: 3/26/18

27 7. Check brake function, equipment should not move forward or reverse. If movement occurs SHUT DOWN and find/fix cause. 8. Prior to starting operation make sure work area is clear of obstructions and other personnel. Daily post operation shut down and maintenance: 1. Flush vacuum system. 2. With equipment stopped and joystick in neutral locked position, turn brake switch to ON position. Leave engine at high idle, clutch engaged and slurry discharge pump ON. 3. Raise equipment until grinding head no longer contacts pavement, yet the vacuum shroud skirting remains in contact with pavement. Turn water valve to full on position. Run system until clear water is discharged from slurry the slurry discharge hose. 4. Return engine to low idle and allow engine to cool. 5. Grease blade shaft bearings. Follow lubrication instructions in manual. 6. Turn slurry pump switch to OFF position. 7. Disengage clutch. 8. Disconnect water and slurry discharge hoses. 9. Remove front pointer and stow. 10. Remove Demister and lobster pot filter and wash. Flush demister and lobster pot housing; reinstall demister and lobster pot filter. 11.Engage clutch to run vacuum blower to dry out filters, housings and blower. Note: If equipment is going to be idle for a period of time blower must be oiled to prevent blower lockup. 11. Disengage clutch. 12. Load equipment. DOCUMENT #: Page 27 of 110 LAST UPDATE: 3/26/18

28 Other equipment service areas: 1. Clean/wire brush, water spray nozzles. Plugged nozzles will cause blade failure. 2. Clean water filter. 3. Drain water system and filter. DOCUMENT #: Page 28 of 110 LAST UPDATE: 3/26/18

29 Section 6 Lubrication and Maintenance DOCUMENT #: Page 29 of 110 LAST UPDATE: 3/26/18

30 PC6000 LUBRICATION SCHEDULE FUEL TANK, DIESEL WATER TANK DEMISTER SILENCER BLOWER ENGINE, QSB 4.5L B TORQUE HUBS PIVOT ENGINE, Q5X 15L TRANSFLUID CLUTCH RIGHT ANGLE DRIVE RIGHT SIDE VIEW LEFT SIDE VIEW *Do not attempt to perform maintenance, repair, or installation on machine until the machine and engine are stopped and secured ITEM # LUBRICATION SCHEDULE DAILY 2-3 PUMPS DAILY 2-5 DAILY PUMPS WEEKLY 5 PUMPS WEEKLY 1-2 PUMPS MONTHLY 1 PUMPS A PIVOT TANK SLIDE *REFER TO OWNERS MANUAL FOR ENGINE, GEARBOX, TRANSFLUID CLUTCH, AND BLOWER MAINTENANCE *Check all pivot point bolts daily FRONT VIEW DOCUMENT #: Page 30 of 110 LAST UPDATE: 3/26/18

31 DEPTH CONTROL ASSEMBLY BLADESHAFT BEARINGS LEFT SIDE RIGHT SIDE DETAIL A SCALE 1:16 SLURRY PUMP 6 ITEM # LUBRICATION SCHEDULE 1 DAILY 2-3 PUMPS 2 DAILY 2-5 PUMPS 3 DAILY PUMPS 4 WEEKLY 5 PUMPS 5 WEEKLY 5 PUMPS 6 MONTHLY 1 PUMPS DETAIL B SCALE 1:12 DOCUMENT #: Page 31 of 110 LAST UPDATE: 3/26/18

32 BOGEY STEERING RIGHT SIDE 1 1 FRONT LEFT SIDE ITEM # LUBRICATION SCHEDULE 1 DAILY 2-3 PUMPS 2 DAILY 2-5 PUMPS 3 DAILY PUMPS 4 WEEKLY 5 PUMPS 5 WEEKLY 1-2 PUMPS 6 MONTHLY 1 PUMPS 1 DOCUMENT #: Page 32 of 110 LAST UPDATE: 3/26/18

33 OPERATOR ASSEMBLY 5 5 C 5 5 ITEM # LUBRICATION SCHEDULE 1 DAILY 2-3 PUMPS 2 DAILY 2-5 PUMPS 3 DAILY PUMPS 4 WEEKLY 5 PUMPS 5 WEEKLY 1-2 PUMPS 6 MONTHLY 1 PUMPS 5 DETAIL C SCALE 1:12 *APPLIES TO BOTH SIDES OF THE MACHINE DOCUMENT #: Page 33 of 110 LAST UPDATE: 3/26/18

34 PC6000 MAINENANCE, DAILY OR MORE OFTEN AS NEEDED *Before cleaning the machine with water or any other cleaner, cover up/ seal off all opening which water are V not permitted to enter. Electrical components, engine inlet and outlets are particularly at risk. Remove all covers/ seals after you have finished cleaning the machine. I II III IV V VI II DAILY MAINTENANCE *DEMISTER CLEAN *LOBSTER POT CLEAN *WATER FILTER CLEAN *SPRAY BAR AND CLEAN TIPS *SLURRY PUMP CLEAN *SEPERATOR CLEAN *REFER TO OWNERS MANUAL FOR ENGINE, GEAR BOX, TRANSFLUID CLUTCH, AND BLOWER MAINTENANCE *CLEAN SILENCER AS NEEDED I VI III IV DOCUMENT #: Page 34 of 110 LAST UPDATE: 3/26/18

35 Recommended Oils, Lubricants, and Filters Oils & Lubricants Hydraulic Oil Tellus/Rando 68 Slurry Pump Refer to manual Blower Refer to manual Torque Hubs Refer to manual Blade Shaft Bearings Lubriplate EMB General Chassis Joints & Pivot Lubriplate EMB Right Angle Drive Refer to manual TRANSFLUID CLUTCH Refer to Manual Trailer Axels Refer to manual Cummins QSX 15L Cummins QSB 4.5L Engine Cummins QSX 15L Filters Refer to manual Engine Cummins 4.5L Filters Vacuum System Refer to manual De Mister Element Blower Filter Element Hydraulic System Functions System Filter Ground Drive Pump Water System Water Filter *CHANGE HYDRAULIC OIL EVERY 1000 HOURS DOCUMENT #: Page 35 of 110 LAST UPDATE: 3/26/18

36 PC6000 Wear Parts for Operator to Carry ITEM # PART # DESCRIPTION QTY DEPTH CONTROL WHEEL ASSEMBLY SLINGERS HEAD BEARING TAPPERED SLEEVE ADAPTER LABYRITH SEAL VACUUM BOX SIDE SKIRTS VACUUM BOX FRONT & BACK SKIRTS VACUUM BOX TOP HAT POLY CHAIN HEAD DRIVE BELT LOBSTER POT FILTER " SLURRY PUMP DIAPHRAGM " SLURRY PUMP RED FLAP VALVE " SLURRY PUMP FLAP VALVE WEIGHT " SLURRY PUMP FLAP VALVE WEIGHT 2 DOCUMENT #: Page 36 of 110 LAST UPDATE: 3/26/18

37 PC6000 Replacment and Wear Parts for Shop to Carry ITEM # PART # DESCRIPTION QTY DEPTH CONTROL WHEEL ASSEMBLY DEPTH CONTROL WHEEL DEPTH CONTROL WHEEL BEARING DRIVE TIRE HEAD BEARING ASSEMBLY SLINGERS BEARING HOUSING MODIFIED HEAD BEARING TAPPERED SLEEVE ADAPTER LABYRITH SEAL VACUUM BOX SIDE SKIRTS VACUUM BOX FRONT & BACK SKIRTS VACUUM BOX TOP HAT HEAD DRIVE IDLER ASSEMBLY IDLER SPROCKET POLY CHAIN HEAD DRIVE BELT HEAD DRIVE SPROCKET 50S HEAD DRIVE SPROCKET 60S HEAD DRIVE TAPER LOCK LOBSTER POT FILTER DEMISTER FILTER WITH LID WATER FILTER BASKET " VACUUM HOSE HOSE,2" X 100'L HOSE, 2 1/2" X 100'L " SLURRY PUMP DIAPHRAGM " SLURRY PUMP PLUNGER ROD " SLURRY PUMP DIAPHRAGM PLATE " SLURRY PUMP RED FLAP VALVE " SLURRY PUMP FLAP VALVE WEIGHT " SLURRY PUMP FLAP VALVE WEIGHT SPRAY BAR NOZZLES 80/ SPRAY BAR NOZZLES 80/15 27 DOCUMENT #: Page 37 of 110 LAST UPDATE: 3/26/18

38 OM SLURRY PUMP MAINTENANCE DSERIES SECTION DRAWING Figure 1. Pump Model 4D-B PAGE E -- 2 MAINTENANCE & REPAIR DOCUMENT #: Page 38 of 110 LAST UPDATE: 3/26/18

39 DSERIES OM PARTS LIST Pump Model 4D-B (From S/N up) If your pump serial number is followed by an N, your pump is NOT a standard production model. Contact the Gorman-Rupp Company to verify part numbers. ITEM PART NAME NO. PART NUMBER MAT L CODE QTY ITEM NO. PART NAME PART NUMBER MAT L CODE QTY 1 COUPLING DRIVE SHAFT COUPLING MTR SHAFT SPIDER COUPLING GUARD KEY N MOTOR NOT FURNISHED 7 BASE AXLE SPACER 6619A COTTER PIN M FLAT WASHER S PNEUMATIC WHEEL S U--- BOLT HEX NUT D LOCKWASHER J HEX HD CAPSCREW B FLAT WASHER K LOCKWASHER J HEX NUT D DIAPHRAGM RING DRAW BAR PLUNGER ROD ASSY LUB FITTING S END CAP GEARBOX ASSY HEX HD CAPSCREW B LOCKWASHER J HEX HD CAPSCREW B LOCKWASHER J HEX NUT D DIAPHRAGM POT ASSY U--- BOLT HEX NUT D LOCKWASHER J HEX HD CAPSCREW B0402 1/ T TYPE LOCK WASHER AK FLAT WASHER K LUBE DECAL ECCENTRIC GUARD NYLOCK CAP SCREW BT WASHER S FLAT WASHER K GUARD WARNING STKER NOT SHOWN: NAME PLATE 2613BP DRIVE SCREW BM# STRAINER DISCHARGE STICKER 6588BJ SUCTION STICKER 6588AG INSTRUCTION TAG OPTIONAL: STATIONARY BASE INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE & REPAIR PAGE E -- 3 DOCUMENT #: Page 39 of 110 LAST UPDATE: 3/26/18

