Blue Diamond Drum Mulcher Operation And Maintenance Manual
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Blue Diamond Drum Mulcher Operation And Maintenance Manual

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  • Page 2 BLUE DIAMOND ATTACHMENTS liability for any defect with respect to accepted goods shall be limited to repairing the goods at a BLUE DIAMOND ATTACHMENTS designated location or at an authorized dealer location, or replacing them, as BLUE DIAMOND ATTACHMENTS shall elect. The above shall be in accordance with BLUE DIAMOND ATTACHMENTS warranty adjustment policies.

  • Page 3: Table Of Contents

    ......... .39 Drum Mulcher Operation and Maintenance Manual...
  • Page 4 ..............79 Drum Mulcher Operation and Maintenance Manual...
  • Page 5 ..........85 Drum Mulcher Operation and Maintenance Manual...
  • Page 6 Table Of Contents Drum Mulcher Operation and Maintenance Manual...

  • Page 7: Introduction

    Introduction Introduction Owner Information 7 Attachment Identification 9 Drum Mulcher Operation and Maintenance Manual...
  • Page 8 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 9: Owner Information

    The serial number plate [Figure 1] is located on Diamond assumes no responsibility for any errors the rear left side of the Drum Mulcher. that may appear in this manual and shall not be liable under any circumstances for incidental,...
  • Page 10 Introduction Figure 2 Hydraulic Motor Serial Number: Overhung Load Adapter Serial Number: Cutting Drum Serial Number: Drum Mulcher Operation and Maintenance Manual...

  • Page 11: Attachment Identification

    Introduction Attachment Identification Drum Mulcher PUSH BAR GATE CYLINDER GUARD MAINTENANCE CHAIN CASE ACCESS PANEL SKID PLATES GATE DRUM DRUM CUTTING ANVIL TOOTH DRIVE SYSTEM ACCESS PANEL FRAME MOUNTED STATIONARY ANVIL Drum Mulcher Drum Mulcher Operation and Maintenance Manual...
  • Page 12 Introduction GATE CYLINDER STEP ATTACHMENT MOUNTING FRAME RUBBER FLAP STEP MOTOR ACCESS PANEL CHAIN CURTAIN Drum Mulcher Operation and Maintenance Manual...

  • Page 13: Safety

    Safety Safety Safety Information 13 Drum Mulcher Operation and Maintenance Manual...
  • Page 14 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 15: Safety Information

    It may also be used to alert against unsafe practices. IMPORTANT The signal word IMPORTANT identifies procedures which must be followed to avoid damage to the machine. Drum Mulcher Operation and Maintenance Manual...

  • Page 16: Importance Of Safety

    The equipment must be used ONLY on ditches to prevent overturn. approved machines. • DO NOT modify the equipment in any way. Unauthorized modification may impair the function and/or safety and may void the warranty. Drum Mulcher Operation and Maintenance Manual...
  • Page 17 Tighten or replace any parts that show leakage. • Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents. Drum Mulcher Operation and Maintenance Manual...
  • Page 18 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 19: Operation

    Operation Operation General Information 19 Attachment Inspection 20 Attachment Installation 22 Operating The Attachment 25 Drum Mulcher Operation and Maintenance Manual...
  • Page 20 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 21: General Information

    Pre-Operation Inspection • Check for damaged or missing safety decals. Replace if necessary. Before operating the drum mulcher for the first time and each time thereafter, use the following • Inspect the machine’s mounting frame. (See list as a guideline during equipment inspection.

  • Page 22: Attachment Inspection

    SEE MACHINE’S OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION. • Check that the drum rotates freely. • Verify that the drum mulcher is properly NOTE: Inspect the attachment by performing a connected to the machine. walk around daily before and after use. •...

  • Page 23: Weekly Inspection

    • Clean debris from the compartment and drive components. • Inspect condition of drive belt cogs for wear and damage. NOTE: No play should be observed between the sprockets and respective shafts. Drum Mulcher Operation and Maintenance Manual...

