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Blue Diamond 190555 Operation And Maintenance Manual

Extreme duty excavator drum mulcher
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Extreme Duty
Excavator Drum Mulcher
Operation and Maintenance Manual
Register your
190555, 190565
WARRANTY
within 30 days
of purchase
888-376-7027 | BlueDiamondAttachments.com

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Summary of Contents for Blue Diamond 190555

  • Page 1 Extreme Duty Excavator Drum Mulcher Operation and Maintenance Manual Register your 190555, 190565 WARRANTY within 30 days of purchase 888-376-7027 | BlueDiamondAttachments.com...

  • Page 2: Serial Number Location

    Manual and thoroughly understand safe and correct operating, installation and maintenance procedures. Model Number: _____________________________ Serial Number: _____________________________ Blue Diamond® is continually working to improve its Dealer Name: ______________________________ products. Blue Diamond® reserves the right to make any improvements or changes as deemed practical Dealer Number:...

  • Page 3: Table Of Contents

    5.10 Non-Drive Side Rotor Bearing Assembly — 290429 ...51 5.11 Rotor Bearing — 290456 ...........52 5.12 Rotor ..................53 5.13 Rotor Assembly Components .......... 54 5.14 Hydraulic Solenoid Valve Block And Hydraulic Connec- tion Panel Parts — 290403 ............55 Blue Diamond® Attachments...

  • Page 4: Introduction

    1. Introduction 1.1 Attachment Identification Mount Plate Access Covers Chain Guard Skid Shoes Lift eyes Access Covers Mount Plate Belt Drive Discharge cover Cover Replaceable Teeth Depth Limiters Blue Diamond® Attachments...

  • Page 5: About This Attachment

    Measured sound power level in this manual to ensure proper and efficient use of Guaranteed sound power level (LWA) machine. NOTE: Blue Diamond® cannot be held liable if 1.3 Attachment Model specified limits are exceeded. Numbers NOTE: Noise emissions in the environment...
  • Page 6 • Before starting operation of the machine, check that the rotor and its hammers are in good condition. • Check that there are no objects wrapped around the rotor. Figure 4 Figure 2 Blue Diamond® Attachments...
  • Page 7 This mulcher features an adjustable intake plate [Figure 9] to control the size of material processed. Figure 6 Hydraulic Connection Panel The hydraulic connection panel [Figure 7] connects the excavator hoses to the mulcher. Figure 9 Figure 7 Blue Diamond® Attachments...

  • Page 8: Safety

    Ensure that all safety pictograms/decals are IMPORTANT legible. If pictograms/decals are worn, they must be replaced with new ones obtained from Blue Diamond® and placed in the position The signal word IMPORTANT identifies indicated by this manual. procedures which must be followed to avoid damage to the machine.

  • Page 9: Operators

    The operator is responsible for scrupulously observing all the instructions given in this manual. Blue Diamond® Attachments...

  • Page 10: Operational Safety

    If the machine vibrates, behaves strangely, area when operating the equipment. This or makes unusual noises, stop operation and attachment discharges debris that can be contact your local dealer or Blue Diamond® hazardous. Product Support immediately. • The equipment must be used ONLY on •...

  • Page 11: Transporting Safety

    Transporting Safety • DO NOT operate in a work area that has • Blue Diamond® Attachments cannot be held not been inspected for foreign debris and responsible for any damage due to transport obstacles. that was carried out by the customer and/or •...

  • Page 12: Hydraulic System

    DO NOT climb on the machine while it is in medical attention is required. operation or when it is off. Wear goggles. Use cardboard to check for leaks. • DO NOT start the mulcher rotor without first raising the machine off the ground. Blue Diamond® Attachments...

  • Page 13: Precautions During Maintenance

    Immediate the ignition. medical attention is required. • Use Blue Diamond® approved spare parts for Wear goggles. Use cardboard to check for leaks. better performance and increased safety. Storage of the Machine Precautions during Maintenance •...

  • Page 14: Start-Up And Operation

    NOT connect or operate the machine or carry removed from the machine. out any maintenance operations. Contact your • Check for damaged or missing safety decals. local dealer or Blue Diamond® Product Support Replace if necessary. immediately to ensure your safety and that of the machine. •...