40 OM DSERIES SECTION DRAWING NOTE: FLAP VALVE ASSEMBLY SHOWN IN POSI- TION ON DISCHARGE SIDE. SUCTION SIDE TO OPEN IN SAME DIRECTION. DISCHARGE SUCTION , 16 15, 14, , 8, 7 6, 5 4 PAGE E -- 4 Figure Diaphragm Pot Assembly MAINTENANCE & REPAIR DOCUMENT #: Page 40 of 110 LAST UPDATE: 3/26/18

41 DSERIES OM PARTS LIST Diaphragm Pot Assembly ITEM NO. PART NAME PART NUMBER MAT L CODE QTY 1 DIAPHRAGM POT SUCT ACCUMULATOR PLUG AND GASKET S591A SUCTION ACCUMULATOR REDUCER PIPE BUSHING AP HEX HD CAPSCREW B LOCKWASHER J STUD C FLAT WASHER KE HEX NUT D SUCTION ACCUMULATOR GASKET 6625G DIAPHRAGM POT DRAIN PLUG P DISCHARGE FLANGE GASKET 6625G STUD C FLAT WASHER KE HEX NUT D HEX HD CAPSCREW B LOCKWASHER J DISCHARGE FLANGE DISCHARGE ELBOW GASKET 6625G STUD C FLAT WASHER KE HEX NUT D DISCHARGE ELBOW VALVE SEAT DISCHARGE FLAP VALVE ASSY VALVE WEIGHT FLAP VALVE VALVE WEIGHT RD HD MACHINE SCREW X0402 1/ LOCKWASHER J VALVE SEAT SUCTION FLAP VALVE ASSY VALVE WEIGHT VALVE WEIGHT RD HD MACHINE SCREW X0402 1/ LOCKWASHER J FLAP VALVE INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE & REPAIR PAGE E -- 5 DOCUMENT #: Page 41 of 110 LAST UPDATE: 3/26/18

42 OM DSERIES SECTION DRAWING 234,, REF HOLD PAGE E -- 6 Figure Plunger Rod Assembly MAINTENANCE & REPAIR DOCUMENT #: Page 42 of 110 LAST UPDATE: 3/26/18

43 DSERIES OM PARTS LIST 6959 Plunger Rod Assembly ITEM NO. PART NAME PART NUMBER MAT L CODE QTY 1 BEARING CAP HEX HD CAPSCREW B0813S HEX NUT D08S LOCKWASHER J PLUNGER ROD ASSEMBLY DIAPHRAGM S LUBRICATION FITTING S DIAPHRAGM PLATE DIAPHRAGM PLATE HEX NUT D SPRING WASHER SPRING SPRING RETAINING NUT INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE & REPAIR PAGE E -- 7 DOCUMENT #: Page 43 of 110 LAST UPDATE: 3/26/18

44 OM DSERIES SECTION DRAWING PAGE E -- 8 Figure Gearbox Assembly MAINTENANCE & REPAIR DOCUMENT #: Page 44 of 110 LAST UPDATE: 3/26/18

45 DSERIES OM PARTS LIST Gearbox Assembly ITEM PART NAME NO. PART NUMBER MAT L CODE QTY ITEM NO. PART NAME PART NUMBER MAT L CODE QTY 1 GEAR HOUSING CRANKSHAFT BEARING S CRANKSHAFT GEAR GEAR HOUSING GSKT 6624G AIR VENT FITTING S HEX HD CAPSCREW B GEAR COVER CRANKSHAFT GEAR KEY N CRANKSHAFT BEARING S HEX HD CAPSCREW B FLAT WASHER WASHER PINION BUSHING S GEAR COVER PLUG S HEX HD CAPSCREW B LOCKWASHER J DRIVE SHAFT KEY N DRIVE SHAFT OIL SEAL S ECCENTRIC HOUSING ECC HOUSING GSKT 6632G DRAIN PLUG P DRIVE SHAFT BEARING S RETAINING RING S DRIVE GEAR SNAP RING S INTERNAL GEAR S PINION SHAFT GEAR HOUSING PLUG S PINION SHAFT BUSHING S WASHER SNAP RING S CRANKSHAFT ROLLER S BEARING 34 RETAINING RING S CRANKSHAFT SNAP RING S HEX HD CAPSCREW B LOCKWASHER J HEX NUT D SHOULDER BOLT S LOCKWASHER J HEX NUT D HEX HD CAPSCREW B LOCKWASHER J HEX NUT D OIL CUP S SHOULDER BOLT S LOCKWASHER J HEX NUT D INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE & REPAIR PAGE E -- 9 DOCUMENT #: Page 45 of 110 LAST UPDATE: 3/26/18

46 OM DSERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. Follow the instructions on all tags, label and decals attached to the pump. This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures 1, 2, 3 and 4) and the accompanying parts lists. Most service functions may be performed without separating the pump and gearbox from the motor. If major repair is required, the pump, gearbox and motor must be disconnected. Before attempting to service the pump, shut off incoming power to the motor and lock it out to ensure that it will remain inoperative. Close all valves in the suction and discharge lines. For motor disassembly and repair, consult the literature supplied with the motor, or contact your local motor representative. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Shut off incoming power to the motor and lock it out to ensure that the pump will remain inoperative. 3. Allow the pump to completely cool if overheated. 4. Close the discharge valve (if used). 5. Drain the pump. Before attempting to service the pump, drain the pump by removing the drain plug (11, Figure 2). Clean and reinstall the drain plug. Suction And Discharge Check Valve Removal (Figure 2) To service the suction and discharge check valves, remove the suction and discharge piping. To service the suction check valve assembly (32), remove the suction accumulator (3) by disconnecting the hardware (8 and 9) securing it to the diaphragm pot (1). Remove the hardware (5 and 6) securing the valve seat (31) and check valve assembly to the diaphragm pot. Pull the check valve assembly from the suction port. To service the discharge check valve assembly (25), loosen the hardware (21 and 22) and remove the assembled outboard discharge elbow (23), check valve, and seat (24). Remove the gasket (19). Remove the hardware (16 and 17) securing the valve seat (24) and discharge check valve assembly to the discharge elbow. To remove the inboard discharge flange (18), loosen the hardware (14 and 15) securing the flange to the diaphragm pot. Remove the gasket (12). The suction and discharge check valve assemblies are identical parts and operate in the same direction. For removal and/or replacement, remove the hardware (29, 30, 35 and 36) securing the check valve weights (26, 28, 33 and 34) to the check valves (27 and 37). Inspect and replace as required. If no further disassembly is required, see Suction And Discharge Check Valve Installation. Diaphragm Removal (Figure 1) To remove the diaphragm (6, Figure 3), disengage the hardware (28, 29 and 30) and remove the diaphragm pot assembly (31). Inspect the diaphragm ring (20) for wear or damage. If replacement is required, the gearbox assembly (25) and the eccentric guard (39) must be removed. (Figure 3) Remove the nuts (10). Separate the lower diaphragm plate assembly (8) from the diaphragm (6) PAGE E MAINTENANCE & REPAIR DOCUMENT #: Page 46 of 110 LAST UPDATE: 3/26/18

47 DSERIES OM and the upper diaphragm plate (9). Inspect the diaphragm and replace a required. If no further disassembly is required, see Diaphragm Installation. Plunger Rod Removal And Disassembly (Figure 3) With the diaphragm pot assembly and diaphragm removed, disengage the hardware (35, 36, 37, 40, 41, and 42, Figure 1) and remove the eccentric guard (39, Figure 1). Loosen the hardware (2, 3 and 4) and remove the end cap (24, Figure 1). Slide the bearing cap (1) off the crankshaft roller bearing (33, Figure 4), and remove the plunger rod assembly. Use a socket wrench to hold the plunger rod (5) securely, and unscrew the bearing cap assembly (1). Unscrew the spring retaining nut (13). Use caution when unscrewing the retaining nut; tension on the spring (12) will be released. Remove the spring (12) and spring washer (11). Slide the plunger rod assembly (5) out of the upper diaphragm plate (9). Inspect the component parts for excessive wear and replace as required. Gearbox Removal And Disassembly (Figure 1) When properly operated and maintained, the gearbox assembly (25) should not require disassembly. Disassemble the gearbox only when there is evidenceofwearordamage. Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel. Support the diaphragm ring (20) with wooden blocks. Disengage the hardware (26 and 27), and remove the diaphragm ring. Inspect the diaphragmringforwearordamageandreplaceas necessary. It is not necessary to remove the drawbar (21) from the diaphragm ring unless replacement is required. Disengage the hardware (33 and 34) from the U-bolts (32) to remove the drawbar. Disengage the hardware (16, 17, 18 and 19) and remove the coupling guard (4). Loosen the hardware securing the coupling (1). Separate the gearbox assembly from the coupling by pulling straight away. Remove the shaft key (17, Figure 4). (Figure 4) Before attempting to disassemble the gearbox assembly, drain the lubricant by removing the drain plug (22) and turning the gearbox on its side. Clean and reinstall the drain plug. Removethehardware(15and16)securingtheeccentric housing (20) and housing gasket (21) to the gear cover (7). Pull the complete drive shaft subassembly from the gear cover. To disassemble the drive shaft subassembly, remove the snap ring (26) and slide the drive gear (25) off the drive shaft (18). Remove the retaining ring (24), and press the drive shaft and assembled bearings (23) out of the eccentric housing. Press the oil seal (19) from the housing bore. Cover the shaft and bearing with a clean cloth until ready to clean and inspect the gearbox components. For access to the remaining gearbox drive components, the gear cover (7) and gear housing gasket (4) must be separated from the gear housing (1) by removing the two close-tolerance shoulder bolts (40 and 47), which act as pilots to ensure accurate concentric positioning of the cover, and the remaining hardware (37, 38, 39, 41, 42, 43, 44, 45, 48 and 49). NOTE The shoulder bolts and capscrews securing the gearbox cover to the gearbox housing are of different lengths. For ease of reassembly, record the positions of the shoulder bolts and capscrews at thetimeofremoval. Remove the gear housing gasket and clean all the mating surfaces. NOTE If the gear cover does not readily separate from the MAINTENANCE & REPAIR PAGE E DOCUMENT #: Page 47 of 110 LAST UPDATE: 3/26/18