  • Page 24: Attachment Installation

    1) and wedge mounts (Item 2) [Figure 3] and all SEE MACHINE’S OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION. welds on the drum mulcher for wear or damage each time the drum mulcher is removed from the machine. Park the machine / attachment on a flat level (See the machine's Operator’s Manual for...

  • Page 25: Connecting Hydraulic Hoses

    Engage attachment locking levers / wedges (See hydraulic hoses. the machine's Operator’s Manual for detailed information). Relieve auxiliary hydraulic pressure. (See the machine’s Operator’s Manual correct procedure.) Disconnect attachment hydraulic hoses from the machine. Drum Mulcher Operation and Maintenance Manual...

  • Page 26: Disconnecting Attachment From The Machine

    Enter the operator’s position. See “Entering The Operator’s Position” on page 22. Slowly tilt the machine’s mounting plate forward until the attachment mounting frame is free from the machine’s mounting plate. Drive the machine slowly backward, away from the attachment. Drum Mulcher Operation and Maintenance Manual...

  • Page 27: Operating The Attachment

    Drum Mulcher Operation and Maintenance Manual...

  • Page 28: Initial Setup

    Move to the operator’s position, lower seat bar, start the engine and release the parking brake. Hydraulic Gate Cylinder (Option) Raise the drum mulcher slightly off the ground to • Extend and Retract Lines allow the mulcher drum to rotate freely.

  • Page 29: Mulcher Functions

    The following is an overview of the Stopping the Drum Mulcher more common techniques. Position the drum mulcher slightly off the ground. Set the machine’s engine RPM to an idle, allow the drum mulcher to slow down, disengage the auxiliary hydraulic flow (see the machine’s...
  • Page 30 Make a first pass forward to shred the upper half of the tree diameter and then finish the lower diameter half on the reverse pass. Drum Mulcher Operation and Maintenance Manual...
  • Page 31 Place all controls in NEUTRAL. • Engage the park brake. • Wait for all moving parts to stop. • Relieve hydraulic system pressure. • Stop the engine and remove the key. SEE MACHINE’S OPERATOR’S MANUAL FOR ADDITIONAL INFORMATION. Drum Mulcher Operation and Maintenance Manual...
  • Page 32 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 33: Maintenance

    Maintenance Maintenance Service Schedule 33 Lubrication 34 Mulcher 35 Cleaning the Attachment 47 Troubleshooting 48 Drum Mulcher Operation and Maintenance Manual...
  • Page 34 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 35: Service Schedule

    Drum Mulcher Frame • • Weekly Maintenance (or every 40 hours) Overhung Load adapter Bearings • • Drive Belt • Sprockets • Cutting Drum • Push Bar • All Hardware • Compartments • Decals • Drum Mulcher Operation and Maintenance Manual...

  • Page 36: Lubrication

    Before servicing the Drum Mulcher: may occur. • Lower the machine’s lift arms and place the drum mulcher on flat, level surface. NOTE: Inspect the grease overflow port for signs of liquid overflow. Liquid grease streaks • Engage parking brake, stop engine, may be a sign of bearing overheating or remove the key and exit the machine.

  • Page 37: Mulcher

    ChippingTeeth AVOID SERIOUS INJURY OR DEATH Before servicing the Drum Mulcher: • Lower the machine’s lift arms and place the drum mulcher on flat, level surface. • Engage parking brake, stop engine, remove the key and exit the machine. •...

  • Page 38: Drive Belt

    Figure 13 5. Loosen both motor lock bolts [Figure 13]. Figure 11 2. Loosen both overhung locknuts [Figure 11]. Figure 14 6. Slide the motor / overhung assembly down and remove belt [Figure 14]. Drum Mulcher Operation and Maintenance Manual...
  • Page 39 Motor Lock Bolts: 140 ft lb (190 N·m) 2. Tighten the tension bolts to apply tension on the belt. d. Tension Bolt Locknut: light lock [Figure 16] 3. Tighten overhung lock bolts and check tension. Drum Mulcher Operation and Maintenance Manual...

