DIAMOND PRODUCTS PC1504 · Operation Parts and Service Manual DIAMOND PRODUCTS PC1504 Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher Rd • Nampa

Operation Parts and Service Manual

DIAMOND PRODUCTS

PC1504

Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher Rd • Nampa ID, 83687

Phone Toll Free 800.225.0142 Fax 208-899-8111

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 #: 1803635 Page 2 of 85 Last Update: 3/23/18 Date Printed: 3/23/18

Table of Contents Owner’s Manual

Warranty Section 1

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

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.

Origional Instructions

Blade Shaft Speeds Section 9

Blade Shaft Removal & Installation Section 10

Placing Parts Orders Section 2

Hydraulic and Electrical Schematics Section 11

Reference Material Section 12

Machine Serial Numbers Section 13

Towing Instructions Section 14

Container Unloading Operation Instructions Section 15


Section

1 Warranty




Section

2 Placing Parts Orders


PLACING PARTS ORDERS FOR: Diamond Products Grinding & Grooving Equipment

CALL: 1‐800‐225‐0142

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, 2nd 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 ServiceRepresentative.

Your Company Name, address, phone and email address,list of items for repair, RGA#, Explanation of repair(s)needed, Original Invoice (Warranty Only)


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 fromour 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 83687

12/7/17 jka


Section

3 Safety


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.

CAUTION Mild and/or moderate injuries 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).


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.


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 well-ventilated.

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


.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.


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.


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.



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Section

4 Operator Orientation


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.


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 4504. 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, 4504. 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 1200‐1500. 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 1200‐1500. Return to operator seat and start main engine. Follow same starting procedure as above for front engine including E‐Stop test.


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


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.


Grinder/Groover Operator Orientation:

Signature: ___________________ Print Name: ___________________ Date: __________













Diamond Products

Representative:___________________ Print Name: ___________________ Date: __________

Diamond Products


Diamond Products


Diamond Products



Section

5 Daily Equipment Inspection


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.


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.


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.


Section

6 Lubrication and Maintenance


99 1364 "

ITEM # LUBRICATION SCHEDULE1 WEEKLY 1-3 PUMPS2 WEEKLY 2-3 PUMPS3 8 PUMPS OR UNTIL VISIBLE GREASE, 12 HR4 *REFER TO MANUFACTURER INSPECTION PLATE

250 HOUR MAINTENANCEENGINE OIL VALVOLINE PREMIUM BLUE 15W-40OIL FILTERS FS19732/2504723AIR FILTER DONALDSON P537876 AND P537877

HYDRAULIC FILTER CHARGE PRESSURE FILTER 2705161, RETURN FILTER 2705083, HYDRAULIC TANK BREATHER 2703305

*PER MANUFACTURER RECOMENDATION

PC 1500 LUBRICATION SCHEDULE

B251 1

2 "RIGHT SIDE VIEW

LEFT SIDE VIEW

A

CF

D

BACK VIEWE


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*Do not attempt to perform maintenance, repair, or installation on machine until the machine and engine are stopped and secured.

FRONT BOGEY

RIGHT SIDE VIEW

ITEM # LUBRCATION SCHEDULE1 WEEKLY 1-3 PUMPS

LEFT SIDE VIEW

1

DETAIL ASCALE 1 : 10

1

1

1

1

DETAIL BSCALE 1 : 10

1 1

1


DEPTH CONTROL ASSEMBLY

CLUTCH

ITEM # LUBRICATION SCHEDULE1 WEEKLY 1-3 PUMPS2 WEEKLY 2-3 PUMPS4 *REFER TO MANUFACTURER

INSPECTION PLATE*PER MANUFACTURER RECOMENDATION

2DETAIL C

SCALE 1 : 8

1

2

2

2

4

DETAIL DSCALE 1 : 8


SLURRY PUMP

BLOWER GREASE BLOCK

ITEM # LUBRICATION SCHEDULE1 WEEKLY 1-3 PUMPS3 8 PUMPS, 12 HR OR UNTIL VISIBLE GREASE

*PER MANUFACTURER RECOMENDATION

DETAIL ESCALE 1 : 8

1

1

DETAIL FSCALE 1 : 4

3


FILL LEVEL

DRAIN

BOGEY

RIGHT ANGLE DRIVE

DRAINDRAIN

FILL

FILL


AIR CLEANER

OIL

FUEL/WATER FILTERDIPSTICK

FUEL

ENGINE LEFT SIDE VIEW

ENGINE RIGHT SIDE VIEW COOLANT


DAILY MAINTENANCEI *DEMISTER CLEANII *LOBSTER POT CLEANIII *SEPARATOR CLEANIV *WATER FILTER CLEANV *TRASH PUMP DRAINVI *SPRAY BAR