48 OM DSERIES housing, remove the hardware (10 and 11), install a 5/8-11 UNC by 4-inch long capscrew, and jack the cover from the housing. Remove the jacking screw and replace the hardware (10 and 11). in cleaning solvent. Inspect the parts for wear or damage and replace as necessary. After the gear cover has been removed, inspect the pinion shaft bushing (13). If replacement is required, remove the cover plug (14) and press the pinion shaft bushing (14) from the cover bore. Slide the pinion shaft washer (12) off the pinion shaft (28) and tag it for reference during reassembly. Use a bearing puller to remove the crankshaft bearing (9) from the crankshaft (35). Remove the spacer (31). Install two 5/8-11 UNC capscrews in the tapped holes in the crankshaft gear (3), and use a gear puller to slide the gear off the crankshaft. Retain the crankshaft gear key (8). Remove the capscrews from the gear. Remove the snap ring (36) and slide the crankshaft and crankshaft bearing (2) out of the gearbox housing. To disassemble the pinion shaft and components, slide the shaft and assembled pinion gear (27) out of the shaft bushing (30). The pinion gear is retained on the shaft by tight friction fit and does not normally require removal. If removal is required, press the pinion gear from the shaft. Inspect the pinion shaft bushing and, if replacement is required, remove the plug (29) and press the bushing from the gear housing bore. After removing the shafts and bearings, clean and inspect the bearings in place as follows. To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed. Clean the gear housing, shaft and all component parts (except the bearings) with a soft cloth soaked Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers. Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil. Bearings must be kept free of all dirt and foreign material. Failure to do so will greatly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing failure. Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If rotation is rough or the bearing balls are discolored, replace the bearings. The bearing tolerances provide a tight press fit onto the shafts and a snug slip fit into the gear housing. Replace the bearings, shafts, eccentric housing, or gear housing if the proper bearing fit is not achieved. If the bearings require replacement, remove the bearing retaining ring (34). Remove the bearing snap ring (32) and use a bearing puller to remove the bearings (2, 23, and 33). Gearbox Reassembly And Installation (Figure 4) Inspect the shafts (18, 28 and 35) for distortion, nicks or scratches. Dress small nicks and burrs with a fine file or emery cloth. Replace the shafts if defective. PAGE E MAINTENANCE & REPAIR DOCUMENT #: Page 48 of 110 LAST UPDATE: 3/26/18

49 DSERIES OM To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and and bearings are removed. The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hotplatemaybeusedtoheatthebearings.bearings should never be heated with a direct flame or directly on a hot plate. NOTE If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thoroughly filtered. Heat the bearings to a uniform temperature no higher than 250F (120C), and slide the bearings onto the shafts, one at a time, until they are fully seated. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft. When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race. Secure the bearing (2) with the snap ring (36). Secure the crankshaft roller bearing (33) with the snap ring (32). If removed, press the pinion shaft bushing (30) into the gear housing until fully seated. Use a hydraulic press to install the pinion gear (27) onto the pinion shaft (28). NOTE The pinion gear is a tight interference fit on the pinion shaft. To ease installation, the gear may be heated (and the shaft cooled) to a temperature differential of 350F (177C). If the gear is heated, use caution when handling the gear to prevent burns. Slide the assembled pinion shaft and gear into the pinion shaft bushing until fully seated. Slide the crankshaft and assembled bearing (2) into the gear housing and secure with the snap ring (36). Use caution when handling hot bearings to prevent burns. NOTE The crankshaft bearing (9) must be installed after the crankshaft gear (3). After the bearings have been installed and allowed to cool, check to ensure that they have not moved out of position in shrinking. If movement has occurred, use a suitable sized sleeve and a press to reposition the bearings. If heating the bearings is not practical, use a suitable sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft. When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage. Install the crankshaft gear key (8) in the shaft keyway. Align the crankshaft gear teeth with those on the pinion shaft, and press the gear onto the crankshaft until fully seated against the shoulder. Install the spacer (31), and press the bearing (9) onto the shaft until fully seated against the spacer. Tap the end of the crankshaft with a soft-faced mallet to ensure that all components are fully seated. If removed, press the pinion shaft bushing (13) into the gear cover (7). Slide the pinion shaft washer (12) onto the pinion shaft (28). Install the gear MAINTENANCE & REPAIR PAGE E DOCUMENT #: Page 49 of 110 LAST UPDATE: 3/26/18

50 OM DSERIES housing gasket (4). Position the gear cover so that the respective bores slip over the crankshaft bearing and pinion shaft. Tap the cover into place with a soft-faced mallet. Install the two close-tolerance shoulder bolts (40 and 47) (which act as pilots to ensure accurate concentric positioning of the cover) through their respective holes, and secure them with the hardware (41, 42, 48 and 49). Secure the gear cover to the gear housing by tightening the remaining hardware (37, 38, 39, 43, 44, and 45) evenly. Install the gear cover plug (14) and the gear housingplug(29). Press the drive shaft and assembled bearings into the eccentric housing (20), and secure with the retaining ring (24). When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage. Lubricate the lip of the oil seal (19) with light oil, and position it on the drive shaft with the lip positioned as shown in Figure 4. Press the oil seal into the eccentric housing bore until the face of the oil seal is just flush with the face of the eccentric housing. Be careful not to roll or cut the lip of the oil seal on the shaft keyway. Installthedrivegear(27)onthedriveshaft,andsecure with the snap ring (26). Clean the mating surface of the eccentric housing and replace the eccentric housing gasket (21). Position the assembled eccentric housing and drive shaftinthegearcoverborewiththeword top on the eccentric housing flange facing up. Slide the housing and drive shaft into the gearbox, making certain the drive gear teeth fully engage those of the pinion gear. Secure the eccentric housing to the gear housing with the hardware (15 and 16). Install the drive shaft key (17). (Figure 1) Position the gearbox on the base (7). Position the diaphragm ring (20) under the base, and secure the gearbox and diaphragm ring with the hardware (26 and 27). If the drawbar (21) was removed, secure it to the diaphragm ring with the U-bolts (32) and hardware (33 and 34). Reinstall the drive coupling (1), and connect the halves. Check the coupling alignment as described in ALIGNMENT, SectionB. Lubricate the gearbox as described in LUBRICA- TION. Plunger Rod Reassembly And Installation (Figure 3) Slide the plunger rod (5) through the upper diaphragm plate (9). Slide the spring washer (11) and spring (12) down over the plunger rod. Install the spring retaining nut (13), and tighten it to obtain the dimension shown in Figure 3. Cleanthebearingcap(1)withaclothsoakedin cleaning solvent. Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers. Inspect the bearing cap for wear or damage and replace if necessary. NOTE The bearing cap consists of an upper and lower half secured with the hardware (2, 3 and 4). The cap is machined as one piece before being split to ensure concentricity of the bore, and is available only as an assembly. PAGE E MAINTENANCE & REPAIR DOCUMENT #: Page 50 of 110 LAST UPDATE: 3/26/18

