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33

Drum Mulcher Operation and Maintenance Manual

Maintenance

Service Schedule

Maintenance Intervals

DESCRIPTION

SERVICE PROCEDURES

Check

Clean

Lube

Change

Daily Maintenance (or every 8 hours)

Cutting Drum Bearings

•

•

Hydraulic Fittings

•

Hydraulic Hoses

•

Hydraulic Cylinder

•

Hydraulic Gate

•

Hydraulic Motor

•

•

Cutting Teeth (wear, damage, and loosening)

•

•

Attachment Mounting Frame

•

All Hardware

•

Drum Mulcher Frame

•

•

Weekly Maintenance (or every 40 hours)

Overhung Load adapter Bearings

•

•

Drive Belt

•

Sprockets

•

Cutting Drum

•

Push Bar

•

All Hardware

•

Compartments

•

Decals

•

Summary of Contents for Drum Mulcher

Page 1: ......

Page 2: ...machine rated capacity WARRANTY CLAIM To submit a warranty claim a return authorization from BLUE DIAMOND ATTACHMENTS must be obtained The failed part may then be returned Tampering with the failed pa...

Page 3: ...ection 21 Attachment Installation 22 Entering The Operator s Position 22 Leaving The Operator s Position 22 Connecting Attachment To The Machine 22 Connecting Hydraulic Hoses 23 Disconnecting Hydrauli...

Page 4: ...49 Parts 51 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 6...

Page 5: ...and Maintenance Manual Table Of Contents Attachment Specifications 81 Dimensions 81 Cutting Drum 82 Hydraulic 82 Relief Valve 83 Check Valve 83 Hydraulic Schematic 84 Torque Specifications 85 Standard...

Page 6: ...iv Drum Mulcher Operation and Maintenance Manual Table Of Contents...

Page 7: ...Introduction 5 Drum Mulcher Operation and Maintenance Manual Introduction Owner Information 7 Attachment Identification 9...

Page 8: ...6 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 9: ...to ensure the accuracy of this publication Blue Diamond makes no warranty or guarantee of any kind written or expressed implied or otherwise with regard to the information contained within this manual...

Page 10: ...8 Drum Mulcher Operation and Maintenance Manual Introduction Figure 2 Hydraulic Motor Serial Number Overhung Load Adapter Serial Number Cutting Drum Serial Number...

Page 11: ...Manual Introduction Attachment Identification Drum Mulcher Drum Mulcher CHAIN CASE PUSH BAR GATE CYLINDER GUARD MAINTENANCE ACCESS PANEL DRUM DRIVE SYSTEM ACCESS PANEL GATE SKID PLATES CUTTING TOOTH D...

Page 12: ...10 Drum Mulcher Operation and Maintenance Manual Introduction RUBBER FLAP GATE CYLINDER ATTACHMENT MOUNTING FRAME STEP STEP MOTOR ACCESS PANEL CHAIN CURTAIN...

Page 13: ...Safety 11 Drum Mulcher Operation and Maintenance Manual Safety Safety Information 13...

Page 14: ...12 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 15: ...nsafe practices IMPORTANT The signal word IMPORTANT identifies procedures which must be followed to avoid damage to the machine Safe Operation Needs A Qualified Operator WARNING AVOID SERIOUS INJURY O...

Page 16: ...T modify the equipment in any way Unauthorized modification may impair the function and or safety and may void the warranty DO NOT make any adjustments or repairs on the equipment while the machine is...

Page 17: ...mponents can cause a fire Transporting Safety Comply with state and local laws governing highway safety and movement of machinery on public roads Check local laws for all highway lighting and marking...

Page 18: ...16 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 19: ...Operation 17 Drum Mulcher Operation and Maintenance Manual Operation General Information 19 Attachment Inspection 20 Attachment Installation 22 Operating The Attachment 25...