AND TIPS CLEAN

*AS OFTEN AS REQUIRED

PC 1500 DAILY MAINTENANCE

J

VI

DETAIL JSCALE 1 : 18

I

VIVIII

II


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Check front pivot bolts tension daily

FILTERS

Cummins Engine 6.7L RGT Oil Filter LF3970 / 2705851 Fuel Filter FF5421/2705852

Fuel/Water Filter FS19732 / 2504723

Vacuum System Demister Element 2504421

Blower Filter Element 2703566

Hydraulic System High Pressure Filter 2705161

Return Filter 2705083Hydraulic Tank Breather 2703305

In-tank Debris Filter 2703956

Right Angle Drive Lube System Lubrication Filter 2704752

Water System Water Filter 2703907

OILS & LUBRICANTS Hydraulic Oil Tellus 68

Trash Pump Transmission SAE 80/90 EP Gear Oil Engine Oil Valvoline Premium Blue 15W-40

Engine Coolant Fleetguard 50/50 Pre-Mix Blower AEON PD Synthetic Blower Lube

Drive Wheel Gearboxes Shell Omala Oil F220 or HD220 Blade Shaft Bearings Lubriplate EMB

General Chassis Joints & Pivots Lubriplate EMB Torque Hubs SAE 75/90, First 500 Hours then

every 1000 hours


2504777 POLY CHAIN SPROCKET 50 TEETH 1

2504778 TAPER LOCK 2

7600100 POLY CHAIN SPROCKET IDLER 1

2504776 POLY CHAIN SPROCKET 43 TEETH 1

2704281 TAPERED SLEEVE ADAPTER 3

2703881 LABRINTH SEAL 6

7600300 EXPULSION SEAL 3

2504324 HEAD BEARING 3

7600142 VACUUM BOX REAR SKIRT 1

7800093 HEAD BEARING HOUSING 3

2504610 SPRAY BAR NOZZLES 80/30 2

7600141 VACUUM BOX FRONT SKIRT 1

7800141 VACUUM BOX TOP HAT 2

2502263 SPRAY BAR NOZZLES 80/15 25

2504775 HEAD DRIVE POLY CHAIN BELT 1

2704592 BLOWER BELTS 2

2705409 WATER FILTER BASKET 1

2706553 PUMP DRIVE POLY CHAIN BELT 1

2502343 3" SLURRY PUMP WOODRUFF KEY 1

3001226 3" SLURRY PUMP STEP KEY 1

2502338 3" SLURRY PUMP 5/8 PINION GEAR 1

2502340 3" CONNECTING ROD BEARING 1

2705799 3" SLURRY PUMP FLAP VALVE WEIGHT 2

2504050 3" SLURRY PUMP DIAPHRAGM 1

2504051 3" SLURRY PUMP BLACK FLAP VALVE 2

2703900 3" SLURRY PUMP FLAP VALVE WEIGHT 2

2502342 3" SLURRY PUMP CONNECTING ROD 1

2504410 3" SLURRY PUMP RED FLAP VALVE 2

2703566 LOBSTER POT FILTER 1

2504421 DEMISTER FILTER WITH LID 1

2703320 RAISE/LOWER WHEEL BEARING 4

7600380 DRIVE TIRES 2

PC1500 SPARE PARTS

2502253 4RAISE/LOWER TIRE

RAISE/LOWER WHEEL

7100090 4

7600028 4

RAISE/LOWER WHEEL ASSEMBLY

2505234 6

2502259 6DEPTH CONTROL WHEEL SPANNER

DEPTH CONTROL WHEEL BEARING

PART#

2505135

QUANITY

6

7100091 6

DEPTH CONTROL WHEEL

DEPTH CONTROL WHEEL ASSEMBLY

DESCRIPTION


Maintenance Requirements:

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Change the transmission oil after the first 40 hours of operation.Use SAE 80/90 EP gear oil. Capacity is 20 oz. (550 ml, 1 ¼ pints). Fill with oil to the oil level plug located in the transmission cover. Check the oil level daily before beginning pump operation.