  • Page 15: Checks Prior To Connecting The Machine

    Zip-tie the harness to the excavator hoses or other available points for routing along the boom. Route the harness in such a way that it will not be stretched, pinched, or otherwise damaged by the movement of the boom or attachment. Blue Diamond® Attachments...

  • Page 16: Initial Set Up Instructions

    Shift Pressure 3. Connect the pressure hose. Wrench Adjustment NOTE: Disconnect in reverse order. 19mm Socket Guard Plate Hose Guard and 8mm Allen Key Access Plates Displacement 6mm Allen Key Adjustment Shift Pressure 3mm Allen Key Adjustment Blue Diamond® Attachments...
  • Page 17 4. Hold the allen key in place, and tighten the jam nut. Repeat the above steps for measurement NOTE: DO NOT engage the hydraulics for more and adjustment until the desired shift pressure than 30 seconds to avoid heat buildup in the is reached. hydraulic system. Blue Diamond® Attachments...
  • Page 18 NOTE: 2200 – 2500 RPM is for optimum performance. Maximum RPM is 2800. NOTE: Rotor speed may decrease as hydraulic oil temperature increases. Figure 16 4. Measure the rotor speed again, and adjust as needed. Blue Diamond® Attachments...

  • Page 19: Machine Operation

    For best results, find the balance between speed, power, and material mulched. Alignment of the Machine to Terrain • At working position, DO NOT put pressure on the mulcher with the arm (ground), as this could damage a component. Blue Diamond® Attachments...

  • Page 20: Maintenance

    DO NOT throw away, dump, or burn products Diamond® cannot be held responsible for that could pollute the environment. improper waste disposal. • Blue Diamond® shall not be held responsible in the event of poor waste management by any maintenance personnel. Blue Diamond® Attachments...

  • Page 21: Hoses And Cylinder

    • Check the piston rod on the cylinder for scratches that could damage the seals. NOTE: Use original Blue Diamond® spare parts for better performance and increased safety. IMPORTANT If the cylinder can be moved manually without...

  • Page 22: Belts

    • Replace worn or broken belts. deflection in the center of the span [Figure 19] NOTE: Use original Blue Diamond® spare parts for is equal to the deflection distance shown in better performance and increased safety. the table when the deflection force shown is applied with a tensiometer.

  • Page 23: Teeth

    The replacement of teeth and tightening torque of teeth must be carried out by qualified personnel or an authorized service technician. • NOTE: Use original Blue Diamond® spare parts for better performance and increased safety. 4.7 Spare Parts Figure 20 To order a spare part, the customer must contact an authorized Blue Diamond®...

  • Page 24: Service Schedule

    • Belts Greasing • Rotor bearing housings • Cylinder Pin • Direct drive * For these tasks Contact your dealer or Blue Diamond® Product Support. ** Refer to 4.3 Greasing and Lubrication on page 20 for interval. Blue Diamond® Attachments...

  • Page 25: Troubleshooting

    Lubricate according to the times indicated in this manual. Respect the working limits indicated by the manufacturer (in Frequent bearing Machine overloaded. case of doubt, contact your dealer or Blue Diamond® Product breakage. Support). Incorrect rotor mounting or Check assembly and adjustments.
  • Page 26 Replace the belt. Check the hydraulic motor drive shaft and if necessary, have Rotor not turning. Broken hydraulic motor bearing or it repaired or replaced. Contact your dealer or Blue Diamond® drive shaft. Product Support. Oil leak. Identify and repair all leaks in the hydraulic circuit.
  • Page 27 This page intentionally left blank Blue Diamond® Attachments...