Page 20: ...18 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 21: ...See Service Schedule on page 33 Check the drum mulcher mounting frame for damage or cracks Check that all shields and guards are in place Check for loose bolts and tighten them if necessary Inspect th...

Page 22: ...ght play Expect 1 8 to 1 4 play Inspect the grease overflow port for signs of liquid overflow Liquid grease streaks may be a sign of bearing overheating or the operating temperature of the grease used...

Page 23: ...of operation Perform inspections at the end the work shift while the machine is hot Check the following items every 40 hours of operation Lubricate the grease zerk labeled 40 hour on the overhung loa...

Page 24: ...for all moving parts to stop SEE MACHINE S OPERATOR S MANUAL FOR ADDITIONAL INFORMATION Park the machine attachment on a flat level surface Place all controls in neutral engage the park brake stop th...

Page 25: ...ent to come off SEE MACHINE S OPERATOR S MANUAL FOR ADDITIONAL INFORMATION Engage attachment locking levers wedges See the machine s Operator s Manual for detailed information Connecting Hydraulic Hos...

Page 26: ...und Leave the operator s position See Leaving The Operator s Position on page 22 Disconnect attachment hydraulic hoses from the machine Disengage locking pins wedges See the machine s Operator s Manua...

Page 27: ...reduces the pressure on the mulcher hydraulic motor case Clearing Work Area IMPORTANT DO NOT operate in a work area that has not been cleared of foreign debris and obstacles Rocks metal construction...

Page 28: ...e pressure NOTE Operation with case pressure in excess of stated limits will damage seals gaskets and or hydraulic motor housings See page 49 in Maintenance Section for causes of high case drain press...

Page 29: ...e machine s operator s manual to the drum mulcher Allow the time for the drum to stop rotating and lower the drum to the ground Stop the engine Mulcher Functions Gate The optional mulcher gate pushed...

Page 30: ...is done on the reverse pass Large Trees Larger than 3 in 8 cm diameter Figure 5 Attack tree at 24 to 36 in 60 to 90 cm off the ground Position mulching head tilted back to expose the drum cutting teet...

Page 31: ...e Lower lift arms and place attachment flat on the ground Place all controls in NEUTRAL Engage the park brake Wait for all moving parts to stop Relieve hydraulic system pressure Stop the engine and re...

Page 32: ...30 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 33: ...Maintenance 31 Drum Mulcher Operation and Maintenance Manual Maintenance Service Schedule 33 Lubrication 34 Mulcher 35 Cleaning the Attachment 47 Troubleshooting 48...

Page 34: ...32 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 35: ...nce or every 8 hours Cutting Drum Bearings Hydraulic Fittings Hydraulic Hoses Hydraulic Cylinder Hydraulic Gate Hydraulic Motor Cutting Teeth wear damage and loosening Attachment Mounting Frame All Ha...

Page 36: ...aned in a specific manner See local state and federal regulations for the correct disposal NOTE Use high temperature with a dropping point of minimum 340 170 C such as Mobil PolyrexEM Below each of th...

Page 37: ...atterns The torqueing pattern is known to all certified mechanics however as a reminder the following illustrates the pattern of torqueing the fasteners on the opposite side of the last fastener tight...

Page 38: ...ls belt access motor access tension access Figure 10 Figure 11 2 Loosen both overhung locknuts Figure 11 Figure 12 3 Loosen both tension bolts Figure 12 4 Loosen both overhung locknuts Figure 13 5 Loo...

Page 39: ...tension 1 Install replacement belt Figure 15 2 Tighten the tension bolts to apply tension on the belt 3 Tighten overhung lock bolts and check tension Figure 16 4 Once belt tension is as specified tigh...

Page 40: ...complete hole will only be threaded on one side 4 Lightly oil the screws and thread them into the half threaded holes indicated by O Figure 17 5 Place the key in the shaft keyway ensure it is fully in...

Page 41: ...on 1 Position the replacement skid plates on elevated blocks and lower the mulcher onto the skid plates 2 Fasten together and torque to 218 ft lb 296 N m Cutting Drum Bearing and Shaft Seal Removal Fi...