Change the transmission oil every 400 hours of operation after the initial (40 hour) oil change. Every 25 hours of operation, grease the pump connecting rod bearing by accessing it through the connecting rod guard. Keep the interior of the pump and the valves clean. Flush the pump out with clean water after each use.Remove the pump connecting rod bearing occasionally and clean the excess grease from the pump connecting rod bearing.

Changing a Diaphragm:

1. Rotate the pump connecting rod to the down position by rotating the crank arm with a large wrench.2. Remove the four bolts that clamp the diaphragm between the pump frame and the water box.3. Remove the three nuts from the bolts that clamp the diaphragm between the connecting rod and the

diaphragm bottom plate.4. Install the new diaphragm onto the bolts and diaphragm bottom plate.5. Using a pipe spacer over the bolts, drive the diaphragm down into position on the diaphragm bottom

plate.6. Install the diaphragm and diaphragm bottom plate assembly onto the connecting rod.7. Tighten the three nuts and torque:

a. For 2” Pumps: 34-40N-m (25-30lb/ft)b. For 3” Pumps: 45-54N-m (35-40lb/ft)

8. Center the diaphragm carefully over the water box and clamp with four bolts to the pump frame.9. Tighten the bolts in a crossing pattern and torque:


Changing Flap Valves:

1. Remove the suction connection, discharge connection, and flap valves.2. Install the weight and binder plates on the new flap valve.

a. Use a thread-sealing compound on the screws.b. Tighten the screws firmly but make sure they do not distort the rubber, which would cause poor

seating.3. Install the flap valves on the valve seat of the water box and suction connection with the binder (the

smaller plate) facing down into the hole.4. Locate the flap valves on the dowel pins in the suction connection and on the water box.5. Reassemble the suction and discharge connections to the water box.6. Tighten the bolts and torque:


4 5400-6400 Electric & Without Power

3" SLURRY PUMP


D--9--611 Page 10

SECTION 3LUBRICATION

All DuroFlow blowers are splash oil lubricated at boththe gear and drive ends. Oil is distributed around thegear housing and drive end chamber by the gears andspecially designed oil flingers.

Series Vertical HorizontalOil Fill Ports Mounting Mounting

One Port --45 Shaft & Gear Ends 29 oz. 55 oz.

Interconnected

FIGURE 3--1 -- APPROXIMATE OIL CAPACITIES

RECOMMENDED LUBRICANT

The factory recommended lubricant is AEON PDSynthetic Lubricant. AEON PD is formulatedespecially for positive displacement blowers to providemaximum protection at any temperature. One filling ofAEON PD will last a minimum of 4 times longer than apremium mineral oil, depending on actual operatingconditions. AEON PD contains a special additivepackage designed for greater rust and corrosionprotection.

AEON PD Lubricant

Description Part Number

1 Quart 28G23Case/12Quarts 28G245 Gallon Pail 28G2555 Gallon Drum 28G28

AEON PD Food Grade Lubricant

Description Part Number

1 Quart 28H97Case/12Quarts 28H985 Gallon Pail 28H9955 Gallon Drum 28H100

FIGURE 3--2 -- AEON PD SYNTHETIC LUBRICANT

LUBRICATION INSTRUCTIONS

For 45 series models, the oil fill port is located on thetop of the blower at the driveshaft end (seeFIGURE 1-- 2, page 5). The two oil sumps areconnected by a passageway through the housing

Addoil until the level stabilizes at the center of thesight-glass(es). Oil level at the sight glass must beestablished when the blower is not operating.

Add fresh oil as required to maintain proper level.

Do not overfill as this will tend tocause excessive heating of the gears,oil to leak through the vent holes, andmay damage the unit.

AEON PD Synthetic Lubricant should be drained after6000 hours of operation. Re--fill with fresh AEON PDoil. If mineral oil is used, perform the above oil--changemaintenance every 1500 hours. Recommendedservice intervals are for normal blower operating condi-tions. Severe operating conditions may warrant morefrequent oil changes. Laboratory analysis of lubricantshould be used to help determine the optimum oilchange interval.