  • Page 28: Parts

    5. Parts 5.1 40” Main Components Blue Diamond® Attachments...
  • Page 29 M12 X 1.75MM X 35MM CARRIAGE BOLT FULL THREAD 290414 REAR SKID SHOE (SEE PAGE 44) — 2.7MM X M16 X 30MM FLAT WASHER — M16 X 2.00 NYLOCK NUT — M12 X 1.75MM X 30MM HEX BOLT FULL THREAD Blue Diamond® Attachments...
  • Page 30 5. Parts 5.1 40” Main Components Cont’d Blue Diamond® Attachments...
  • Page 31 M16 X 2MM X 40MM CARRIAGE BOLT FULL THREAD 290476 ADJUSTABLE INTAKE PLATE — M16 X 2.00MM NYLOCK NUT 290405 CHAIN 10 DIN 5685 11 LINKS L=460 MM 290521 CHAIN ROD 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD Blue Diamond® Attachments...
  • Page 32 5. Parts 5.1 40” Main Components Cont’d Blue Diamond® Attachments...
  • Page 33 M12 X 1.75 NYLOCK NUT — 2.3MM X M12 X 24MM WASHER 290436 ROTOR SHAFT OUTLET COVER — M12 X 1.75MM X 25MM BOLT HEX HEAD FULL THREAD 290437 BELT DRIVE COVER PLATE 290438 POLYCHAIN BELT DRIVE ASSEMBLY (SEE PAGE 49) Blue Diamond® Attachments...
  • Page 34 5. Parts 5.1 40” Main Components Cont’d Blue Diamond® Attachments...
  • Page 35 — M12 X 1.75MM NYLOCK NUT 290519 LARGE COUNTERBLADE – 300MM 299068 M12 X 1.75MM X 30MM CARRIAGE BOLT FULL THREAD — M16 X 2.00MM X 140MM BOLT HEX HEAD PARTIAL THREAD 290518 SMALL COUNTERBLADE – 200MM Blue Diamond® Attachments...

  • Page 36: 50" Main Components

    5. Parts 5.2 50” Main Components Blue Diamond® Attachments...

  • Page 37: Mount Plate

    2.3MM X M12 X 24MM FLAT WASHER — M12 X 1.75MM NYLOCK NUT 290413 FRONT SKID SHOE (SEE PAGE 45) 299069 M12 X 1.75MM X 35MM CARRIAGE BOLT FULL THREAD 290414 REAR SKID SHOE (SEE PAGE 44) Blue Diamond® Attachments...
  • Page 38 5. Parts 5.2 50” Main Components Cont’d Blue Diamond® Attachments...

  • Page 39: Mm X M12 X 24Mm Flat Washer

    M16 X 2MM X 40MM CARRIAGE BOLT FULL THREAD 290401 ADJUSTABLE INTAKE PLATE — M16 X 2.00MM NYLOCK NUT 290405 CHAIN 10 DIN 5685 11 LINKS L=460 MM 290515 CHAIN ROD 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD Blue Diamond® Attachments...
  • Page 40 5. Parts 5.2 50” Main Components Cont’d Blue Diamond® Attachments...

  • Page 41: M16 X 2.00 Nylock Nut

    POLYCHAIN BELT DRIVE ASSEMBLY (SEE PAGE 49) 290576 M16 X 2MM X 27MM SHANK EYEBOLT FULL THREAD — 2.7MM X M16 X 30MM FLAT WASHER — M16 X 2.00 NYLOCK NUT 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD Blue Diamond® Attachments...
  • Page 42 5. Parts 5.2 50” Main Components Cont’d Blue Diamond® Attachments...
  • Page 43 85CC MOTOR AND LOAD ADAPTER ASSY (SEE PAGE 47) — M16 X 2MM X 50MM CARRIAGE BOLT FULL THREAD — M12 X 1.75MM NYLOCK NUT 290519 LARGE COUNTERBLADE - 300MM 299068 M12 X 1.75MM X 30MM CARRIAGE BOLT FULL THREAD Blue Diamond® Attachments...

  • Page 44: Rear Skid Shoe - 290414

    5. Parts 5.3 Rear Skid Shoe — 290414 ITEM PART NUMBER DESCRIPTION 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD 290411 REAR SKID SHOE WELDMENT 290416 REAR SKID SHOE WEAR STRIP Blue Diamond® Attachments...

  • Page 45: Front Skid Shoe - 290413

    5. Parts 5.4 Front Skid Shoe — 290413 ITEM PART NUMBER DESCRIPTION 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD 290418 FRONT SKID SHOE WELDMENT 290421 FRONT SKID SHOE WEAR STRIP Blue Diamond® Attachments...