Page 42: ...ller holes to separate the bearing housing away from the side wall along with the bearing and both inner and outer spacers inside the housing NOTE Bearing spacers are only installed with the bearing o...

Page 43: ...knut groove 12 Bend one of the daisy lock washer petals to lock the bearing locknut 13 Torque the bearing housing fasteners to 174 ft lb 236 N m with medium strength thread locker Figure 23 1 Pack the...

Page 44: ...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...

Page 45: ...k on the hydraulic motor Figure 27 3 Remove all four fasteners to separate the hydraulic motor from the overhung load adapter OLA 4 Remove the grease lines off the OLA case 5 Remove both OLA slot fast...

Page 46: ...ing temperature with a temperature gun The break in process can take up to 3 hours Expect the temperature to rise steadily to maximum 300 F 149 C and then drop The break in period can stop as soon as...

Page 47: ...160 F 70 C Follow the welding pattern illustrated Figure 31 Mig wire weld 0 45 Flux Core AWS A5 29 Weld fillet size 1 4 Relief Valve Adjustment Figure 32 1 Tighten the relief valve to maximum Figure...

Page 48: ...The minimum displacement screw setting limits the motor maximum speed Figure 34 3 Cutting drum maximum speed 2400 rpm NOTE Adjust while the mulcher is disengaged and turned off 4 Hold the adjusting sc...

Page 49: ...exit the machine Disconnect attachment hydraulic hoses WARNING AVOID SERIOUS INJURY OR DEATH Securely block up the attachment before working underneath WARNING Drum Wrapping Debris such as rope wire...

Page 50: ...ns Obstruction between drum and frame Remove debris Damaged motor shaft or seized motor Contact your dealer or Blue Diamond Attachments Service Department Faulty hydraulic coupler Replace hydraulic co...

Page 51: ...nd engine rpm is raised quickly Allow oil to warm to proper operating temperature Drain Line Restriction Oil flow restriction in hydraulic lines from quick coupler Remove the quick coupler from the dr...

Page 52: ...50 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 53: ...d Maintenance Manual 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...

Page 54: ...r Access Panel 66 Overhung Load Adapter 67 Overhung Load Adapter Grease Lines 68 Push Bar 69 Relief Block 70 Rotating Drum Left Side 71 Rotating Drum Right Side 72 Skid Plates 73 Hydraulic Motor Case...

Page 55: ...ration and Maintenance Manual Parts Chain Curtain ITEM DESCRIPTION PART QTY 1 P30 Coil Welded Chain ZP 5 16 1900 lb WLL 290151 41 2 Chain Curtain Rod 290152 1 3 Hose Fitting 0103 4 4 2 Hose Fitting 05...

Page 56: ...54 Drum Mulcher Operation and Maintenance Manual Parts Drum Mulcher 4 8 12 6 15 10 1 6 19 14 18 8 5 17 13 11 3 9 4 7 16...

Page 57: ...em Access Panel SEE PAGE 60 7 Gate Hydraulic Cylinder SEE PAGE 61 8 Grease Lines SEE PAGE 62 9 Hydraulic Gate SEE PAGE 63 10 Maintenance Panel SEE PAGE 64 11 Motor SEE PAGE 65 12 Motor Access Panel SE...

Page 58: ...56 Drum Mulcher Operation and Maintenance Manual Parts Cutting Teeth Carbide ITEM DESCRIPTION PART QTY 1 Tooth Carbide Reversible 290101 1 2 Cap Screw HH 1 14 x 2 5 GR8 290106 1 2 1...

Page 59: ...Mulcher Operation and Maintenance Manual Parts Cutting Teeth Chipping ITEM DESCRIPTION PART QTY 1 Adapter Spacer Tooth 290110 1 2 Tooth Woodchuck Reversible 290100 1 3 Cap Screw HH 1 14 x 3 GR8 290105...

