Operation, Parts and Service Manual

PC6004



Diamond Products Limited
Heavy & Specialty Equipment Operations
2016 East Karcher Rd • Nampa ID, 83687
Phone 208-899-8020 • Phone Toll Free 800.225.0142
Fax 208-899-8111
 Foreword: 
Operators and maintenance personnel must carefully read and understand this manual before using the 
machine or performing maintenance operations. 

Diamond Products cannot reasonably predict every circumstance that might involve a potential hazard 
during the operation or maintenance of the machine; for this reason, the safety messages included in 
this manual and applied into the machine may not include all possible safety precautions. 

DOCUMENT #: 1803659 Page 3 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Table of Contents
Owner’s Manual
 
Warranty Section 1

Placing Parts Orders Section 2

Safety Section 3

Operator Orientation Section 4

Daily Equipment Inspection Section 5

Lubrication and Maintenance Section 6

Controls Overview Section 7

Basic Operation Instructions Section 8

Blade Shaft Speeds Section 9

Blade Shaft Removal & Installation Section 10

Hydraulic and Electrical Schematics Section 11

Reference Material Section 12

Machine Serial Numbers Section 13

Origional Instructions

Please Note: The information provided is subject to change. Diamond Products has provided this
information in good faith and is not liable for how this information is interpreted or applied.

DOCUMENT #: 1803659 Page 4 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 1
Section

Warranty  

DOCUMENT #: 1803659 Page 5 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 6 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 7 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 Cat Engine Warranty and Service: 
 

This engine has been registered in Cat’s system. For any warranty issues or service contact your 
local Cat dealer. The link below will help you find your nearest Cat dealer. 