  • Page 40: Sprocket

    11. Recheck all screw torque values after initial drive run in. Torque Specifications Bolts Torque Bushing Style Size ft-lb N•m 34 Teeth 1/2 x 13 x 1 35.8 50 Teeth 1/2 x 13 x 1 x 1/2 83.3 Drum Mulcher Operation and Maintenance Manual...

  • Page 41: Skid Plate

    1. Position the replacement skid plates on 6. Remove excess grease out of the housing. elevated blocks and lower the mulcher onto the skid plates. 2. Fasten together and torque to 218 ft-lb (296 N·m). Drum Mulcher Operation and Maintenance Manual...
  • Page 42 NOTE: Bearing spacers are only installed with the bearing on the drive belt side. The bearing on the opposite side has no spacers in the bearing housing. Drum Mulcher Operation and Maintenance Manual...
  • Page 43 12. Bend one of the daisy lock washer petals to indicative of a bad bearing or bad installation. lock the bearing locknut. 13. Torque the bearing housing fasteners to 174 ft- lb (236 N·m) with medium strength thread- locker. Drum Mulcher Operation and Maintenance Manual...

  • Page 44: Stub Shaft

    3. Remove all M16 fasteners off the stub shaft [Figure 25]. 4. Use two of the M16 fasteners with clean and lubricated threads to insert in the puller holes to separate the stub shaft flange away from the cutting drum. Drum Mulcher Operation and Maintenance Manual...

  • Page 45: Overhung Load Adapter (Ola) Bearing And Shaft Seal

    (OLA). 4. Remove the grease lines off the OLA case. 5. Remove both OLA slot fasteners. 6. Remove all 4 OLA wall fasteners to separate the overhung load adapter from the wall flange. Drum Mulcher Operation and Maintenance Manual...

  • Page 46: Drum Anvil

    Figure 29 Figure 30 1. Pack grease in the bearing. Fill the space in NOTE: Use Blue Diamond approved cutting teeth between the internal rollers on both sides of the and anvils. The replaced teeth must all be bearing then insert the bearing into the OLA of the same type and series to avoid case [Figure 29].

  • Page 47: Frame Mounted Stationary Anvil Removal And Replacement

    6. Lock the relief valve in position. 7. Adjust the machine pressure limiter 200 psi below the mulcher head relief valve. Follow the welding pattern illustrated [Figure 31]. Mig wire weld....0.45 Flux Core (AWS A5.29) Weld fillet size..........1/4” Drum Mulcher Operation and Maintenance Manual...

  • Page 48: Shift Pressure Adjustment

    One full turn of the adjusting screw changes the shift pressure by approximately 1305 psi (90 bar). d. Tighten adjusting screw locknut to 6 ft-lb (8 N·m). e. Maximum shift pressure: 4,350 psi (300 bar). Drum Mulcher Operation and Maintenance Manual...

  • Page 49: Cleaning The Attachment

    Before servicing the Drum Mulcher: damage. • Lower the machine’s lift arms and place the drum mulcher on flat, level surface. • Engage parking brake, stop engine, remove the key and exit the machine. • Disconnect attachment hydraulic hoses.

  • Page 50: Troubleshooting

    Turning Slow. mulcher or machine. Department. Debris build up between drum and Remove debris. frame. Belt and sprockets worn. Replace belt and sprockets. Noise in Drive Compartment. Belt tension not properly adjusted. Adjust belt tension. Drum Mulcher Operation and Maintenance Manual...