For best performance and equipment protection, useAEONPDSynthetic Lubricant, which has been specifi-cally formulated for positive displacement blowers. Ifyou choose not to use AEON PD Synthetic BlowerLubricant, select an oil with rust and oxidation inhibi-tors, anti--foam additives, and the viscosities listed inFIGURE 3--3, page 12. Do not use an oil thatcontains EP additives.


D--9--611 Page 16

SECTION 5MAINTENANCE AND TROUBLESHOOTING

Your DuroFlow blower has been designed, manufac-tured and tested to precise specifications. EveryDuroFlow blower is backed by over 70 years of provenperformance in the most demanding applications thatmodern industry can produce. DuroFlow blowers havebeen designed specifically for long, trouble--freeservice. Minimal maintenance is required to keep yourDuroFlow blower in top operating condition. Yourattention to the following key points will insure years ofdependable DuroFlow blower performance.

Key Points for Long Blower Life

1. Use AEON PD Synthetic Blower Lubricant toassure maximum blower protection.

2. The oil level must be checked periodically.

3. Drain and refill the blower with fresh AEON PDLubricant every 6000 hours of operation, 1500hours if using mineral based lubricant.

4. Clean the breather filters at every oil change ormore often if dust conditions are severe.

5. Service the intake and in--line filters regularly tomake sure that air flow restriction does not occurand that foreign material does not enter theblower.

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 andmanufactured, there may be times when servicing willbe required due to normal wear, the need foradjustment, or various external causes. Whenever

equipment needs attention, the operator or servicetechnician should be able to locate the cause andcorrect the trouble quickly by following the Trouble-shooting Chart given below:

PROBLEM POSSIBLE CAUSES SOLUTION

1. Unit out of time. 1. Retime rotors. (See page 18.)

2. Distortion due to improper 2. Check mounting alignment andmounting 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. Checksheave set

3. Plugged filter or silencer. 3. Remove cause of obstruction.

4. Excessive pressure differential. 4. Reduce pressure differentialacross 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.

Knocking andexcessivemechanical noise.

Excessive blowertemperature.


1. TypeIn normal applications use an extreme pressure lubricant API-GL-5 approved.AGI recommends SAE 80W, 90, 80W-90 and 85W-90 grades of lube undernormal climate and operating conditions. See chart below. For severe orabnormal applications with special requirements consult either Auburn Gearor a lubricant manufacturer for further assistance.

2. Change IntervalInitial lubrication change after 50 hours of operation. Subsequent changesevery 1000 hours or yearly whichever comes first.

3. Lube TemperatureContinuous operating temperatures of 160°F are allowable. Maximumintermittent temperature recommended is 200°F.

4. Amount of LubeThe unit should be half full when mounted horizontal. Lube levels for othermounts will vary. Consult Auburn Gear for details.

5. Shaft or Spindle Up MountingIf mounting unit vertically with shaft or spindle up, special provisions applyto ensure adequate lubrication of output bearings. Consult Auburn Gear.

Lubrication DataPower Wheel Planetary Drives are shipped without lubricant and must be filled to the proper level prior to start-up.

15

Auburn Gear Power Wheel Low Temperature Gear Lube Requirement

* Maximum temperature for Brookfield Viscosity1 of 150,000 centipoise (cP)2 per SAE J306 MAR851 Brookfield Viscosity - apparent viscosity as determined under ASTM D 29832 150,000 cP determined to provide sufficient low temperature lube properties for Auburn Gear Power Wheels

SAEViscosity Grade

75W-90

80W, 80W-90

85W, 85W-90

90

Auburn GearRecommended Minimum Temperature

-40°F (-40°C)*-15°F (-26°C)*10°F (-12°C)*

35°F (2°C)