https://www.cat.com/en_US/support/dealer‐locator.html 

DOCUMENT #: 1803659 Page 8 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Effective with sales to the first user on or after June 1, 2012
CATERPILLAR LIMITED WARRANTY
New and Remanufactured 3000 Family, C0.5 through C4.4, and ACERT™ Engines
DOCUMENT #: 1803659
Caterpillar Inc. or any of its subsidiaries (“Caterpillar”) warrants new and
remanufactured 3000 Family, C0.5 through C4.4, and ACERT industrial
engines sold by it, to be free from defects in material and workmanship.
ACERT industrial engines refer to the C6.6, C7, C7.1, C9, C9.3, C11,
C13, C15, C18, C27, and C32 engine models.
This warranty does not apply to engines sold for use in marine,
petroleum, electric power generation and on-highway vehicle
applications, engines in machines manufactured by Caterpillar, or Cat®
batteries. These products are covered by other Caterpillar warranties.
This warranty is subject to the following:
Warranty Period
The standard warranty period for new and remanufactured 3003, 3011,
3013, 3014, 3024, C0.5, C0.7, C1.1, C1.5, C1.6, C1.7, and C2.2 engines
used in mobile agricultural, industrial and locomotive applications is 24
months or 2000 hours, whichever occurs first (with the first 12 months at
unlimited hours) after the date of delivery to the first user.
The standard warranty period for new and remanufactured 3034,
3044, 3054, 3056, C3.4, C4.4, C6.6 and C7.1 engines used in mobile
agricultural, industrial, and locomotive applications is 24 months or 3000
Page 9 of 170
hours, whichever occurs first (with the first 12 months at unlimited hours)
after the date of delivery to the first user.
For new and remanufactured 3034, 3044, 3054, 3056, C0.5, C0.7, C1.1,
C1.5, C1.6, C1.7, C2.2, C3.4, C4.4, C6.6 and C7.1 engines:
• Low Usage: In cases where the engine use does not exceed 500
hours per year, the warranty period is extended for one additional
year or until the engine use reaches a total of 1500 hours in the
3rd year of warranty, whichever occurs first, after the date of
delivery to the first user.
The standard warranty period for new and remanufactured C7, C9,
C9.3, C11, C13, C15, C18, C27, and C32 engines (i) for use in mobile
agricultural applications, 24 months after the date of delivery to the first
user and (ii) for industrial, and locomotive applications 24 months or
3000 hours, whichever occurs first (with the first 12 months at unlimited
hours), after the date of delivery to the first user.
The standard warranty period for rotating electrics (i) used on new
and remanufactured 3000 Family, C0.5 through C4.4, C6.6 and C7.1
engines is 12 months from the date of engine delivery to the first user,
and (ii) used on new and remanufactured C7, C9, C9.3, C11, C13, C15,
C18, C27, C32 engines is 24 months or 3000 hours, whichever occurs
first (with the first 12 months at unlimited hours) after the date of engine
delivery to the first user.
For all other applications the warranty period is 12 months after date of
delivery to the first user.
DATE PRINTED: 9/20/18
LAST UPDATE: 9/20/18
SELF5720
Worldwide
Extended Warranty
For all new and remanufactured 3000 Family, C0.5 through C4.4, and
ACERT engines:
• Major Components: A major components extended warranty
applies solely to the following components: cylinder block casting,
cylinder head casting, crankshaft (excluding bearings), camshaft,
and connecting rods. These parts are warranted against defects in
material and workmanship for 36 months after the date of delivery
to the first user. This warranty runs concurrently with the standard
warranty period.
Caterpillar Responsibilities
If a defect in material or workmanship is found during the standard
warranty period or the extended warranty period, as applicable,
Caterpillar will, during normal working hours and at a place of business
of a Cat dealer or other source approved by Caterpillar:
• Provide (at Caterpillar’s choice) new, remanufactured, or
Caterpillar approved repaired parts or assembled components
needed to correct the defect.
Note: New, remanufactured, or Caterpillar approved repaired parts or
assembled components provided under the terms of this warranty
are warranted for the remainder of the warranty period applicable
to the product in which installed as if such parts were original