  • Page 51: Case Drain Pressure

    Install Hydraulic Motor Case Machine Hydraulic Design. setup properly for drum mulcher Pressure Protection Kit. causing pressure spikes. Machine has loop flush valve Disable the loop flush valve on the Excessive Case Drain Flow system. machine. Drum Mulcher Operation and Maintenance Manual...
  • Page 52 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 53: Parts

    Chain Curtain 53 Drum Mulcher 54 Cutting Teeth (Carbide) 56 Cutting Teeth (Chipping) 57 Debris Shield 58 Drive System 59 Drive System Access Panel 60 Gate, Hydraulic Cylinder 61 Grease Lines 62 Hydraulic Gate 63 Drum Mulcher Operation and Maintenance Manual...
  • Page 54 Push Bar 69 Relief Block 70 Rotating Drum, Left Side 71 Rotating Drum, Right Side 72 Skid Plates 73 Hydraulic Motor Case Drain Protection Kit (Option) 74 Serviceable Parts 75 Decal Identification And Location 76 Drum Mulcher Operation and Maintenance Manual...

  • Page 55: Chain Curtain

    Parts Chain Curtain ITEM DESCRIPTION PART # P30 Coil Welded Chain, ZP 5/16” 1900 lb. WLL 290151 Chain Curtain Rod 290152 Hose Fitting, 0103-4-4 Hose Fitting, 05CP6 290152 Drum Mulcher Operation and Maintenance Manual...

  • Page 56: Drum Mulcher

    Parts Drum Mulcher Drum Mulcher Operation and Maintenance Manual...
  • Page 57 Overhung Load Adapter Grease Lines SEE PAGE 68 Push Bar SEE PAGE 69 Relief Block SEE PAGE 70 Rotating Drum Left SEE PAGE 71 Rotating Drum Right SEE PAGE 72 Skid Plates SEE PAGE 73 Drum Mulcher Operation and Maintenance Manual...

  • Page 58: Cutting Teeth (Carbide)

    Parts Cutting Teeth (Carbide) ITEM DESCRIPTION PART # Tooth Carbide Reversible 290101 Cap Screw, HH, 1”-14 x 2.5” GR8 290106 Drum Mulcher Operation and Maintenance Manual...

  • Page 59: Cutting Teeth (Chipping)

    Parts Cutting Teeth (Chipping) ITEM DESCRIPTION PART # Adapter, Spacer Tooth 290110 Tooth Woodchuck Reversible 290100 Cap Screw, HH, 1”-14 x 3” GR8 290105 Drum Mulcher Operation and Maintenance Manual...

  • Page 60: Debris Shield

    Parts Debris Shield ITEM DESCRIPTION PART # Rubber Flap Clamp Outer Plate 290157 Rubber Flap Clamp Center Plate 290158 Cap Screw, Flange, HH, M12-1.75 x 40 mm, GR10.9 290156 Rubber Flap 290155 Drum Mulcher Operation and Maintenance Manual...

  • Page 61: Drive System

    Included: (2) SHCS-1500-13-1000 Bushing, 2517, 14 MX-34S-68 290120 Cap Screw, Socket Head, 1/2-13 x 1.5” Cap Screw, Socket Head, 1/2-13 x 1” Belt, Poly Chain, 14 mm Pitch, 290130 68 mm Wide, 112 Teeth Drum Mulcher Operation and Maintenance Manual...

  • Page 62: Drive System Access Panel

    Parts Drive System Access Panel ITEM DESCRIPTION PART # Cap Screw, Flange, HH, M12-1.75 x 30 mm, GR10.9 290262 Access Panel, Drive Compartment 290570 Drum Mulcher Operation and Maintenance Manual...

  • Page 63: Gate, Hydraulic Cylinder

    Cylinder, Door 290185 Adapter, 90 ORFS-M/ORB-M 06/06 290259 Pin, Hydraulic Cylinder, 1” x 2.75 290253 Hair Pin, Hydraulic Cylinder, 1” Hydraulic Hose - Short 290257 Hydraulic Hose - Long 290258 Seal Kit Hose 290255-1 Drum Mulcher Operation and Maintenance Manual...

  • Page 64: Grease Lines

    Parts Grease Lines ITEM DESCRIPTION PART # Hose Fitting, 2103-2-4 Grease Fitting, 1/8” NPT Hose Fitting, 0103-2-4 Grease Line Grease Line Grease Line Grease Line Drum Mulcher Operation and Maintenance Manual...