51 DSERIES OM Screw the bearing cap assembly onto the plunger rod until fully seated against the spring retaining nut. Loosen the hardware (2, 3 and 4), and position the bearing cap over the crankshaft roller bearing (33, Figure 4). Secure the plunger rod assembly by tightening the hardware (2, 3 and 4). Secure the eccentric guard (39, Figure 1) with the hardware (35, 36, 37, 40, 41, and 42, Figure 1). Lubricate the plunger rod assembly as described in LUBRICATION, SectionE. Diaphragm Installation (Figure 3) Position the diaphragm (6) on the upper diaphragm plate (9), making sure the lip is properly seated. Slide the studs in the lower diaphragm plate (8) through the holes in the upper diaphragm plate, and secure with the nuts (10). (Figure 1) Clean the mating surfaces of the valve seat and discharge flange. Install the gasket (19) and secure assembled discharge elbow, check valve, and seat to the discharge flange with the hardware (21 and 22). Check the operation of the check valve to ensure proper seating and free movement. Subassemble the suction check valve (32). Clean the mating surfaces, and position the gasket (10), check valve assembly, and valve seat (31) against the diaphragm pot with the weights positioned as shown in Figure 2. Secure with the hardware (5 and 6). Check the operation of the check valve to ensure proper seating and free movement. Secure the suction accumulator (3) to the diaphragm pot with the hardware (8 and 9). Connect the suction and discharge piping as described in INSTALLATION, SectionB. Refer to OPERATION, Section C before starting the pump. Secure the diaphragm pot assembly (31) to the diaphragm ring (20) with the hardware (28, 29 and 30). LUBRICATION Suction And Discharge Check Valve Installation (Figure 2) Plunger Rod Assembly (Figure 1) Inspect the check valve components and replace as required. Subassemble the check valve weights (26, 28, 33 and 34) and check valves (27 and 37) with the hardware (29, 30, 35 and 36). If the inboard discharge flange (18) was removed, clean the mating surfaces and install the gasket (12). Secure the flange to the diaphragm pot (1) with the hardware (14 and 15). Subassemble the valve seat (24) and discharge check valve (25) to the discharge elbow (23) with the weights positioned as shown in Figure 2, and secure with the hardware (16 and 17). The crankshaft roller bearing (33, Figure 4) should be lubricated thoroughly after each 8 hours of operation. Failure to do so may cause the bearing to overheat and fail. Apply No. 2 lithium base grease to the upper lubrication fitting (23) until grease escapes from the end cap (24). Apply No. 2 lithium base grease to the lower fitting (7, Figure 3) until grease escapes from the top of the upper diaphragm plate inside the spring. MAINTENANCE & REPAIR PAGE E DOCUMENT #: Page 51 of 110 LAST UPDATE: 3/26/18

52 OM DSERIES Gearbox (Figure 4) The gearbox was fully lubricated when shipped from the factory. Check the oil level regularly at the oil cup (46), and keep the oil cup full. Lubricate with SAE No. 30 non-detergent when lubrication is required. Do not over-lubricate. Over-lubrication can cause the bearings to overheat, resulting in premature bearing failure. Under normal conditions, change the oil after each 5000 hours of operation, or at 12 month intervals, whichever occurs first. Change the oil more frequently if the pump if operated continuously or installed in a dirty or humid environment with rapid temperature change. Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and cold temperatures are common. When lubricating a dry (or overhauled) gearbox, add one ounce of Molykote M Gear Guard and top off with clean oil. For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil. Motor Refer to the motor manufacturer s recommendations or contact your local motor representative. PAGE E MAINTENANCE & REPAIR DOCUMENT #: Page 52 of 110 LAST UPDATE: 3/26/18

53 BLOWER MAINTENANCE SECTION 3 LUBRICATION All DuroFlow blowers are splash oil lubricated at both the gear and drive ends. Oil is distributed around the gear housing and drive end chamber by the gears and specially designed oil flingers. Series Vertical Horizontal Oil Fill Ports Mounting Mounting One Port Shaft & Gear Ends 29 oz. 55 oz. Interconnected FIGURE APPROXIMATE OIL CAPACITIES RECOMMENDED LUBRICANT The factory recommended lubricant is AEON PD Synthetic Lubricant. AEON PD is formulated especially for positive displacement blowers to provide maximum protection at any temperature. One filling of AEON PD will last a minimum of 4 times longer than a premium mineral oil, depending on actual operating conditions. AEON PD contains a special additive package designed for greater rust and corrosion protection. LUBRICATION INSTRUCTIONS For 45 series models, the oil fill port is located on the top of the blower at the driveshaft end (see FIGURE 1-- 2, page 5). The two oil sumps are connected by a passageway through the housing Add oil until the level stabilizes at the center of the sightglass(es). Oil level at the sight glass must be established when the blower is not operating. Add fresh oil as required to maintain proper level. Do not overfill as this will tend to cause excessive heating of the gears, oil to leak through the vent holes, and may damage the unit. Description AEON PD Lubricant Part Number 1 Quart 28G23 Case/12Quarts 28G24 5 Gallon Pail 28G25 55 Gallon Drum 28G28 AEON PD Food Grade Lubricant Description Part Number 1 Quart 28H97 Case/12Quarts 28H98 5 Gallon Pail 28H99 55 Gallon Drum 28H100 FIGURE AEON PD SYNTHETIC LUBRICANT AEON PD Synthetic Lubricant should be drained after 6000 hours of operation. Re--fill with fresh AEON PD oil. If mineral oil is used, perform the above oil--change maintenance every 1500 hours. Recommended service intervals are for normal blower operating conditions. Severe operating conditions may warrant more frequent oil changes. Laboratory analysis of lubricant should be used to help determine the optimum oil change interval. For best performance and equipment protection, use AEON PD Synthetic Lubricant, which has been specifically formulated for positive displacement blowers. If you choose not to use AEON PD Synthetic Blower Lubricant, select an oil with rust and oxidation inhibitors, anti--foam additives, and the viscosities listed in FIGURE 3--3, page 12. Do not use an oil that contains EP additives. D Page 10 DOCUMENT #: Page 53 of 110 LAST UPDATE: 3/26/18

54 SECTION 5 MAINTENANCE AND TROUBLESHOOTING Your DuroFlow blower has been designed, manufactured and tested to precise specifications. Every DuroFlow blower is backed by over 70 years of proven performance in the most demanding applications that modern industry can produce. DuroFlow blowers have been designed specifically for long, trouble--free service. Minimal maintenance is required to keep your DuroFlow blower in top operating condition. Your attention to the following key points will insure years of dependable DuroFlow blower performance. Key Points for Long Blower Life 1. Use AEON PD Synthetic Blower Lubricant to assure maximum blower protection. 2. The oil level must be checked periodically. 3. Drain and refill the blower with fresh AEON PD Lubricant every 6000 hours of operation, 1500 hours if using mineral based lubricant. 4. Clean the breather filters at every oil change or more often if dust conditions are severe. 5. Service the intake and in--line filters regularly to make sure that air flow restriction does not occur and that foreign material does not enter the blower. 6. If the blower is taken out of service for any reason, be sure to protect all interior surfaces from rusting. TROUBLE SHOOTING No matter how well the equipment is designed and manufactured, there may be times when servicing will be required due to normal wear, the need for adjustment, or various external causes. Whenever equipment needs attention, the operator or service technician should be able to locate the cause and correct the trouble quickly by following the Troubleshooting Chart given below: PROBLEM POSSIBLE CAUSES SOLUTION Knocking and excessive mechanical noise. Excessive blower temperature. 1. Unit out of time. 1. Retime rotors. (See page 18.) 2. Distortion due to improper 2. Check mounting alignment and mounting or pipe strains. relieve pipe strains. 3. Excessive pressure differential. 3. Reduce to manufacturer s recom-- mended pressure or vacuum. Exam-- ine relief valve, re-set if necessary. 4. Worn gears. 4. Replace timing gears. (See page 18.) 5. Worn bearings. 5. Replace bearings. (See page 18.) 1. Too much oil in gear case. 1. Reduce oil level. 2. Too low operating speed. 2. Increase blower speed. Check sheave set 3. Plugged filter or silencer. 3. Remove cause of obstruction. 4. Excessive pressure differential. 4. Reduce pressure differential across the blower. 5. Worn rotors clearances. 5. Replace rotors. (See page 18.) 6. Internal contact. 6. Correct clearances. (See page 18.) 7. Excessive inlet temperature. 7. Relocate intake to cooler area. D Page 16 DOCUMENT #: Page 54 of 110 LAST UPDATE: 3/26/18

55 Section 7 Controls Overview DOCUMENT #: Page 55 of 110 LAST UPDATE: 3/26/18

56 CENTER CONTROL BOX DOCUMENT #: Page 56 of 110 LAST UPDATE: 3/26/18

57 CENTER CONTROL BOX ITEM # DESCRIPTION NOTE 1 ENGINE SCREEN 2 IGNITION SWITCH 3 THROTTLE ON/OFF 4 SPEED CONTROL INCREASE/DECREASE 5 IDLE INCREASE/DECREASE 6 DIAGNOSTIC ON/OFF 7 INDICATOR LIGHT STOP 8 INDICATOR LIGHT WARNING 9 INDICATOR LIGHT WAIT 10 E-STOP LEFT LOAD CELL PRESSURE GAUGE RIGHT LOAD CELL PRESSURE GAUGE 13 AIR PRESSURE GAUGE 14 WATER PRESSURE GUAGE 15 TRACTION FRAME 16 LIGHTS ON/OFF 17 OPERATOR SELECT 18 BEACONS ON/OFF 19 WATER PUMP ON/OFF 20 SLURRY PUMP ON/OFF 21 BLOWER ON/OFF 22 CLUTCH ON/OFF 23 TANK SLIDE SWITCHES OPERATOR CONTROL TO EITHER SIDE OF THE MACHINE DOCUMENT #: Page 57 of 110 LAST UPDATE: 3/26/18

58 LEFT AND RIGHT OPERATOR BOXES ITEM # DESCRIPTION NOTE 1 E-STOP 2 2 SPEED HIGH/LOW 3 BRAKE ON/OFF 4 LEFT DEPTH CONTROL LIFT/LOWER 5 RIGHT DEPTH CONTROL LIFT/LOWER HIGH SPEED FOR TRAVEL AND LOW SPEED FOR GRINDING BRAKE MUST BE ON TO START ENGINE RAISE/LOWER LEFT DEPTH CONTROL WHEELS RAISE/LOWER RIGHT DEPTH CONTROL WHEELS 6 MAIN FRAME LIFT/LOWER RAISE LOWER MAIN FRAME DOCUMENT #: Page 58 of 110 LAST UPDATE: 3/26/18