  • Page 46: Main Frames

    5. Parts 5.5 Main Frames ITEM PART NUMBER DESCRIPTION 290480 MAIN FRAME 40” 290464 MAIN FRAME 50” Blue Diamond® Attachments...

  • Page 47: 85Cc Motor And Load Adapter Assembly Components - 290427

    290444 BELT TENSIONER PLATE — 2.3MM X M12 X 24MM FLAT WASHER M12 X 1.75MM X 30MM BOLT SOCKET HEAD FULL — THREAD SAE SPLIT FLANGE HALF #16 CODE 62 295000-16-62SF (2 HALVES REQUIRE 1X O-RING 295011-16) Blue Diamond® Attachments...

  • Page 48: Overhung Load Adapter Assembly - 290442

    M10 90º GREASE ZERK 290637 3/8” MALE PLUG 50MM SHAFT X 110MM HOUSING ID X 40MM WIDE 290634 SPHERICAL ROLLER BEARING 290562 120MM ID X 4MM THICK RETAINING RING 290453 55MM ID X 120MM OD X 16MM THICK SEAL Blue Diamond® Attachments...

  • Page 49: Polychain Belt Drive Assembly - 290438

    LOWER PULLEY - 90 TOOTH 290624 UPPER PULLEY - 80 TOOTH SYNCHRO BELT POLY CHAIN GTC-GTV 1440MM OD X 290623 8MM PITCH X 62MM WIDE 290628 BELT DRIVE TAPERLOCK KEY 290627 TAPERLOCK FOR KEY 3020 SHAFT 45MM Blue Diamond® Attachments...

  • Page 50: Drive Side Rotor Bearing Assembly - 290433

    ROLLER BEARING + SLEEVE H2312 290457 BEARING HOUSING 290458 55MM ID X 90MM OD X 8MM THICK SEAL 290573 90MM ID X 3MM THICK RETAINING RING INTERNAL 290463 55MM ID X 75MM OD X 8MM THICK SEAL Blue Diamond® Attachments...

  • Page 51: Non-Drive Side Rotor Bearing Assembly - 290429

    65MM SHAFT X 140MM HOUSING ID X 48MM WIDE 290456 ROLLER BEARING + SLEEVE H2312 290457 BEARING HOUSING 290458 55MM ID X 90MM OD X 8MM THICK SEAL 290573 90MM ID X 3MM THICK RETAINING RING INTERNAL Blue Diamond® Attachments...

  • Page 52: Rotor Bearing - 290456

    5. Parts 5.11 Rotor Bearing — 290456 ITEM PART NUMBER DESCRIPTION 65MM SHAFT X 140MM HOUSING ID X 48MM WIDE 290636 SPHERICAL ROLLER BEARING 290459 TAPERED SLEEVE H2312 Blue Diamond® Attachments...

  • Page 53: Rotor

    5. Parts 5.12 Rotor ITEM PART NUMBER DESCRIPTION 290461 ROTOR OUTER WASHER 290481* 40” ROTOR ASSEMBLY WITH CHIPPING TEETH (SEE PAGE 54) 290462* 50” ROTOR ASSEMBLY WITH CHIPPING TEETH (SEE PAGE 54) *Serial #1800083 is Blue Diamond® Attachments...

  • Page 54: Rotor Assembly Components

    M8 X 1.25MM X 25MM BOLT HEX HEAD FULL THREAD — 2.3MM X M12 X 24MM FLAT WASHER TOOTH KIT MULCHER MODEL DESCRIPTION 290508-KIT-40 190555 40” CHIPPING TEETH 290509-KIT-40 190555 40” CARBIDE TEETH 290508-KIT-50 190565 50” CHIPPING TEETH 290509-KIT-50 190565 50” CARBIDE TEETH Blue Diamond® Attachments...

  • Page 55: Hydraulic Solenoid Valve Block And Hydraulic Connection Panel Parts - 290403

    5. Parts 5.14 Hydraulic Solenoid Valve Block And Hydraulic Connection Panel Parts — 290403 Blue Diamond® Attachments...
  • Page 56 M12 X 1.75 NYLOCK NUT — 2.3MM X M12 X 24MM WASHER M12 X 1.75MM X 30MM FLANGED BUTTON HEAD BOLT — FULL THREAD 290488 HOSE PROTECTION COVER 290643 M12 X 1.75MM X 25MM BOLT FLANGED BUTTON HEAD Blue Diamond® Attachments...