Section

7 Controls Overview


17

PC1500 CONTROL BOX

21

22

20

6

7

8

19

9

3

4

5

2

1

10

11

12

13

14

15

16

18


PC1500 CONTROL BOXITEM # DESCRIPTION NOTE

1 Engine Screen2 THROTTLE ON/OFF3 SPEED CONTROL

INCREASE/DECREASE4 IDLE INCREASE/DECREASE5 DIAGNOSTIC ON/OFF6 IGNITION SWITCH7 INDICATOR LIGHT STOP8 INDICATPR WARNING

LIGHT9 INDOCATOR LIGHT WAIT

10 UTILITY LIGHT11 SLURRY PUMP ON/OFF

12 BEACONS, FLASHERS, WORK LIGHTS ON/OFF

13 WATER ON/OFF 14 BRAKE ON/OFF BRAKE MUST BE ON TO

START ENGINE15 TRAVEL/GRIND HI/ GRIND

LOW

16 LEFT DEPTH UP/DOWN RAISE/LOWER LEFT DEPTH CONTROL WHEELS

17 MAIN FRAME UP/DOWN

18 RIGHT DEPTH UP/DOWN RAISE/LOWER RIGHT DEPTH CONTROL WHEELS

19 WATER PRESSURE GAUGE20 FUEL LEVEL SENSOR21 E-Stop22 OPERATOR SCREEN


GAUGE PANEL

ITEM # DESCRIPTION1 SYSTEM PRESSURE GAUGE

2 DRIVE PRESSURE GAUGE

3 CHARGE PRESSURE GAUGE

4 LUBE OIL PRESSURE GAUGE

ITEM # DESCRIPTION1 SYSTEM PRESSURE GAUGE

2 DRIVE PRESSURE GAUGE

3 CHARGE PRESSURE GAUGE

4 LUBE OIL PRESSURE GAUGE

2

3

1

4


ITEM # DESCRIPTION

1 FORWARD/NEUTRAL LOCKED/ REVERSE JOYSTICK

2 LIFT/LOWER MAIN FRAME SWITCH

ITEM # DESCRIPTION

1 FORWARD/NEUTRAL LOCKED/ REVERSE JOYSTICK

2 LIFT/LOWER MAIN FRAME SWITCH

A

DETAIL A

2

SCALE 1 : 3

1

OPERATOR SEAT CONTROLS


Section

8 Basic Operation Instructions


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


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 10‐15 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.


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.


Section

9 Blade Shaft Speeds



Section

10 Blade Shaft Removal & Installation



Section

11 Hydraulic and Electrical Schematics


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Section

12 Reference Material


BLOWER

30WSYN

250‐500 HOURS 1000HRS 500HRS

BLADE SHAFT TIE BOLTS TORQUE TO 180 FT LBS

BLADE SHAFT HEAD BEARING BOLTS 5/8" X 3"

P537877

OIL FILTER

LF3970

FUEL FILTER PRIMARY

FF5421

FUEL SEPERATOR

WATER FILTER BASKET CLEAN DAILY & THROUGH OUT SHIFT

VACUUM HEAD BOX INSPECT AND CLEAN DAILY

VACUUM SEPERATOR CLEAN & INSPECT DAILY

DRAIN ALL WATER LINES

LEAVE WATER BALL VALVE PARTIALLY OPEN

SPRAY BLOWER LOBES WITH LITE OIL & RUN FOR 30 SECONDS

CHECK FLUIDS DAILY (ENGINE OIL,HYDRAULIC OIL, COOLANT)