59 HYDRAULIC CONTROLS ITEM # DESCRIPTION 1 SYSTEM PRESSURE GAUGE 2 DRIVE PRESSURE GAUGE 3 CHARGE PRESSURE GAUGE 4 LUBE PRESSURE GAUGE 5 MAIN FRAME LEFT PRESSURE GAUGE 6 MTRACTION FRAMTE PRESSURE 7 MAIN FRAME RIGHT PRESSURE GAUGE 8 LEFT MAIN FRAME ADJUSTMENT 9 TRACTION FRAME ADJUSTMENT 10 RIGHT MAIN FRAME ADJUSTMENT DOCUMENT #: Page 59 of 110 LAST UPDATE: 3/26/18

60 OPERATOR SEAT CONTROLS A 1 DETAIL A SCALE 1 : 3 ITEM # 1 DESCRIPTION FORWARD / NEUTRAL LOCKED / REVERSE JOYSTICK DOCUMENT #: Page 60 of 110 LAST UPDATE: 3/26/18

61 PLUS ONE CONTROL BOX MANUAL OVERRIDE SWITCHES ITEM # DESCRIPTION NOTE 1 PLUS ONE ON/OFF 2 FORWARD/REVERSE BYPASS 3 ESTOP BYPASS DOCUMENT #: Page 61 of 110 LAST UPDATE: 3/26/18

62 PLUS ONE Cruise Control Screen ICONS 1. System fault indicator flashes if there is a system fault 2. Left Down Pressure adjust with potentiometer a. LC=Load Cell b. MF=Main Frame 3. Right Down Pressure adjust with potentiometer a. LC=Load Cell b. MF=Main Frame 4. Feet per Minute Indicator 5. Trip Footage measures footage per shift, reset to 0 before starting grind 6. Total Footage Lifetime odometer displays in feet 7. Percent of Speed When in manual mode (see item 8) ground drive speed is controlled by joystick only. When in Auto speed is controlled by cruise control, Up/Down arrows increase or decrease speed in Auto Only 8. Auto/Manual shows what mode the Plus One is in 9. Droop Set Point arrows raise or lower droop (engine RPM) set point. Set point to be determined based on cutting situations 10. Water In/Out Temperature water out temperature indicates whether grinding head is working well 11. Bar Graph shows graph when engine RPM is above droop point setting (arrow) goes red when past droop point DOCUMENT #: Page 62 of 110 LAST UPDATE: 3/26/18

63 PLUS ONE Cruise Control Screen 1. Push to show fault screen, ESC to return to operator screen 2. Push to reset daily footage, follow directions on screen to reset 3. Push to increase % of joystick 4. Push to decrease % of Joystick 5. Not used 6. Push for manual or auto operation 7. Droop setting increase 8. Droop setting decrease 9. Press for system pressures and temperature readings DOCUMENT #: Page 63 of 110 LAST UPDATE: 3/26/18

64 PLUS ONE System Temperature and Pressure Screen PLUS ONE Fault Screen Red dot next to system listed indicates a fault in that system DOCUMENT #: Page 64 of 110 LAST UPDATE: 3/26/18

65 DOCUMENT #: Page 65 of 110 LAST UPDATE: 3/26/18

66 Section 8 Basic Operation Instruction DOCUMENT #: Page 66 of 110 LAST UPDATE: 3/26/18

67 Grinding Operation: 1. Prior to the equipment being transported to the project location, the operator should perform a DAILY EQUIPMENT INSPECTION. See DAILY EQUIPMENT INSPECTION check list in the manual. 2. Prior to unloading, adjust seat and operator control panel to comfortable position. Lock pins must be installed to keep seat and panel from moving while in operation. WARNING: NEVER operate the equipment with the operator adjacent to live traffic. 3. Equipment is on project location and unloaded, grinding head clear of pavement, joystick in neutral locked position, brake on, two speed switched to LOW, engine at LOW idle, beacons and flashers on. PROPER SAFETY GEAR including but not limited to: HARD HAT, HEARING PROTECTION, SAFETY VEST, and SAFETY GLASSES must be worn. 4. Install hose carrier. Connect water and slurry discharge hoses. Hoses should be attached to hose carrier to keep hoses from becoming entangled with equipment while in operation. 5. Install and adjust pointers. NOTE: further pointer adjustment may be necessary during operation. WARNING: DO NOT adjust pointer while equipment is in operation. If pointer requires adjustment operator MUST stop operation, joystick must be in neutral locked position, grinding head clear of pavement surface, brake set and engine RPM to low idle setting before exiting operator station to make adjustment. 6. Setting grinding head to ZERO. A. Equipment must be parked on a smooth and level section of pavement, brake must be on, engine at low idle and clutch OFF or disengaged. B. Lower grinding head to pavement surface. The PC1500 relies on the weight of the equipment only. Lower equipment and bring lift lower wheels off the pavement surface. Follow steps C, D & E. C. When grinding head contacts pavement STOP then raise profile wheels using RIGHT/LEFT DEPTH control switches. This will allow grinding head to settle to pavement surface. STOP raising profile wheels when they spin freely. D. Lower profile wheels until they contact pavement. Once wheels contact the pavement and DO NOT turn, BUMP raise/lower switches a couple times to raise grinding head barely above pavement surface. This will prevent cutting to deep. Further adjustment of profile wheels will be required while grinding to achieve proper profile and to adjust for grinding head wear. E. When adjustment is complete raise engine frame/mainframe until vacuum skirt is just clear of the pavement. Raise lower switch is now in NEUTRAL position. 7. Check water spray bar: Raise equipment fully and INSTALL SAFETY PINS. Turn water valve to full on position. Observe water spray bar nozzles for full spray pattern. Turn off water and clean nozzles if necessary prior to grinding. CLOGGED NOZZLES WILL CAUSE DAMAGE TO GRINDING HEAD. WARNING: IF cleaning is required, brake must be ON and engine SHUT OFF prior to cleaning spray bar and nozzles. 8. Remove SAFETY PINS and return to seat. Lower equipment, STOP when vacuum skirting touches pavement. 9. Whether BUMP grinding or CONTINOUS grinding the process usually starts at the DOCUMENT #: Page 67 of 110 LAST UPDATE: 3/26/18

68 shoulder of the pavement. If grinding with a PC1500 (THE PC1500 IS NOT DESIGNED NOR RECOMMENDED TO BE USED FOR CONTINOUS GRINDING) it will require four (4) passes to completely grind a twelve (12) foot wide traffic lane. Care must be taken when maneuvering the equipment close to the edge of the pavement to be ground. WARNING: KEEP EQUIPMENT ON PAVEMENT TO BE GROUND, STAY OFF SHOULDERS. Shoulders may be thin and may not support the weight of the equipment. 10. Observe area around equipment and make sure area is clear of vehicles, people, debris, and hoses. Keeping the engine at LOW idle slowly back equipment towards shoulder and align equipment parallel to the shoulder joint. Due to the position of the grinding head within the vacuum shroud, the shroud will overhang the shoulder joint approximately four (4) inches. Drive the equipment forward keeping equipment parallel to the joint. STOP and SET BRAKE. Exit seat and check if front wheels are straight. If not straighten and align front pointer with shoulder joint. If needed back equipment feet past starting point of grind area NOTE: Profile wheels are laterally adjustable. For initial grinding pass both sets of profile wheels are to be set IN BOARD. Asphalt pavement MAY NOT have a shoulder joint. If no joint is present the grind area must be laid out prior to grinding. With vacuum skirt touching the pavement TURN ON slurry pump, vacuum blower, two speed set to LOW, engage clutch, increase engine RPM to no more then 2000, turn water valve ON. Observe water flow/pressure. Adjust water pressure to accommodate cutting conditions. NOTE: Allow water to flow and observe that water is being vacuumed and being pumped away. If water is NOT being pumped away STOP. Find cause and remedy. Failure to do so may cause vacuum system to BLOW OVER. 11. To begin grinding: slowly move joystick forward and using raise/lower switch lower the equipment. Continue to move forward slow and straight following pointer. As the grinding head enters the bump engine RPM will drop slightly. Observe cut pattern behind the vacuum shroud and alignment of cut pattern to pavement. Front pointer and Profile wheel adjustment may be necessary at this point. If front pointer requires further adjustment raise engine frame slightly so grinding head clears pavement. Turn BRAKE ON, lower engine RPM to LOW idle. Adjust pointer as necessary. To start cut again back equipment 5 10 feet and slowly start forward and lower equipment. Continue to move forward driving straight. If profile wheels require adjustment DO NOT STOP, adjustment of profile wheels is made while grinding. Make small adjustments by BUMPING right, left or both switches. Continue to observe cut pattern and continue to adjust as necessary. 12. When cut is complete: FEATHER out of the cut using the raise/lower switch, BUMP switch to raise grinding head clear of pavement. Shut off water. 13. To make adjacent pass, slowly drive equipment backwards and align equipment parallel with and overlapping previous cut. 14. STOP, set brake and return engine to low idle. Dismount equipment and remove clamshell on right side profile wheel assembly. Slide profile wheel assembly out and reinstall clamshell. 15. Return to operator seat and repeat process 11. Adjust right side profile wheel to match previous cut while grinding. DOCUMENT #: Page 68 of 110 LAST UPDATE: 3/26/18

