DIAMOND PRODUCTS PC6004EC Serial Number · Machine Start Up DIAMOND PRODUCTS PC6004EC Serial Number: Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher

Machine Start Up

DIAMOND PRODUCTS

PC6004EC Serial Number:

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

Phone Toll Free 800.225.0142Fax 208-899-8111

DOCUMENT #: 1803633 Page 1 of 32 LAST UPDATE: 3/26/18 DATE PRINTED: 3/26/18

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.


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.



KPolito

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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/demonstrateadjustment and purpose.

17. Check profile wheel raise/lower function and purpose. Discuss/demonstrate settingthe 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 last page.


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.


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.


APIVOT PIVOT

LEFT SIDE VIEWTANK SLIDE

FRONT VIEW

RIGHT SIDE VIEW

B

WATER TANK

BLOWER

FUEL TANK, DIESEL

ENGINE, Q5X 15LTORQUE HUBS TRANSFLUID CLUTCH

QSB 4.5L

SILENCERDEMISTER

ENGINE,

RIGHT ANGLE DRIVE

PC6000 LUBRICATION SCHEDULE

ITEM # LUBRICATION SCHEDULE1 DAILY 2-3 PUMPS2 DAILY 2-53 DAILY 15-20 PUMPS4 WEEKLY 5 PUMPS5 WEEKLY 1-2 PUMPS6 MONTHLY 1 PUMPS

*REFER TO OWNERSMANUAL FOR ENGINE, GEARBOX, TRANSFLUID CLUTCH, AND BLOWER MAINTENANCE

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

*Check all pivot point bolts daily


KPolito

Sticky Note

Unmarked set by KPolito

6

LEFT SIDE

3

DEPTH CONTROL ASSEMBLY

DETAIL ASCALE 1:16

BLADESHAFT BEARINGS

ITEM # LUBRICATION SCHEDULE1 DAILY 2-3 PUMPS2 DAILY 2-5 PUMPS3 DAILY 15-20 PUMPS4 WEEKLY 5 PUMPS5 WEEKLY 5 PUMPS6 MONTHLY 1 PUMPS

DETAIL BSCALE 1:12

SLURRY PUMPSLURRY PUMP

RIGHT SIDE

36


1

RIGHT SIDE

1 1

1

BOGEY STEERING

ITEM # LUBRICATION SCHEDULE1 DAILY 2-3 PUMPS2 DAILY 2-5 PUMPS3 DAILY 15-20 PUMPS4 WEEKLY 5 PUMPS5 WEEKLY 1-2 PUMPS6 MONTHLY 1 PUMPS

1

1

1

FRONT

1

1

LEFT SIDE

1 1


OPERATOR ASSEMBLY

ITEM # LUBRICATION SCHEDULE1 DAILY 2-3 PUMPS2 DAILY 2-5 PUMPS3 DAILY 15-20 PUMPS4 WEEKLY 5 PUMPS5 WEEKLY 1-2 PUMPS6 MONTHLY 1 PUMPS

5

5

5

5

*APPLIES TO BOTH SIDES OF THE MACHINE

5

DETAIL CSCALE 1:12

C


PC6000 MAINENANCE, DAILY OR MORE OFTEN AS NEEDED

DAILY MAINTENANCEI *DEMISTER CLEANII *LOBSTER POT CLEANIII *WATER FILTER CLEANIV *SPRAY BAR AND

TIPS CLEANV *SLURRY PUMP CLEANVI *SEPERATOR CLEAN

*REFER TO OWNERS MANUALFOR ENGINE, GEAR BOX, TRANSFLUID CLUTCH, AND BLOWER MAINTENANCE

*REFER TO OWNERS MANUALFOR ENGINE, GEAR BOX, TRANSFLUID CLUTCH, AND BLOWER MAINTENANCE

II

V

III

I

VI

IV

*CLEAN SILENCER AS NEEDED

*Before cleaning the machine withwater or any other cleaner, cover up/seal off all opening which water are 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.