  • Page 65: Hydraulic Gate

    Socket Head Cap Screw, 1/2-13 x 1.5” 290278 Locknut, Hex, M16-2.00 GR8 290280 Included with # 12 Adapter, 090 ORFS-M/ORB-M 06/06 290259 Pin, Hydraulic Cylinder, 1” x 2.75 290258 Hydraulic Hose - Short 290257 Hydraulic Hose - Long 290258 Drum Mulcher Operation and Maintenance Manual...

  • Page 66: Maintenance Panel

    Parts Maintenance Panel ITEM DESCRIPTION PART # Cap Screw, Flange, HH, M12-1.75 x 30 mm GR 10.9 290262 Frame Access Panel 290575 Drum Mulcher Operation and Maintenance Manual...

  • Page 67: Motor

    Cap Screw, Flange, HH, M12-1.75 x 30 mm GR 10.9 290262 Cap Screw, HH, M12-1.75 x 120 mm GR 10.9 290620 Bolt, Flange, M16-2.0 x 50 mm GR 10.9 290640 See Relief Block on page 70 for breakdown. Drum Mulcher Operation and Maintenance Manual...

  • Page 68: Motor Access Panel

    ITEM DESCRIPTION PART # Cap Screw, Flange, HH, M12-1.75 x 30 mm GR 10.9 290262 Access Panel Hydraulic Motor 290580 Rubber Flap Clamp 290585 Cap Screw, Flange, HH, M08-1.25 x 30 mm GR 10.9 290610 Drum Mulcher Operation and Maintenance Manual...

  • Page 69: Overhung Load Adapter

    Overhung Load Adapter Shaft, 2-1/4” x 13T-8/16 Spline 290445 Bearing, Spherical Roller/Straight Bore 290185 Retaining Ring, 75 mm 290465 Retaining Ring, 130 mm 290460 Shaft Seal, 85 mm x 130 mm x 12 mm 290455 Overhung Load Adapter Case 290440 Drum Mulcher Operation and Maintenance Manual...

  • Page 70: Overhung Load Adapter Grease Lines

    Overhung Load Adapter Shaft, 13T-8/16 DP x 2.25”, 1/2’ x 1/2” Key 290450 Hose Fitting, 2103-2-4 290705 Grease Line 290740 Grease Line 290735 Grease Line 290730 Grease Line 290725 Grease Fitting, 1/8” NPT 290710 Hose Fitting, 0103-2-4 290706 Drum Mulcher Operation and Maintenance Manual...

  • Page 71: Push Bar

    Parts Push Bar ITEM DESCRIPTION PART # Tree Pusher 290350 Tree Pusher Arm 290355 Washer, Flat 290270 Bolt, Shoulder, M20 Spacer 290368 Washer, Flat 290276 Cap Screw, Socket Head, 290278 Locknut, Hex 290280 Drum Mulcher Operation and Maintenance Manual...

  • Page 72: Relief Block

    Parts Relief Block ITEM DESCRIPTION PART # Manifold 290510 Plug, ORB 290535 Flange 290530 Washer, Flat 290660 Cap Screw, HH 290625 Durometer, Nitrile 290525 Check Valve 290515 Relief Valve 290520 Drum Mulcher Operation and Maintenance Manual...

  • Page 73: Rotating Drum, Left Side

    Cap, Screw, Socket Head 290645 Washer, Serrated 290655 Shaft, Stub 290410 Bearing Housing, Lower 290425 Shaft, Stub 290180 Cap Screw, Socket Head 290605 Cap Screw, Flange, HH 290635 Mulcher Drum, 290590 Plate, Drum Gap Ring 290412 Drum Mulcher Operation and Maintenance Manual...