69 16. At end of shift/day follow Daily POST OPERATION shut down guidelines. 17. NOTE: Bump grinding means grinding the pavement surface in a localized area. The length of the pass made in bump grinding is usually short. CONTINUOUS or PROFILE grinding means grinding a long distance of a pavement surface. It is not uncommon to grind the same pass for several miles of pavement. In either case Feather grinding head out at the end of cut. 18. Cutting Speed: The speed at which material is removed or cutting speed is measured in Feet per minute (FPM) and depends upon depth of cut or amount of removal, size and hardness of aggregate, type of sand in mix and the specification of the blades that make up the grinding head. DOCUMENT #: Page 69 of 110 LAST UPDATE: 3/26/18

70 Section 9 Blade Shaft Speed DOCUMENT #: Page 70 of 110 LAST UPDATE: 3/26/18

71 PC6000 Series and PC4500 Series Blade Shaft Speeds Belt Gear Box Ratio 14M 2660 x Low Range Sheave Setup Engine RPM Drive Sheave Driven Sheave Blade Shaft RPM High Range Sheave Setup Engine RPM Drive Sheave Driven Sheave Blade Shaft RPM *Note: Engine cannot be run below 1600 RPM for sustained periods DOCUMENT #: Page 71 of 110 LAST UPDATE: 3/26/18

72 Section 10 Blade Shaft Removal & Installation DOCUMENT #: Page 72 of 110 LAST UPDATE: 3/26/18

73 Blade Shaft and Blade Removal and installation This process is typical for PC4500, PC4504, and PC6000. The PC6000 blade shaft is shown in pictures. The Blade Shaft assembly weighs approximately 4000 lbs. and is approximately 7 6 in length. It must be lifted to the vertical position to change blades. Failure to follow these instructions and/or failure to use the proper tools and fixtures can lead to serious injury or death. Always heed the following WARNINGS when performing this procedure. Two people familiar with normal and safe rigging practices and familiar with this process should be used for this procedure. one person should not attempt this alone Never attempt to stand the Blade Shaft vertically on anything except a hard, flat, level concrete surface capable of supporting the weight of the Blade Shaft. Never stand the Blade Shaft in anything except the stand provided. (Figure 1). Never attempt to lift the Blade Shaft with anything except the proof tested hoist ring provided. (Figure 2). Always inspect these two items for damage and inspect all other rigging used prior to lifting the assembly. Figure Stand Figure Hoist Ring DOCUMENT #: Page 73 of 110 LAST UPDATE: 3/26/18

74 To Remove the Blade Shaft Assembly from the Machine 1. Position the machine on a flat concrete or asphalt surface, and set the brakes. 2. Shut off the Main Engine and disengage the clutch. 3. Adjust the Depth Control Wheels so that the head is just touching the pavement with the Main Frame down. 4. Remove the belt guard and belt. 5. Remove the cap screws that secure the head bearings to the Main Frame. 6. Slowly raise the Main Frame. The head will remain on the ground. (Figure3). Figure 3 - Blade Head and Shaft on the ground after Main Frame raised 7. Pin the Main Frame in the raised position and roll the head forward until it can be turned 90 degrees and rolled out from under the machine. Note: Field experience has shown that it is often helpful to roll the assembly up onto two used spacers which can then be used as a turn-table. Two people must be used for this step. 8. Block the Blade Shaft front and rear of the blades so it cannot roll. (Wooden 2 x 4 s are good for this.) Now remove the driven sheaves and keys on each end of the shaft. DOCUMENT #: Page 74 of 110 LAST UPDATE: 3/26/18

75 9. The Blade Shaft is made with one fixed flange on one end and one flange that is a threaded nut with 12 5/8 cap screws in the outer face. Remove the bearing from the end with this nut. The bearing on the fixed flange end need not be removed. 10. Using a 15/16 socket and ratchet, alternately loosen, but do not remove, all 12 5/8 cap screws. 11. Using the special spanner provided, loosen just slightly the threaded nut. Note: If there are any exposed threads on the 8 diameter Blade Shaft protruding beyond the nut, be sure to clean and lubricate them thoroughly before loosening the nut. 12. The push plate, blades, and spacers can now all be removed one at a time Install the hoist ring into the threaded hole provided on the nut end of the Blade Shaft and tighten. (Figure 4). Figure Hoist Ring installed on nut end of the Blade Shaft DOCUMENT #: Page 75 of 110 LAST UPDATE: 3/26/18

76 Note: Be sure that the bolt enters fully and the shoulder rests squarely on the end of the Blade Shaft. It may be necessary to clean or tap the threads in the end of the Blade Shaft. Caution: Never attempt to lift the Blade Shaft without the hoist ring fully seated. 14. Attach a suitable lifting device to the hoist ring and slowly lift the Blade Shaft assembly to the vertical position. (Figure 5) Figure 5 - Slowly lift Blade Shaft assembly to the vertical position DOCUMENT #: Page 76 of 110 LAST UPDATE: 3/26/18

77 15. Position the Blade Shaft over the stand and slowly lower the Blade Shaft into the stand until it is fully seated against the step shoulder in the shaft. (Approximately 6 ) (Figure 6) Figure 6 - Lower Blade Shaft into stand until fully seated against the step shoulder 16. Slacken the hoist, and before removing the rigging, attempt to rock the Blade Shaft. It should be stable. If it is not stable, find out why before proceeding, your life may depend on it. 17. With the Blade Shaft standing solidly in the vertical position, and working from the ground or an approved safe work platform, remove the rigging, the joist ring, and the threaded end nut. 18. The push plate, blades, and spacers can now all be removed one at a time. DOCUMENT #: Page 77 of 110 LAST UPDATE: 3/26/18

78 Assembly and Installation of the Blade Shaft This process is typical for PC4500, PC4504, and PC6000. PC6000 shaft is shown in photos. Cleanliness is all important. There must be no foreign material on the Blade Shaft, threaded nut, pusher plate, or in between the blades and spaces. If there is blade wobble and short blade life will result. 1. With a clean Blade Shaft standing in the stand as described above, alternately stack blades and spacers onto the shaft followed by a.375 push plate. The number of blades and spacers may vary due to manufacturing tolerances. The total width of the stack including the push plate should be Add spacers as necessary behind the push plate to achieve this dimension. (Figure 7) Figure 7 - After thorough cleaning stack blades and spacers on Blade Shaft DOCUMENT #: Page 78 of 110 LAST UPDATE: 3/26/18

79 2. Coat the shaft threads with "Never-Seize" and snug them against the push plate with all 12 5/8" bolts backed out below the face of the nut. Tighten these only by hand at this time. (Figure 8). Figure 8- Coat shaft threads with "Never-Seize" and hand tighten 5/ff'bolts at this stage DOCUMENT #: Page 79 of 110 LAST UPDATE: 3/26/18

80 3. Install the hoist ring and attach to a suitable lifting device as described above. (Figure 9). 4. Using spanner wrench tighten loose flange (fig 10). Make sure pusher spacer does not turn when tightening loose flange. When you cannot tighten loose flange further by hand with Spanner STOP. Figure 9 - Install Hoist Ring and hold and stabilize shaft DOCUMENT #: Page 80 of 110 LAST UPDATE: 3/26/18

81 Figure 10 Tighten the threaded nut 5. Tighten the cap screws alternately and evenly at 180 degree intervals (much like you would tighten a cylinder head). Torque to ft/lbs. This will adequately compress the stack. (Figure 10 and Figure 11) Figure 11 - Tighten 5/8" cap screws alternately and evenly at 180 degree intervals to ft/lbs DOCUMENT #: Page 81 of 110 LAST UPDATE: 3/26/18

82 6. Place a bead of silicone around the gap between the nut and the push plate. This will prevent concrete slurry from damaging the threads of the 5/8 cap screws Figure 12 - Placing silicone around gap between nut and push plate as well as thread at outside of Blade Shaft 7. Put a bead of silicone around the thread at the outside of the Blade Shaft to protect it. (Figure 12) Note: Allow adequate cure time for silicon. Wrap with duct tape if adequate cure time can t be met.. DOCUMENT #: Page 82 of 110 LAST UPDATE: 3/26/18

83 8. Using a suitable lifting device as discussed above, lift the Blade Shaft out of the stand and lower it into the horizontal position. (Figure 13). Figure 13 - Lowering Blade Shaft into horizontal position 9. Re-install the bearing and drive sheaves, and position the shaft back under the machine. 10. Lower the machine slowly until the bearing mounts are just above the bearing housings, and then install the bolts. Be sure that the Blade Shaft assembly is mounted squarely under the machine and tighten the bolts. Install and tighten the belts and re-install the belt guards. DOCUMENT #: Page 83 of 110 LAST UPDATE: 3/26/18

84 Removal of Blade Shaft Bearings 1. Remove the sealant from the three (3) Allen head bolts that secure the outer seal retainer to the bearing housing and remove the Allen bolts and the retainer from the bearing housing. 2. After removing the sealant from the two (2) Allen bolts that clamp the centrifugal labyrinth seal to the Blade Shaft, remove the bolts and the seal. 3. After removing the sealant from the Allen bolts that retain the inner seal retainer to the bearing housing remove the bolts and the retainer. 4. After placing a suitable block under the bearing housing remove the four (4) nuts that hold the bearing housing together. 5. Separate the bearing housing halves exposing the bearing, taking note of the position of the stabilizing ring, the rubber labyrinth seals and the V- ring contact seals. 6. Remove the outer rubber labyrinth and the V-ring contact seal. 7. Using a suitable tool, mark the location of the taper adapter sleeve on the shaft. 8. With a suitable tool, lift the locking tab of the locking ring from the bearing retaining nut. 9. Using the hammer driven wrench supplied with the PC4500, PC4504, or PC6000, remove the retaining nut. 10. Remove the locking ring. 11. Thread the retaining nut back on the adapter sleeve leaving 1/8 (3mm) clearance between the retaining nut and the bearing. 12. Place the U shaped fixture of the bearing puller tool supplied with the PC4500 behind the bearing being careful to place the U shaped fixture the adapter sleeve, NOT THE SHAFT. 13. Using the threaded rods supplied, attach the circular fixture of the bearing puller to the U shaped fixture, making certain that the circular fixture is resting on the shaft and the side of the circular fixture is against the end of the adapter sleeve. DOCUMENT #: Page 84 of 110 LAST UPDATE: 3/26/18