  • Page 57: Hydraulic Valve Block Assembly

    ENCAPSULATED SEAL 290486 VALVE BLOCK 290487 RELIEF VALVE CARTRIDGE SAE SPLIT FLANGE HALF #12 CODE 62 295000-12-62SF (2 HALVES REQUIRE 1X O-RING 295001-12) SAE SPLIT FLANGE HALF #16 CODE 62 295000-16-62SF (2 HALVES REQUIRE 1X O-RING 295001-16) Blue Diamond® Attachments...

  • Page 58: Hydraulic Hoses

    ROTOR HUB LONG GREASE HOSE 40” – 1350 OAL 90° MALE 290478 1/8” NPT TO 90° MALE 1/8” NPT ROTOR HUB LONG GREASE HOSE 50” – 1450MM OAL 90° 290432 MALE 1/8” NPT TO 90° MALE 1/8” NPT 290428 M10 X 1.0 GREASE ZERK STRAIGHT Blue Diamond® Attachments...

  • Page 59: Electrical Wire Harness Kit - 290680

    36" 6" Switch Power Leg 240" Control Leg Delphi Adapter Segment – 290683 120" 12V Plug Segment – 200021 11 1/2" Op 500 2 1/2" Battery Terminal Segment – 290682 28" Positive 8" 10A Fuse FUSE Ground Blue Diamond® Attachments...

  • Page 60: Electrical Wire Harness Kit Cont'd - 290680

    OPEN DISCHARGE COVER GROUND OTHER COMPONENTS: PART NUMBER DESCRIPTION 290023 ATTACHMENT HARNESS TO SOLENOIDS (NOT SHOWN) 290684 5 FT CONTROL LEG EXTENSION (OPTIONAL) 216921 10 FT CONTROL LEG EXTENSION (OPTIONAL) 200013 10 FT POWER LEG EXTENSION (OPTIONAL) Blue Diamond® Attachments...

  • Page 61: Safety Decals

    DESCRIPTION BD-063 DECAL - EXTREME DUTY BD-055 DECAL - DANGER - DEBRIS DISCHARGE AREA BD-081 DECAL - WARNING - KEEP HANDS AND FEET AWAY BD-060 DECAL - BLUE DIAMOND ATTACHMENTS BD-092 DECAL - REGISTER YOUR PRODUCT NOW Blue Diamond® Attachments...

  • Page 62: Specifications

    2 Rows Maximum Cutting Capacity 7” In the table below, document the specifications of the excavator the mulcher is tuned to each time it is tuned for a new machine. Date Host Machine ID Auxiliary Pressure Auxiliary Flow Blue Diamond® Attachments...

  • Page 63: Torque Specifications

    850 lbf•ft 1300 lbf•ft 1650 lbf•ft 1850 lbf•ft 2350 lbf•ft 2150 lbf•ft 2750 lbf•ft 1150 N•m 1450 N•m 2250 N•m 2850 N•m 3200 N•m 4050 N•m 3750 N•m 4750 N•m 850 lbf•ft 1075 lbf•ft 1650 lbf•ft 2100 lbf•ft 2350 lbf•ft 3000 lbf•ft 2750 lbf•ft 3500 lbf•ft Blue Diamond® Attachments...

  • Page 64: Warranty

    ATTACHMENTS before work is performed. ® The BLUE DIAMOND® PRODUCT SUPPORT TEAM will advise repairs and applicable parts exchanges. Tampering with the failed part may void the warranty. This warranty does not include freight or delivery charges incurred when returning machinery for servicing. Dealer mileage, service calls, and pickup/delivery charges are the customers’...
  • Page 65 This page intentionally left blank Blue Diamond® Attachments...
  • Page 66 QUALITY | DEPENDABILITY | INTEGRITY Blue Diamond® Attachments 4512 Anderson Road, Knoxville, TN 37918 888-376-7027...

This manual is also suitable for:

190565

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