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 ManualTrailer Axels Refer to manual

Cummins QSX 15L Refer to manual

Cummins QSB 4.5L Refer to manual

De‐Mister Element 2504421Blower Filter Element 2703380

Functions System Filter 2703304Ground Drive Pump 2706897

Water Filter 2703907

Water System

*CHANGE HYDRAULIC OIL EVERY 1000 HOURS

Recommended Oils, Lubricants, and FiltersOils & Lubricants

Engine Cummins QSX 15L Filters

Engine Cummins 4.5L Filters

Vacuum System

Hydraulic System


PC6000 Wear Parts for Operator to CarryITEM # PART # DESCRIPTION QTY

1 7100001 DEPTH CONTROL WHEEL ASSEMBLY 6

2 7100049 SLINGERS 2

3 2502448 HEAD BEARING 2

4 2703927 TAPPERED SLEEVE ADAPTER 2

5 2703312 LABYRITH SEAL 4

6 7600059 VACUUM BOX SIDE SKIRTS 2

7 7600066 VACUUM BOX FRONT & BACK SKIRTS 2

8 7800119 VACUUM BOX TOP HAT 2

9 2504092 POLY CHAIN HEAD DRIVE BELT 2

10 2703380 LOBSTER POT FILTER 1

11 2505160 4" SLURRY PUMP DIAPHRAGM 1

12 2706950 4" SLURRY PUMP RED FLAP VALVE 2

13 7600392 4" SLURRY PUMP FLAP VALVE WEIGHT 2



PC6000 Replacment and Wear Parts for Shop to CarryITEM # PART # DESCRIPTION QTY

1 7100001 DEPTH CONTROL WHEEL ASSEMBLY 6

2 2502225 DEPTH CONTROL WHEEL 6

3 2703320 DEPTH CONTROL WHEEL BEARING 6

4 2502222 DRIVE TIRE 8

5 7100347 HEAD BEARING ASSEMBLY 2

6 7100049 SLINGERS 2

7 7800001 BEARING HOUSING MODIFIED 2

8 2502448 HEAD BEARING 2

9 2703927 TAPPERED SLEEVE ADAPTER 2

10 2703312 LABYRITH SEAL 4

11 7600059 VACUUM BOX SIDE SKIRTS 2

12 7600066 VACUUM BOX FRONT & BACK SKIRTS 2

13 7800119 VACUUM BOX TOP HAT 2

14 7100045 HEAD DRIVE IDLER ASSEMBLY 2

15 2703393 IDLER SPROCKET 2

16 2504092 POLY CHAIN HEAD DRIVE BELT 2

17 2703396 HEAD DRIVE SPROCKET 50S 2

18 2703398 HEAD DRIVE SPROCKET 60S 2

19 2703361 HEAD DRIVE TAPER LOCK 1

20 2703380 LOBSTER POT FILTER 1

21 2504421 DEMISTER FILTER WITH LID 1

22 2705752 WATER FILTER BASKET 1

23 7100971 6" VACUUM HOSE 2

24 7100845 HOSE,2" X 100'L 1

25 7100847 HOSE, 2 1/2" X 100'L 1

26 2505160 4" SLURRY PUMP DIAPHRAGM 1

27 2505444 4" SLURRY PUMP PLUNGER ROD 1

28 2707641 4" SLURRY PUMP DIAPHRAGM PLATE 1

29 2706950 4" SLURRY PUMP RED FLAP VALVE 2



32 2504610 SPRAY BAR NOZZLES 80/30 4

33 2502263 SPRAY BAR NOZZLES 80/15 27




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 Service Representative.

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 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 83687 12/7/17 jka


Grinder/Groover Operator Orientation:

Signature: ___________________ Print Name: ___________________ Date: __________













Diamond Products

Representative:___________________ Print Name: ___________________ Date: __________

Diamond Products


Diamond Products


Diamond Products



Documents

DIAMOND PRODUCTS PC6004EC Serial Number · Machine Start Up DIAMOND PRODUCTS PC6004EC Serial Number: Diamond Products Limited Heavy & Specialty Equipment Operations 2016 East Karcher