85 14. Tighten the nuts on the threaded rods, alternately, so that an even pressure is exerted on the circular fixture. Continue tightening the nuts until the bearing is released from the sleeve. 15. Remove the bearing puller assembly. 16. Remove the bearing and adapter from the shaft. Installation of Blade Shaft Bearings Install the Blade Shaft bearings in reverse order of removal, as outlined above. Always pack the bearing with fresh grease. Use Lubriplate EMB. (Figure 14). Figure 14 - Using Lubriplate EMB to pack bearings with fresh grease DOCUMENT #: Page 85 of 110 LAST UPDATE: 3/26/18

86 Use caution when installing the V ring seal. This seals should be rolled onto the labyrinth seal # after the bearing housing is bolted together. The lip face of the seal must have full face contact on the bearing housing. (Figure 15). Figure 15 - "V" ring seal DOCUMENT #: Page 86 of 110 LAST UPDATE: 3/26/18

87 Section 11 Hydraulic and Electrical Schematics DOCUMENT #: Page 87 of 110 LAST UPDATE: 3/26/18

88 1 DOCUMENT #: Page 88 of 110 LAST UPDATE: 3/26/18 4,5,6 PLUSONE BOX PLUG PLUG 24V 24V GND SENSOR POWER SIGNAL SENSOR GROUND 6, 7, AND 8 GO TO PLUS ONE 4 PIN FORWARD REVERSE PLUS ONE 6,7,8 LEFT SENSOR GROUND SIGNAL JOYSTICK SENSOR POWER 6 PIN J1939 3, 4, 5, AND 6 GO TO PLUS ONE 1 AND 2 GO TO CUMMINS 15L CONTROL BOX 6, 7, AND 8 GO TO PLUS ONE HEAVY & SPECIALTY EQUIPMENT OPERATIONS, NAMPA, IDAHO

89 CENTER BOX F E D 6 PIN ROUND POWER/GROUND PIN E-STOP C B A 8 PIN FWD/REV PLUSONE DIAMOND PRODUCTS-GGEM. THIS LEGEND SHALL APPEAR ON ANY REPRODUCTION OF THIS DRAWING IN WHOLE OR IN PART." NOTES: (UNLESS OTHERWISE SPECIFIED) DRAWING TO BE INTERPRETED PER: ASME Y DIMENSIONS AND TOLERANCING, ASME Y ABBREVATIONS. 1. FUSEBOX PIN JOYSTICK FWD/REV PIN PIN REVERSE ALARM MAIN FRAME DOWN SIGNAL DRIVE PUMP DP J L CUMMINS CONTROL BOX ENCODER RIGHT/LEFT JOYSTICKS UNLESS OTHERWISE SPECIFIED DRAWING IS IN INCHES AND TOLERANCES ARE BELOW.X.XX.XXX.XXXX "THIS DRAWING IS THE PROPERTY OF DIAMOND PRODUCTS- GGEM. IT IS TRANSMITTED AS A CONFIDENTIAL DISCLOSURE, AND IS RETURNABLE UPON REQUEST. IT CONTAINS PROPRIETARY INFORMATION IN GENERAL AND IN DETAIL, AND IT MAY NOT BE COPIED, OR ITS CONTENTS REVEALED TO OTHERS, WITHOUT THE WRITTEN CONSENT OF DIAMOND PRODUCT-GGEM. ANY PATENTS OBTAINED COVERING DESIGN AND CONSTRUCTION SHOWN HEREON BELONG SOLELY TO ±.1 ±.03 ±.005 ±.0002 FINISH ANGULAR ± 1 DIAMOND PRODUCTS HEAVY & SPECIALY EQUIPMENT OPERATIONS, NAMPA, IDAHO DESC: MATERIAL: PLUS ONE SCHEMATIC PC6000 FINISH FINISH: DRAWN BY: KP SHEET: SCALE: 1 OF 1 DATE: PART NO: 7/24/17 1:1 DWG. NO: SIZE: D REVISION: F E D C B A DOCUMENT #: Page 89 of 110 LAST UPDATE: 3/26/18

90 HEAVY & SPECIALTY EQUIPMENT OPERATIONS, NAMPA, IDAHO 1 DOCUMENT #: Page 90 of 110 LAST UPDATE: 3/26/18

91 A A 3 Ground Drive Control Joystick MB B Drive Wheel 2 0 RPM B B Ground Drive Motor C C 1 4 DOCUMENT #: Page 91 of 110 LAST UPDATE: 3/26/18 Drive Wheel 1 0 RPM T1 X3 S MA A Ground Drive Pump D D E E Ground Drive Motor HEAVY & SPECIALTY EQUIPMENT OPERATIONS, NAMPA, IDAHO NAME: PC6004EC GROUND DRIVE HYDRAULIC CIRCUIT F F DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE 1 Charge 350 p.s.i. DWG. DATE: 6/24/2011 PART NO: REV. NO: 1 REV. DATE: DWG. NO: SHEET 1 OF

92 Reference Part Number Quantity Catalog Description Ground Drive Pump Charge Filter Element A Joystick A Ground Drive Motor B B C C DOCUMENT #: Page 92 of 110 LAST UPDATE: 3/26/18 D D NAME: PC6000EC GROUND DRIVE HYDRAULIC CIRCUIT E E M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: DWG. DATE: 6/24/2011 PART NO: REV. NO: 1 REV. DATE: DWG. NO: !01 SHEET 2 OF

93 A A B B B2 A2 B1 A X 05 1 C C 2 2 P UNLOADER VALVE T D D FRONT HAND VALVE ASSEMBLY P P T TO FUNCTION PUMP MANIFOLD E E S FUNCTION PUMP HYDRAULIC CIRCUIT PC6000 NAME: F 1 Pressure 2100 p.s.i. 2 Load Sense Standby 275 DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE F p.s.i. DOCUMENT #: Page 93 of 110 LAST UPDATE: 3/26/18 1 CASE DRAIN REV. NO: 2 PART NO: DWG. DATE: 7/1/ $01 SHEET 1 OF 4 REV. DATE: 8/8/2011 DWG. NO:

94 A A B B TO GROUND DRIVE MOTORS 'X' PORT A B A B A B B B A B A B C C DOCUMENT #: Page 94 of 110 LAST UPDATE: 3/26/18 2 D D 1 P E E T TWO SPEED MAIN FRAME TRACTION FRAME TANK SLIDE WATER PUMP TRASH PUMP LEFT DEPTH RIGHT DEPTH Reduced Pressure 400 p.s.i. Reduced Pressure 250 p.s.i. 1 2 FUNCTION PUMP HYDRAULIC CIRCUIT PC NAME: F F SCALE: NONE APPROVED BY: M.C.D.S. DWG. BY: REV. NO: 2 PART NO: DWG. DATE: 7/1/ $01 SHEET 2 OF 4 REV. DATE: 8/8/2011 DWG. NO:

95 Reference Part Number Quantity Catalog Description Function Pump Unloader Valve Cartridge A VDC Coil A Unloader Valve Body Hand Valve Loading Leg Cylinder Wheel Base Adjustment Cylinder Return Filter Thermal Transfer Cooler Main Frame Cylinder B Traction Frame Cylinder B Tank Slide Cylinder Water Pump Motor Trash Pump Motor Depth Motor PC6000 Function Manifold Valve Body Reducing/Relieving Cartridge C 19 FDCB 1 Flow Control Cartridge C 20 GCI 1 Flow Control Body 22 DCI 1 Flow Control Body DOCUMENT #: Page 95 of 110 LAST UPDATE: 3/26/18 D D NAME: FUNCTION PUMP HYDRAULIC CIRCUIT PC6000 E E SCALE: NONE APPROVED BY: M.C.D.S. DWG. BY: DWG. DATE: 7/1/2011 PART NO: REV. NO: :01 SHEET 3 OF 4 REV. DATE: 8/8/2011 DWG. NO:

96 A A Atmospheric Reservoir Fully Adjustable Needle with Reverse Flow Check Double&Acting Cylinder Relief Valve B B Variable Piston Pump with Load Sense C C Hydrostatic Reservoir Pilot to Open Check Valve 1&Direction Motor Directional Valve, Solenoid Operated 3&Way Pressure Regulator with Drain DOCUMENT #: Page 96 of 110 LAST UPDATE: 3/26/18 D D Ball&Type Load Shuttle E Bidirectional Motor E Directional Valve, Manually Operated Two&Stage Pressure Reducing Valve FUNCTION PUMP HYDRAULIC CIRCUIT PC6000 NAME: F F Cooler Filter DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE REV. NO: 2 PART NO: DWG. DATE: 7/15/ &01 SHEET 4 OF 4 REV. DATE: 8/8/2011 DWG. NO:

97 A A A B 1 2 X B B 2 1 LS 1 2 C C P DOCUMENT #: Page 97 of 110 LAST UPDATE: 3/26/ D D CASE DRAIN S P T E E BLOWER HYDRAULIC CIRCUIT NAME: F F M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: Relief 5000 p.s.i. Pressure Compensator 4800 p.s.i. 1 2 REV. NO: 1 PART NO: DWG. DATE: 7/6/ $01 SHEET 1 OF 3 REV. DATE: DWG. NO:

98 Reference Part Number Quantity Catalog Description Function Pump Blower Motor A Blower Manifold A B B C C DOCUMENT #: Page 98 of 110 LAST UPDATE: 3/26/18 D D NAME: BLOWER HYDRAULIC CIRCUIT E E M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: DWG. DATE: 7/6/2011 PART NO: REV. NO: 1 REV. DATE: DWG. NO: SHEET 2 OF

99 A A B B Solenoid Operated, 3Way, 2Position, Directional Spool Valve, Soft Shift Air Bleed Startup Valve Poppet, PilottoOpen, Spring Biased Closed Variable Piston Pump with Load Sense C C DOCUMENT #: Page 99 of 110 LAST UPDATE: 3/26/18 Check Valve Fully Adjustable Needle Valve Relief Valve, Direct Acting Bidirectional Motor D D BLOWER HYDRAULIC CIRCUIT NAME: Hydrostatic Reservoir Atmospheric Reservoir E E M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: REV. NO: 1 PART NO: DWG. DATE: 7/6/ SHEET 3 OF 3 REV. DATE: DWG. NO:

100 A A 7 R L 8 STEERING CYLINDER LEFT STEERING VALVE B B STEERING DIVERTER C VALVE P T C 2 R L 7 3 D D RIGHT STEERING VALVE STEERING RELIEF VALVE DOCUMENT #: Page 100 of 110 LAST UPDATE: 3/26/ E E P T STEERING PUMP STEERING CIRCUIT PC6000 NAME: F F M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: REV. NO: 1 PART NO: DWG. DATE: 8/3/2011 Relief 2000 p.s.i $01 SHEET 1 OF 3 REV. DATE: DWG. NO:

101 Reference Part Number Quantity Catalog Description Steering Pump, PC Relief Cartridge A Relief Valve Body A Drectional Valve Cartridge Directional Valve Body VDC Coil Steering Valve Steering Cylinder B B C C DOCUMENT #: Page 101 of 110 LAST UPDATE: 3/26/18 D D NAME: STEERING CIRCUIT PC6000 E E M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: DWG. DATE: 8/3/2011 PART NO: REV. NO: 1 REV. DATE: DWG. NO: SHEET 2 OF

102 A A Double"Acting Cylinder Fixed Displacement Pump B B Steering Valve C C DOCUMENT #: Page 102 of 110 LAST UPDATE: 3/26/18 Atmospheric Reservoir Drectional Valve Cartridge Relief Valve D D NAME: STEERING CIRCUIT PC6000 Hydrostatic Reservoir E E M.C.D.S. APPROVED BY: SCALE: NONE DWG. BY: DWG. DATE: 8/3/2011 PART NO: REV. NO: 1 REV. DATE: DWG. NO: "01 SHEET 3 OF

103 Section 12 Reference Material DOCUMENT #: Page 103 of 110 LAST UPDATE: 3/26/18

104 GROUND DRIVE PUMP: SET PSI 2700 AUXILIARY PUMP: SET PSI 1800 BLOWER PUMP: SET PSI 2000 GREASE SCHEDULE HEAD BEARINGS 16 PUMPS EVERY 10HRS FRONT BOGEY GREASE POINTS 5 PUMPS WEEKLY ENGINE FRAME PIVIOT POINTS 3 PUMPS WEEKLY FRONT SLIDE GREASE RAILS MONTHLY DEPTH CONTROL WHEEL ASSEMBLY 2 PUMPS WEEKLY BLOWER 2 PUMPS MONTHLY TRASH PUMP 2 PUMPS DAILY TRACTION FRAME PIVIOT POINTS 5 PUMPS WEEKLY TANK SLIDE GREASE POINTS 5 PUMPS MONTHLY CUMMINS QSX15 PRIMARY AIR FILTER AF472 SAFETY AIR FILTER AF417M OIL FILTER LF9000 FUEL FITER FS1040STD CAT C18 AIR FILTER PRIMARY 1W 3637 AIR FILTER SECONDARY 1W3636 OIL FILTER 1R 0716 (REQUIRES 2) FUEL FILTER 1R 0749 WATER FILTER PC6000 REFRENCE CHART BLADE SHAFT BOLTS TORQUE 85 FT LBS BLADE SHAFT BOLTS 5/8 11 x 1 1/4 (15/16 SOCKET) WASH OUT & DAILY MAINTENANCE TRASH PUMP FLUSH DAILY DEMISTER FILTER & HOUSING WASH OUT DAILY LOBSTER POT FILTER & HOUSING WASH OUT DAILY CLEAN SPRAY BAR NOZZLES DAILY PRIOR TO SHIFT AND INSPECT THROUGH OUT SHIFT WATER FILTER BASKET CLEAN DAILY & THROUGH OUT SHIFT VACUUM HEAD BOX INSPECT & CLEAN DAILY VACUUM SEPERATOR CLEAN & INSPECT DAILY CHECK FLUIDS DAILY (ENGINGE OIL, HYDRAULIC OIL, COOLANT, TRASH PUMP OIL) WINTERIZING DRAIN ALL WATER LINES DRAIN BOWL AT TRASH PUMP LEAVE WATER BALL VALVE PARTIALLY OPEN SPRAY BLOWER LOBES WITH LITE OIL & RUN FOR 30 SECONDS CHECK ANTI FREEZE/CONDITION & CONTACT LOCAL ENGINE DEALER FOR FUTHER QUESTIONS ENGINE SERVICE OIL 15W HOURS HYDRAULIC SERVICE OIL ISO68 FITERS 500 HOURS OIL 1000 HOURS BLOWER 30W SYN 1000 HOURS RIGHT ANGLE DRIVE GEAR OIL 75W/90SYN 1000 HOURS TRASH PUMP OIL 30W SYN 500 HOURS TORQUE HUBS GEAR OIL 75W/90 SYN 1000 HOURS SERVICE PARTS transfluid clutch ISO HM 32 CUMMINS QSB4.5 PRIMARY AIR FILTER P SAFETY AIR FILTER P OIL FILTER LF3970 PRIMARY FUEL FILTER FS19732 SECONDARY FUEL FILTER FF5421 SERVICE PARTS CAT C4.4 AIR FILTER PRIMARY AIR FILTER SECONDARY OIL FILTER WATER FILTER DP# DESCRIPTION GROUND DRIVE PUMP FILTER RETURN FILTER HYDRAULIC TANK BREATHER DOCUMENT #: Page 104 of 110 LAST UPDATE: 3/26/18

105 FUSE BOX 101A RED 24 V RELAY POWER 101B RED 24 V 101C RED 24V ENCODER POWER 302 ORANGE BECON POWER 303U BLACK/STRIPE LIGHT POWER 302L BLACK/STRIPE LIGHT POWER 102 TAN TRACTION FRAME UP 103 TAN/STRIPE TRACTIONFRAME DOWN 104 WIGHT BRAKE 107 BLUE 2 SPEED HIGH 108 PURPLE WATER PUMP 109 PINK TRASH PUMP 110 GREEN BLOWER COIL 111 LIGHT BLUE TANK SLIDE LEFT 112 LIGHT BLUE/STRIPE TANK SLIDE RIGHT 113 YELLOW LEFT DEPTH UP 114 YELLOW/STRIPE LEFT DEPTH DOWN 115 BLUE RIGHT DEPTH UP 116 BLUE/STRIPE RIGHT DEPTH DOWN 117 BROWN MAIN FRAME UP 118 BROWN/STRIPE MAIN FRAME DOWN MFD ORANGE/STRIPE DUMP COIL POWER 101A RED PLUS ONE POWER 101A RED PLUS ONE POWER 119 GRAY SMART COIL SIGNAL 120 WIGHT BACKUP ALARM POWER 200R LIGHT GREEN REAR E STOP IN FRONT E STOP IN ORANGE 201F 201R LIGHT GREEN ESTOP IN FRONT ESTOP OUT ORANGE 202F 202R LIGHT GREEN ESTOP OUT 203F ORANGE FRONT ESTOP OUT 205F ORANGE/STRIPE FRONT ESTOP OUT 205F ORANGE/STRIPE LIGHTS ON ESTOP 302A ORANGE/STRIPE BECON POWER 302A ORANGE/STRIPE BECON POWER 302A ORANGE/STRIPE BECON POWER 303U BLACK/STRIPE LIGHT POWER 303U BLACK/STRIPE LIGHT POWER 303U BLACK/STRIPE LIGHT POWER 303U BLACK/STRIPE LIGHT POWER 303U BLACK/STRIPE LIGHT POWER 303U BLACK/STRIPE LIGHT POWER 303L BLACK/STRIPE LIGHT POWER 303L BLACK/STRIPE LIGHT POWER 303L BLACK/STRIPE LIGHT POWER 303L BLACK/STRIPE LIGHT POWER GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK GROUND BLACK DO NOT CHANGE, ADD, OR ALTER ELECTRICAL SYSTEM DOCUMENT #: Page 105 of 110 LAST UPDATE: 3/26/18

106 How to Recalibrate Joysticks PC6000 Series and PC4500 Series 1. PC6000 Series turn on front engine key power. PC4500 series turn on engine Key Power. 2. Unplug joystick from the bottom of joystick box (figure 1) Figure 1: Unplug Joystick 3. Turn key power off 4. Plug Joystick back in at the bottom of the joystick box (figure 1) 5. Turn key power back on, go to DP610 Screen, press button 1 to show faults (figure 2) DOCUMENT #: Page 106 of 110 LAST UPDATE: 3/26/18