Page 60: ...ntenance Manual Parts Debris Shield ITEM DESCRIPTION PART QTY 1 Rubber Flap Clamp Outer Plate 290157 2 2 Rubber Flap Clamp Center Plate 290158 1 3 Cap Screw Flange HH M12 1 75 x 40 mm GR10 9 290156 8...

Page 61: ...rdware Included 3 SHCS 0500 13 1500 290135 1 3 Key 1 2 x 1 2 x 2 50 AISI 4140 290142 2 4 Bushing Taper Lock 2517 2 25 Keyset 1 2 x 1 4 Hardware Included 2 SHCS 1500 13 1000 290140 1 5 Bushing 2517 14...

Page 62: ...rum Mulcher Operation and Maintenance Manual Parts Drive System Access Panel ITEM DESCRIPTION PART QTY 1 Cap Screw Flange HH M12 1 75 x 30 mm GR10 9 290262 16 2 Access Panel Drive Compartment 290570 2...

Page 63: ...er ITEM DESCRIPTION PART QTY 1 Cylinder Door 290185 1 2 Adapter 90 ORFS M ORB M 06 06 290259 2 3 Pin Hydraulic Cylinder 1 x 2 75 290253 2 4 Hair Pin Hydraulic Cylinder 1 4 5 Hydraulic Hose Short 29025...

Page 64: ...and Maintenance Manual Parts Grease Lines ITEM DESCRIPTION PART QTY 1 Hose Fitting 2103 2 4 4 2 Grease Fitting 1 8 NPT 2 3 Hose Fitting 0103 2 4 4 4 Grease Line 1 5 Grease Line 1 6 Grease Line 1 7 Gr...

Page 65: ...290262 4 5 Gate Cylinder Protecting Cover 290260 1 6 Bushing Long 290274 6 Bushing Short Not Shown 290275 6 7 Washer Flat M16 x 30 mm OD 290276 3 8 Socket Head Cap Screw 1 2 13 x 1 5 290278 3 9 Locknu...

Page 66: ...64 Drum Mulcher Operation and Maintenance Manual Parts Maintenance Panel ITEM DESCRIPTION PART QTY 1 Cap Screw Flange HH M12 1 75 x 30 mm GR 10 9 290262 8 2 Frame Access Panel 290575 1 1 2...

Page 67: ...Flange HH M12 1 75 x 50 mm GR 10 9 290615 4 6 Cap Screw Flange HH M14 2 00 x 60 mm GR 10 9 290630 2 7 Cap Screw HH M20 2 50 x 50 mm GR 10 9 290650 4 8 Guide Belt Tensioner 290131 2 9 Washer Flat M20 x...

Page 68: ...nual Parts Motor Access Panel ITEM DESCRIPTION PART QTY 1 Cap Screw Flange HH M12 1 75 x 30 mm GR 10 9 290262 7 2 Access Panel Hydraulic Motor 290580 1 3 Rubber Flap Clamp 290585 1 4 Cap Screw Flange...

Page 69: ...ION PART QTY 1 Overhung Load Adapter Shaft 2 1 4 x 13T 8 16 Spline 290445 1 2 Bearing Spherical Roller Straight Bore 290185 2 3 Retaining Ring 75 mm 290465 1 4 Retaining Ring 130 mm 290460 2 5 Shaft S...

Page 70: ...CRIPTION PART QTY 1 Overhung Load Adapter Shaft 13T 8 16 DP x 2 25 1 2 x 1 2 Key 290450 1 2 Hose Fitting 2103 2 4 290705 6 3 Grease Line 290740 1 4 Grease Line 290735 1 5 Grease Line 290730 1 6 Grease...

Page 71: ...al Parts Push Bar ITEM DESCRIPTION PART QTY 1 Tree Pusher 290350 1 2 Tree Pusher Arm 290355 2 3 Washer Flat 290270 6 4 Bolt Shoulder M20 Spacer 290368 4 5 Washer Flat 290276 6 6 Cap Screw Socket Head...