components of that product. Items replaced under this warranty
become the property of Caterpillar.
• Replace lubricating oil, filters, coolant, and other service items
made unusable by the defect.
Provide reasonable and customary labor needed to correct the defect.
For new and remanufactured 3003, 3011, 3013, 3014, 3024, C0.5, C0.7,
C1.1, C1.5, C1.6, C1.7, and C2.2 engines:
- A maximum of 10 hours of labor to disconnect and reconnect the
product to its attached equipment, mounting, and support system
For new and remanufactured 3034, 3044, 3054, 3056, C3.4, C4.4, C6.6
and C7.1 engines:
- A maximum of 15 hours of labor to disconnect and reconnect the
product to its attached equipment, mounting, and support system
For new and remanufactured 3000 Family and C0.5 through C7.1
engines:
• Provide travel labor, up to four hours round trip, if in the opinion
of Caterpillar, the product cannot reasonably be transported to a
place of business of a Cat dealer or other source approved by
Caterpillar (travel labor in excess of four hours round trip, and any
meals, mileage, lodging, etc. is the user’s responsibility).
For new and remanufactured C9, C9.3, C11, C13, C15, C18, C27, and
C32 engines:
• Provide reasonable travel expenses for authorized mechanics,
including meals, mileage, and lodging when Caterpillar elects to
make the repair on-site.
User Responsibilities
The user is responsible for:
• Providing proof of the delivery date to the first user.
• Labor costs, except as stated under “Caterpillar Responsibilities.”
• Travel expenses not covered under “Caterpillar Responsibilities.”
• All costs associated with transporting the product to and from the
place of business of a Cat dealer or other source approved by
Caterpillar.
• Premium or overtime labor costs.
• Parts shipping charges in excess of those that are usual and
customary.
• Local taxes, if applicable.
• Costs to investigate complaints, unless the problem is caused by
a defect in Caterpillar material or workmanship.
• Giving timely notice of a warrantable failure and promptly making
the product available for repair.
• Performing all required maintenance (including use of proper fuel,
oil, lubricants, and coolant) and items replaced due to normal
wear and tear.
• Allowing Caterpillar access to all electronically stored data.
Limitations
Caterpillar is not responsible for:
• Failures resulting from any use or installation that Caterpillar
judges improper.
• Failures resulting from attachments, accessory items, and parts
not sold or approved by Caterpillar.
• Failures resulting from abuse, neglect, and/or improper repair.
• Failures resulting from user’s delay in making the product
available after being notified of a potential product problem.
• Failures resulting from unauthorized repair or adjustment, and
unauthorized fuel-setting changes.
• Damage to parts, fixtures, housings, attachments, and accessory
items, which are not part of the engine.
(Continued on reverse side…)
 This warranty covers every major component of the products. Claims under this warranty should be
limited to a place of business of a Cat dealer or other source approved by Caterpillar. For further
information concerning either the location to submit claims or Caterpillar as the issuer of this warranty,
write Caterpillar Inc., 100 N.E. Adams St., Peoria, IL USA 61629.
Caterpillar’s obligations under this Limited Warranty are subject to, and shall not apply in contravention
of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of
any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
A) For products operating outside of Australia, Fiji, Nauru, New Caledonia, New Zealand, Papua New
Guinea, the Solomon Islands, and Tahiti, the following is applicable:
CATERPILLAR EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY NEGLIGENCE ON
ITS PART OR ON THE PART OF ANY OF ITS EMPLOYEES, AGENTS, OR REPRESENTATIVES
IN RESPECT OF THE MANUFACTURE OR SUPPLY OF GOODS OR THE PROVISION OF
SERVICES RELATING TO THE GOODS.
CATERPILLAR IS NOT LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES UNLESS
IMPOSED UNDER MANDATORY RIGHTS.
IF OTHERWISE APPLICABLE, THE VIENNA CONVENTION ON CONTRACTS FOR THE
INTERNATIONAL SALE OF GOODS IS EXCLUDED IN ITS ENTIRETY.
C) For products supplied in Australia:

DOCUMENT #: 1803659
NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY BY
CATERPILLAR, EXPRESS OR IMPLIED, IS APPLICABLE TO ANY ITEM CATERPILLAR SELLS
THAT IS WARRANTED DIRECTLY TO THE USER BY ITS MANUFACTURER.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE
PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN.
CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
CATERPILLAR EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY NEGLIGENCE ON
ITS PART OR ON THE PART OF ANY OF ITS EMPLOYEES, AGENTS, OR REPRESENTATIVES
IN RESPECT OF THE MANUFACTURE OR SUPPLY OF GOODS OR THE PROVISION OF
SERVICES RELATING TO THE GOODS.
IF OTHERWISE APPLICABLE, THE VIENNA CONVENTION ON CONTRACTS FOR THE
INTERNATIONAL SALE OF GOODS IS EXCLUDED IN ITS ENTIRETY.
For personal or family use engines operating in the USA, its territories and its possessions, some states
do not allow limitations on how long an implied warranty may last nor allow the exclusion or limitation
of incidental or consequential damages. Therefore, the previously expressed exclusion may not apply
to you. This warranty gives you specific legal rights and you may also have other rights, which vary by
jurisdiction. To find the location of the nearest Cat dealer or other authorized repair facility, call 1 (309)
IF THE PRODUCTS TO WHICH THIS WARRANTY APPLIES ARE:
I. PRODUCTS OF A KIND ORDINARILY ACQUIRED FOR PERSONAL, DOMESTIC OR
HOUSEHOLD USE OR CONSUMPTION; OR
II. PRODUCTS THAT COST AUD 40,000 OR LESS,
WHERE THOSE PRODUCTS WERE NOT ACQUIRED FOR THE PURPOSE OF RE-SUPPLY OR
FOR THE PURPOSE OF USING THEM UP OR TRANSFORMING THEM IN THE COURSE OF
PRODUCTION OR MANUFACTURE OR IN THE COURSE OF REPAIRING OTHER GOODS OR
FIXTURES, THEN THIS SECTION C APPLIES.
THE FOLLOWING MANDATORY TEXT IS INCLUDED PURSUANT TO THE AUSTRALIAN
CONSUMER LAW AND INCLUDES REFERENCES TO RIGHTS THE USER MAY HAVE AGAINST
THE DIRECT SUPPLIER OF THE PRODUCTS: OUR GOODS COME WITH GUARANTEES THAT
CANNOT BE EXCLUDED UNDER THE AUSTRALIAN CONSUMER LAW. YOU ARE ENTITLED
TO A REPLACEMENT OR REFUND FOR A MAJOR FAILURE AND COMPENSATION FOR ANY
OTHER REASONABLY FORESEEABLE LOSS OR DAMAGE. YOU ARE ALSO ENTITLED TO
HAVE THE GOODS REPAIRED OR REPLACED IF THE GOODS FAIL TO BE OF ACCEPTABLE
QUALITY AND THE FAILURE DOES NOT AMOUNT TO A MAJOR FAILURE. THE INCLUSION
OF THIS TEXT DOES NOT CONSTITUTE ANY REPRESENTATION OR ACCEPTANCE BY
CATERPILLAR OF LIABILITY TO THE USER OR ANY OTHER PERSON IN ADDITION TO THAT
WHICH CATERPILLAR MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW.