FS19732

DP# SERVICE PARTS CUMMINS #

2703305 RETURN FILTER

2703305 HYDRAULIC TANK BREATHER

2504508 HEAD DRIVE BELT

DEMISTER FILTER WITH LID

2704592 VACUUM BELTS

2706897 CHARGE FILTER‐GROUND DRIVE PUMP

PC1500 REFRENCE CHARTGROUND DRIVE PUMP: SET PSI 2700

RIGHT ANGLE LUBE PUMP: 100 PSI

GREASE SCHEDULE

TRASH PUMP 2 PUMPS DAILY

AUXILIARY PUMP: SET 1800 PSI

AIR FLITER PRIMARY

P537876

AIR FILTER SAFETY

HEAD BEARINGS 8 PUMPS EVERY 10HRS

2703566 LOBSTER POT FILTER

FRONT BOGEY GREASE POINTS 5 PUMPS DAILY

DEPTH CONTROL WHEEL GREASE POINTS 3 PUMPS WEEKLY

BLOWER GREASE 2 PUMPS MONTHLY

WINTERIZING

DRAIN BOWL AT TRASH PUMP

DAILY WASH OUT MAINTENANCE

DEMISTER FILTER & HOUSING WASH OUT DAILY

CLEAN SPRAY BAR NOZZLES DAILY PRIOR TO SHIFT AND INSPECT THROUGH OUT SHIFT

CLUTCH TOP GREASE POINTS EVERY 10HRS: LOWER GREASE POINT EVERY 100HRS

TRASH PUMP FLUSH DAILY

LOBSTER POT FILTER & HOUSING WASH OUT DAILY

2504421

7600142 VACUUM BOX REAR SKIRT

2504410 FLAP VALVE

2504050 DIAPHRAGM

7600141 VACUUM BOX FRONT SKIRT

R.A.D&DRIVE HUBS :TRASH PUMP

1000HRS

HYDRAULIC SERVICE

75W/90 SYN: 30WSYN

OIL‐1000HRS: FILTERS 500HRS

CHECK ANTI‐FREEZE/CONDITION & CONTACT LOCAL ENGINE DEALER FOR FUTHER QUESTIONS

ENGINE SERVICE

15W‐40 ISO68


WIRE# FUSE

101 10AMP

102 3AMP

103 3AMP

104 3AMP

105 3AMP

106 3AMP

107 3AMP

108 3AMP

109 3AMP

110 3AMP

111 3AMP

112 3AMP

113 3AMP

301 10AMP

303 7.5AMP

303 7.5AMP

303 7.5AMP

303 7.5AMP

303 7.5AMP

302 7.5AMP

302 7.5AMP

302 7.5AMP

FWD

REV

101

101

1 4

2 3

85 30

86 87

MAIN FRAME UP

MAIN FRAME DOWN

PC1500 ELECTRICAL 24 VOLT

RED

BROWN

BATTERY SUPPLY +

WIRE COLOR

YELLOW LEFT DEPTH UP

YELLOW/STRIPE LEFT DEPTH DOWN

BLUE RIGHT DEPTH UP

BROWN/STRIPE

WHITE BRAKE

LITE GREEN 2‐SPEED

WATER ALARM

ORANGE BACK‐UP ALARM

RED LIGHT POWER +

BLUE/STRIPE RIGHT DEPTH DOWN

VIOLET WATER VALVE

PINK TRASH PUMP

GROUND

SIGNAL

LIGHT RELAY

DESCRIPTION

TAN/STRIPE REVERSE SIGNAL

RED BATTERY SUPPLY +

RED BATTERY SUPPLY +

ORANGE/STRIPE BEACON/STROBE


TAN FORWARD SIGNAL

BLACK/STRIPE WORK LIGHT

WORK LIGHT



BROWN

DO NOT CHANGE OR ALTER ELECTRICAL SYSTEM

GROUND

SIGNAL

BATTERY SUPPLY

FUSE SUPPLY

SYSTEM RELAY

FUSE SUPPLY

BATTERY SUPPLY



BLACK/STRIPE


CHAIN UP

CHAIN UP

CHAIN UP CHAIN UP

WINCHING EYE

PC 1500 CHAIN POINTS


Section

13 Machine Serial Numbers


PC1500 Serial Number Plate:

Item # Description1 Machine Model #2 Machine Serial Number3 Engine Serial Number4 Manufacture Date (month/year)5 Manufacture Location6 Toll Free Number for Parts and Service


KPolito

Callout

1

KPolito

Callout

2

KPolito

Callout

3

KPolito

Callout

4

KPolito

Callout

5

KPolito

Callout

6

B

A

DET

AIL

ASC

ALE

1 :

16M

AC

HIN

E SE

RIA

L N

UMBE

R PL

ATE

LO

CA

TED

ON

FRA

ME

DET

AIL

B

MA

CHI

NE

SERI

AL

NUM

BER

PLA

TE

LOC

ATE

D IN

SID

E FU

SE B

OX

PC1500 Serial Number Plate Locations:


FRO

NT

AN

D R

EAR

POW

ER W

HEEL

OR

TORQ

UE U

BTO

RQUE

HUB

DEP

TH C

ON

TRO

L M

OTO

R RI

GHT

STEE

RIN

G C

YLIN

DER

GEA

RBO

X A

ND

FUN

CTIO

N

MA

NIF

OLD

CO

OLE

RS

RIG

HT L

IFT

LOW

ER

CYL

IND

ER

FUN

CTIO

N

PUM

PFR

ON

T A

ND

REA

R D

RIV

E M

OTO

R

BLO

WER

GRO

UND

DRI

VE

PUM

PTWIN

DIS

K C

LUTC

H

DEP

TH C

ON

TRO

L M

OTO

R LE

FTLE

FT L

IFT/

LOW

ER

CYL

IND

ER

SLUR

RY

PUM

PEN

CO

DER

PC1500 Component Serial Number Plate Locations:


PC1500 Serial Numbers:

Manufacture Date: _________________

Serial #:_________________

Engine Serial #:_________________

Front Power Wheel or Torque Hub Serial #’s: _________________

Rear Power Wheel or Torque Hub Serial #’s: _________________

Front Drive Motor Serial #:_________________

Rear Drive Motor Serial #:_________________

Blower Serial #:_________________

Function Pump Serial #:_________________

Ground Drive Pump Serial #:_________________

Right Angle Drive Assembly #: _________________

Twin Disk Serial #: _________________

Depth Control Motor Right Serial #: _________________

Depth Control Motor Left Serial #: _________________


Steering Cylinder Serial #: _________________

Gearbox Cooler Serial #: _________________

Function Manifold Cooler Serial #: _________________

Gear Box Cooler Serial #: _________________

Left L/L Cylinder Serial #: _________________

Right L/L Cylinder Serial #: _________________

Slurry Pump Serial #: _________________

Steering Motor Serial #: _________________

Slurry Pump Motor Serial #: _________________

Encoder Serial #: _________________


Section

14 Towing Instructions


PC1500 Towing Instructions

Towing if engine is running when Grinding and Grooving: 1. Place joystick in center neutral position2. Raise machine until blade shaft is off the ground3. Switch engine off4. Use chocks to stop machine rolling away5. Disengage the clutch (See detail A, Image 3)

Remove disengagement cap on power wheel or torque hub, flip it over and reinstall it to put machine into neutral (See detail B and Image 1, Image 1A, and Image 1B) Warning: Flipping the disengagement cap disable’s the parking brake

6. Start engine to work hydraulic steering7. Use a towing bar to move machine to safe position8. Use chocks to prevent machine from rolling away9. Remove disengagement cap on power wheel or torque hub, flip it over and reinstall it to take

machine out of neutral (See detail B and Image 1, Image 1A, and Image 1B)10. Remove the towing bar

Towing if engine not running when grinding: 1. Place joystick in center neutral position (See Diagram 1)2. Use chocks to stop machine rolling away3. Disengage the clutch (See detail A, Image 4), the machine will roll on the blade shaft

Remove disengagement cap on power wheel or torque hub, flip disengagement cap over and reinstall it to put machine into neutral (See detail B and Image 1, Image 1A, and Image 1B) Warning: Flipping the disengagement cap disable’s the parking brake

4. Steering will be heavy and require more effort5. Use a towing bar to move machine to safe position6. Use chocks to prevent machine from rolling away7. Remove disengagement cap on power wheel or torque hub, flip it over and reinstall it to take


Towing if engine not running when grooving: 1. Place joystick in center neutral position (See Diagram 1)2. Use chocks to stop machine rolling away3. Disengage the clutch (See detail A, Image 4)4. Adjust grooving legs until blade shaft is off the ground

WARNING Equipment is not designed to be towed. Towing is only to be done if machine has lost power and must be removed from work site. Never attempt to tow on uphill or downhill grade.


Remove disengagement cap on power wheel or torque hub, flip disengagement cap over and reinstall it to put machine into neutral (See detail B and Image 1, Image 1A, and Image 1B) Warning: Flipping the disengagement cap disable’s the parking brake

5. Steering will be heavy and require more effort6. Use a towing bar to move machine to safe position7. Use chocks to prevent machine from rolling away8. Remove disengagement cap on power wheel or torque hub, flip it over and reinstall it to take


*NOTE: Maximum towing speed is 1MPH, tow to nearest safe location.