  • Page 74: Rotating Drum, Right Side

    Cap Screw, Socket Head 290645 Cap Screw, Flange, HH 290635 Washer, Serrated 290655 Cap Screw, Socket Head 290605 Bearing Housing, Lower 290425 Drum, Mulcher 290590 Shaft, Stub 290175 Plate, Drum Gap Ring 290412 Shaft, Stub 290410 Drum Mulcher Operation and Maintenance Manual...

  • Page 75: Skid Plates

    Parts Skid Plates ITEM DESCRIPTION PART # Cap Screw, Flange, HH 290635 Plate, Skid 290165 Washer, Flat 290270 Locknut, Hex 290280 Drum Mulcher Operation and Maintenance Manual...

  • Page 76: Hydraulic Motor Case Drain Protection Kit (Option)

    Kit can be connected to the hydraulic motor port “L1” to protect against case drain over pressure and spikes minimizing the possibility of shaft seal failures, case cracking or other case over pressure related failures. Drum Mulcher Operation and Maintenance Manual...

  • Page 77: Serviceable Parts

    Flange Hex Head Cap Screw, M16-2.00 x 40mm GR10.9 Yellow Zinc 290635 Flat Washer, M20 x 37MM OD DIN 125 Low Carbon Yellow Zinc 290270 Hex Locknut, M16-2.00 GR8 Yellow Zinc 290280 STATIONARY ANVIL PART # Stationary Anvil Drum Well Cutter Bar Drum Mulcher Operation and Maintenance Manual...

  • Page 78: Decal Identification And Location

    Parts Decal Identification And Location Drum Mulcher Operation and Maintenance Manual...
  • Page 79 BD-907 DECAL, WARNING PINCH POINT BD-908 DECAL, LIFT POINT BD-909 DECAL, WARNING FLYING DEBRI BD-910 DECAL, WARNING STAY CLEAR BD-911 DECAL, WARNING BD-912 DECAL, WARNING WEAR PROTECTIVE GEAR BD-913 DECAL, WARNING STAY CLEAR BD-914 Drum Mulcher Operation and Maintenance Manual...
  • Page 80 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 81: Specifications

    Specifications Specifications Attachment Specifications 81 Hydraulic Schematic 84 Torque Specifications 85 Drum Mulcher Operation and Maintenance Manual...
  • Page 82 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

  • Page 83: Attachment Specifications

    72.8 in. (1848 mm) Overall Height (B) 64.3 in. (1633 mm) Length (C) 41.8 in. (1061 mm) Drum Width (D) 59.5 in. (1511 mm) Push Bar Width (E) 69.5 in. (1767 mm) Weight 2500 lbs. (1136 kg) Drum Mulcher Operation and Maintenance Manual...

  • Page 84: Cutting Drum

    Relief Valve Flow Rate. 50 gpm (190 l/min) Relief Valve Pressure Range 1000 - 6000 psi (70 - 420 bar) Relief Valve Adjustment 1000 psi / turn (70 bar / turn) Pressure Test Port Type Compucheck® Drum Mulcher Operation and Maintenance Manual...

  • Page 85: Relief Valve

    Seal kit - Cartridge Buna, 990303007 Check Valve DESCRIPTION CUTTING DRUM Sun Hydraulics Model CXFA Series Capacity 40 gpm Valve Hex Size 1-1/8 in. Valve Installation Torque 45 - 50 ft-lb Seal kit - Cartridge Buna, 990203007 Drum Mulcher Operation and Maintenance Manual...

  • Page 86: Hydraulic Schematic

    Specifications Hydraulic Schematic Drum Mulcher Operation and Maintenance Manual...

  • Page 87: Torque Specifications

    708 ft / lb 773 ft / lb 1000 ft / lb 386 ft / lb 545 ft / lb (289 N•m) (373 N•m) (742 N•m) (960 N•m) (1048 N•m) (1356 N•m) (523 N•m) (739 N•m) Drum Mulcher Operation and Maintenance Manual...
  • Page 88 QUALITY / DEPENDABILITY / INTEGRITY Drum Mulcher Operation and Maintenance Manual...

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