Page 10 of 170
675-1000. If you have questions concerning this warranty or its application, call or write:
TO THE EXTENT THE PRODUCTS FALL WITHIN THIS SECTION C BUT ARE NOT OF A
In USA and Canada: Caterpillar Inc., 100 N.E. Adams St, Peoria, IL USA 61629, Attention: Customer KIND ORDINARILY ACQUIRED FOR PERSONAL, DOMESTIC OR HOUSEHOLD USE OR
Service Manager, Telephone 1 (309) 675-1000, outside the USA and Canada: Contact your Cat CONSUMPTION, CATERPILLAR LIMITS ITS LIABILITY TO THE EXTENT IT IS PERMITTED TO
dealer. DO SO UNDER THE AUSTRALIAN CONSUMER LAW TO, AT ITS OPTION, THE REPAIR OR
REPLACEMENT OF THE PRODUCTS, THE SUPPLY OF EQUIVALENT PRODUCTS, OR THE
B) For products operating in Australia, Fiji, Nauru, New Caledonia, New Zealand, Papua New Guinea,
PAYMENT OF THE COST OF SUCH REPAIR OR REPLACEMENT OR THE ACQUISITION OF
the Solomon Islands, and Tahiti, the following is applicable:
EQUIVALENT PRODUCTS.
THIS WARRANTY IS IN ADDITION TO WARRANTIES AND CONDITIONS IMPLIED BY STATUTE
THE WARRANTY SET OUT IN THIS DOCUMENT IS GIVEN BY CATERPILLAR INC. OR ANY
AND OTHER STATUTORY RIGHTS AND OBLIGATIONS THAT BY ANY APPLICABLE LAW
OF ITS SUBSIDIARIES, 100 N. E. ADAMS ST, PEORIA, IL USA 61629, TELEPHONE 1 309 675
CANNOT BE EXCLUDED, RESTRICTED, OR MODIFIED (“MANDATORY RIGHTS”). ALL OTHER
1000, THE USER IS RESPONSIBLE FOR ALL COSTS ASSOCIATED WITH MAKING A CLAIM
WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED (BY STATUTE OR OTHERWISE), ARE
UNDER THE WARRANTY SET OUT IN THIS DOCUMENT, EXCEPT AS EXPRESSLY STATED
EXCLUDED. WITHOUT LIMITING THE FOREGOING PROVISIONS OF THIS PARAGRAPH, WHERE
OTHERWISE IN THIS DOCUMENT, AND THE USER IS REFERRED TO THE BALANCE OF THE
A PRODUCT IS SUPPLIED FOR BUSINESS PURPOSES, THE CONSUMER GUARANTEES
DOCUMENT TERMS CONCERNING CLAIM PROCEDURES, CATERPILLAR RESPONSIBILITIES
UNDER THE CONSUMER GUARANTEES ACT 1993 (NZ) WILL NOT APPLY.
AND USER RESPONSIBILITIES.
NEITHER THIS WARRANTY NOR ANY OTHER CONDITION OR WARRANTY BY CATERPILLAR,
TO THE EXTENT PERMISSIBLE BY LAW, THE TERMS SET OUT IN THE REMAINDER OF THIS
EXPRESS OR IMPLIED (SUBJECT ONLY TO THE MANDATORY RIGHTS), IS APPLICABLE TO
WARRANTY DOCUMENT (INCLUDING SECTION B) CONTINUE TO APPLY TO PRODUCTS TO
ANY ITEM CATERPILLAR SELLS THAT IS WARRANTED DIRECTLY TO THE USER BY ITS
WHICH THIS SECTION C APPLIES.
MANUFACTURER.
©2017 Caterpillar All Rights Reserved.
IF THE MANDATORY RIGHTS MAKE CATERPILLAR LIABLE IN CONNECTION WITH SERVICES
CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow", the "Power Edge" trade dress as
OR GOODS, THEN TO THE EXTENT PERMITTED UNDER THE MANDATORY RIGHTS, THAT
well as corporate and product identity used herein, are trademarks of Caterpillar and may not be
LIABILITY SHALL BE LIMITED AT CATERPILLAR’S OPTION TO (a) IN THE CASE OF SERVICES,
used without permission.
THE SUPPLY OF THE SERVICES AGAIN OR THE PAYMENT OF THE COST OF HAVING THE
SERVICES SUPPLIED AGAIN AND (b) IN THE CASE OF GOODS, THE REPAIR OR REPLACEMENT
OF THE GOODS, THE SUPPLY OF EQUIVALENT GOODS, THE PAYMENT OF THE COST OF