Page 72: ...ual Parts Relief Block ITEM DESCRIPTION PART QTY 1 Manifold 290510 1 2 Plug ORB 290535 4 3 Flange 290530 4 4 Washer Flat 290660 8 5 Cap Screw HH 290625 8 6 Durometer Nitrile 290525 4 7 Check Valve 290...

Page 73: ...er Lock 290150 1 5 Nut Lock 290145 1 6 Hose Fitting 2103 2 4 290705 2 7 Washer Serrated 290665 8 8 Cap Screw Socket Head 290645 8 9 Washer Serrated 290655 8 10 Shaft Stub 290410 1 11 Bearing Housing L...

Page 74: ...Nut Lock 290145 1 7 Hose Fitting 2103 2 4 290705 2 8 Bearing Spacer 290435 1 9 Bearing Spacer 290430 1 10 Washer Serrated 290665 8 11 Cap Screw Socket Head 290645 8 12 Cap Screw Flange HH 290635 6 13...

Page 75: ...3 Drum Mulcher Operation and Maintenance Manual Parts Skid Plates ITEM DESCRIPTION PART QTY 1 Cap Screw Flange HH 290635 16 2 Plate Skid 290165 2 3 Washer Flat 290270 16 4 Locknut Hex 290280 16 3 4 1...

Page 76: ...ulic 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...

Page 77: ...3 0 GR8 Black Oxide 290105 34 DEBRIS SHIELD PART QTY Rubber Flap Clamp Outer Plate 290157 2 Rubber Flap Clamp Center Plate 290158 1 Flange Hex Head Cap Screw M12 1 75 x 40mm GR10 9 Yellow Zinc 290156...

Page 78: ...76 Drum Mulcher Operation and Maintenance Manual Parts Decal Identification And Location 2 1 3 5 6 8 7 9 8 10 4...

Page 79: ...TS BD 903 5 DECAL REGISTER PRODUCT BD 904 6 DECAL GREASE EVERY 40 HOURS BD 905 7 DECAL GREASE EVERY 8 HOURS BD 906 8 DECAL WARNING BD 907 9 DECAL WARNING PINCH POINT BD 908 10 DECAL LIFT POINT BD 909...

Page 80: ...78 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 81: ...Specifications 79 Drum Mulcher Operation and Maintenance Manual Specifications Attachment Specifications 81 Hydraulic Schematic 84 Torque Specifications 85...

Page 82: ...80 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

Page 83: ...cations Attachment Specifications Dimensions DESCRIPTION DRUM MULCHER Overall Width A 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 Wi...

Page 84: ...7 in3 or 115 cc 7 0 in3 Max Pressure 6000 psi 413 bar Rated Pressure 5800 psi 400 bar Mfg Sauer Danfoss or Leduc Model H1B or MVA Type 2 Speeds Number of Motors 1 Maximum Motor Speed 3600 rpm Max Case...

Page 85: ...er of Clockwise Turns to Increase Setting 6 Valve Hex Size 1 1 8 in Valve Installation Torque 45 50 ft lb Adjustment Screw Internal Hex Size 5 32 in Locknut Hex Size 9 16 in Locknut Torque 80 90 ft lb...

Page 86: ...84 Drum Mulcher Operation and Maintenance Manual Specifications Hydraulic Schematic...

Page 87: ...5 ft lb 47 N m 42 ft lb 57 N m 54 ft lb 73 N m 59 ft lb 80 N m 77 ft lb 104 N m 30 ft lb 41 N m 42 ft lb 57 N m 1 2 42 ft lb 57 N m 54 ft lb 73 N m 64 ft lb 87 N m 83 ft lb 113 N m 91 ft lb 123 N m 11...

Page 88: ...86 Drum Mulcher Operation and Maintenance Manual QUALITY DEPENDABILITY INTEGRITY...

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