Joys

tick

DIA

GRA

M 1

A

Tow

poi

nt

B

DET

AIL

ASC

ALE

1 :

16

DIS

ENG

AG

E C

LUTC

H

IS O

FF T

HE G

ROUN

DUN

TIL B

LAD

E SH

AFT

LO

WER

WHE

ELS

AD

JUST

GRO

OV

ING

LEG

S UN

TIL

BLA

DE

SHA

FT IF

OFF

GRO

UND

DET

AIL

BSC

ALE

1 :

16

REM

OV

E D

ISEN

GA

GEM

ENT

CA

P, F

LIP

IT O

VER

A

ND

REI

NST

ALL

IT T

O

PUT

INTO

NEU

TRA

L



KPolito

Callout

Remove disengagement cap, flip it over and reinstall to put power wheel or torque hub into neutral

KPolito

Text Box

Image 1

KPolito

Line

KPolito

Text Box

Power Wheel

KPolito

Text Box

Torque Hub

KPolito

Text Box

Image 1A

KPolito

Text Box

Image 1B


KPolito

Text Box

Image 2

KPolito

Callout

Raise machine until blades are off ground

KPolito

Callout

Disengage clutch

KPolito

Rectangle

KPolito

Text Box

Image 3

Section

15 Container Unloading Operation Instruction


1803549


5

1

3

24

6

DIA

GRA

M #

1: P

C 1

500 ITE

M #

DES

CRI

PTIO

N1

BATT

ERY

MA

STER

SW

ITCH

2O

PERA

TOR

SEA

T3

OPE

RATO

R PA

NEL

4RE

MO

VE

PIN

AN

D P

OSI

TION

SEA

T5

REM

OV

E PI

N A

ND

PO

SITIO

N P

AN

EL

6LI

FT/L

OW

ER W

HEEL

S

ITEM

#D

ESC

RIPT

ION

1BA

TTER

Y M

AST

ER S

WITC

H2

OPE

RATO

R SE

AT

3O

PERA

TOR

PAN

EL4

REM

OV

E PI

N A

ND

PO

SITIO

N S

EAT

5RE

MO

VE

PIN

AN

D P

OSI

TION

PA

NEL

6LI

FT/L

OW

ER W

HEEL

S

1803550


DIAGRAM # 2: OPERATOR PANEL

ITEM # DESCRIPTION1 BRAKE SWITCH

2 GRIND HI/LOW SWITCH

ITEM # DESCRIPTION1 BRAKE SWITCH

2 GRIND HI/LOW SWITCH

1

2

1803551


CONTAINER

TOP VIEW

304.8012"

POSITION TO ENGAGE RAISE/LOWER TIRES.MOVE RAMPS TOGETHER FOR FRONT TIRES

DIAGRAM #3: CONTAINER RAMP:

SIDE VIEW

RAMP

60"1524 177.80

7"

CONTAINER FLOOR IS APPROXIMATLY

CONTAINER

7" (177.8mm) OFF OF GROUND LEVEL

RAMP

RAMP

*NOTE: RAMP NOT PROVIDED,MAKE OUT OF WOOD

1803552


DIAGRAM # 4: RAMP DIMENSIONS

* RAMP NOT INCLUDED,MAKE RAMP OUT OF WOOD

SIDE VIEW

7"177.80

152460"

TOP VIEW

304.8012"

1803553


1

22

1

DIAGRAM # 5: PC 1500 UNLOADING ILLUSTRATION

ITEM # DESCRIPTION1 LIFT/LOWER WHEELS2 RAMP

STEPS 1-12:

STEPS 13:

SLOWLY BACK MACHINE TO EDGE OF CONTAINER

POSITION RAMPS TO ALIGN WITH LIFT LOWER

TIRES

1

1803554


STEP 14:

2WHEN LIFT LOWER TIRES ARE OFF RAMP

REPOSITION RAMPS TO ALIGN WITH FRONT TIRES

2 2

RAMPS PUSHED TOGETHER FOR FRONT TIRES


1803555


KPolito

Callout

ITEM # 4: PIN

KPolito

Text Box

ITEM # 5: PIN LOCATED ON UPPER FRAME

KPolito

Typewritten Text

KPolito

Text Box

PHOTO # 1

1803556


KPolito

Text Box

PHOTO # 2 FORWARD/REVERSE JOYSTICK

KPolito

Callout

ITEM #1: ROCKER SWITCH

1803557


KPolito

Text Box

PHOTO # 3

Documents

DIAMOND PRODUCTS PC1504 · Operation Parts and Service Manual DIAMOND PRODUCTS PC1504 Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher Rd • Nampa