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
SUCH REPAIR OR REPLACEMENT OR THE ACQUISITION OF EQUIVALENT GOODS.

SELF5720
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Caterpillar Inc. ("Caterpillar") are pleased to explain the emission control
system warranty on your 2015 through 2019 engine. In California, new off-road engines must be designed, built,
and equipped to meet the State’s stringent anti-smog standards. Caterpillar must warrant the emission control
system on your engine for the periods of time listed below, provided there has been no abuse, neglect, or improper
maintenance of your engine.
Your emission control system may include parts such as fuel-injection system and the air induction system. Also
included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Caterpillar will repair your heavy-duty off-road engine at no cost to you
including diagnosis, parts, and labor.
MANUFACTURER’S WARRANTY COVERAGE:
The 2015 through 2019 heavy-duty off-road engines are warranted for the warranty period set forth below. If any
emission-related part on your engine is defective, the part will be repaired or replaced by Caterpillar.
OWNER’S WARRANTY RESPONSIBILITIES:
– As the off-road engine owner, you are responsible for the performance of the required maintenance listed
in your owner’s manual. Caterpillar recommends that you retain all receipts covering maintenance on your
off-road engine, but Caterpillar cannot deny warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
– As the off-road engine owner, you should however be aware that Caterpillar may deny you warranty coverage
if your off-road engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved
PRGL¿FDWLRQV
– Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with California’s emissions requirements.
– You are responsible for initiating the warranty process. The ARB suggests that you present your off-road
engine to a Caterpillar dealer as soon as a problem exists. The warranty repairs should be completed by the
dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact Caterpillar Inc.,
Warranty Manager at 1-309-675-1000.
Emission Control Warranty for California
Caterpillar Inc. (Caterpillar) warrants to the ultimate purchaser and each subsequent purchaser that new nonroad
diesel engines (including Tier 1 and Tier 2 marine propulsion engines < 37 kW and Tier 1 through Tier 4 marine
auxiliary engines < 37 kW, but excluding locomotive and other marine engines) operated and serviced in
California, including all parts of their emission control system ("emission related components"), are:
1. Designed, built, and equipped so as to conform, at the time of sale, to all applicable regulations adopted by
the California Air Resources Board (ARB).
2. Free from defects in materials and workmanship which cause the failure of an emission related component to
EHLGHQWLFDOLQDOOPDWHULDOUHVSHFWVWRWKHFRPSRQHQWGHVFULEHGLQ&DWHUSLOODU¶VDSSOLFDWLRQIRUFHUWL¿FDWLRQIRU
the warranty period.
• Miscellaneous Items Used in Above Systems
ƒ Vacuum, temperature, and time sensitive valves and switches
ƒ Electronic control units, sensors, solenoids, and wiring harnesses
ƒ +RVHVEHOWVFRQQHFWRUVDVVHPEOLHVFODPSV¿WWLQJVWXELQJVHDOLQJJDVNHWVRUGHYLFHVDQGPRXQWLQJ
hardware
ƒ Pulleys, belts and idlers
ƒ Emission control information labels
ƒ Any other part with the primary purpose of reducing emissions or that can increase emissions during
IDLOXUHZLWKRXWVLJQL¿FDQWO\GHJUDGLQJHQJLQHSHUIRUPDQFH
ƒ Components from any other system developed to control emissions.
ƒ Damages to other engine components caused by a failure under warranty of any warranted part.
This Emission Control Warranty does not cover components whose failure would not increase the engine’s
emissions of any pollutant.
Caterpillar Responsibilities
During the warranty period, if a defect in materials or workmanship is found which causes the failure of an
emission related component to be identical in all material respects to the component as described in Caterpillar’s
DSSOLFDWLRQIRUFHUWL¿FDWLRQ&DWHUSLOODUZLOOSURYLGHWKHIROORZLQJDWQRFKDUJHWKURXJKD&DWGHDOHURURWKHUVRXUFH
approved by Caterpillar:
ƒ New, remanufactured, or repaired components (at Caterpillar’s choice) required to correct the defect. Note:
emission related components replaced under warranty become the property of Caterpillar.
ƒ Reasonable or customary labor, during normal working hours, needed to correct the defect, including labor
for removal and installation when necessary to make the repair
In an emergency, repairs may be performed at any service establishment, or by the user. Caterpillar will
reimburse the user for their expenses including diagnostic charges for such emergency repair These expenses
shall not exceed Caterpillar’s suggested retail price for all warranted emission related components replaced, and
labor charges based on Caterpillar’s recommended time allowance for the warranty repair and the geographically
appropriate hourly labor rate. An emission related component not being available within 30 days or a repair not
being complete within 30 days constitutes an emergency.
User Responsibilities
During the warranty period the user is responsible for the following:
ƒ Providing proof of delivery date to the ultimate purchaser
ƒ Parts shipping charges in excess of those that are usual and customary.
ƒ Premium or overtime labor costs.
ƒ Local taxes, if applicable.
ƒ Costs to investigate complaints which are not caused by a defect in Caterpillar material or workmanship.
ƒ Providing timely notice of a warrantable failure and promptly making the product available for repair The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
ƒ Presenting replaced emission related components and validated invoices at a place of business of a Cat
dealer or other source approved by Caterpillar, as a condition of reimbursement.

Warranty Period ƒ Proper maintenance of the engine, at the owner’s expense, including all recommended maintenance and
ÀXLGFKDQJHVDWVFKHGXOHGLQWHUYDOVDQGXVHRISURSHUIXHORLOOXEULFDQWVFRRODQWDQG¿OWHUV&DWHUSLOODU
7KHZDUUDQW\SHULRGVKDOOEHWKHSHULRGRI\HDUVRUKRXUVRIRSHUDWLRQVSHFL¿HGLQWKHIROORZLQJWDEOHZKLFKHYHU recommends that you retain all receipts and records covering the maintenance on your engine, but cannot
RFFXUV¿UVWDIWHUWKHGDWHRIGHOLYHU\WRWKHXOWLPDWHSXUFKDVHU deny warranty solely for the lack of receipts and records or for your failure to ensure the performance of all
If your engine is certified as: And its maximum And its rated Then its warranty period is scheduled maintenance.
power is: speed is: (whichever occurs first): Maintenance, replacement, or repair of the emission control devices and systems may be performed by any off-
Variable speed or constant speed kW < 19 Any speed 1,500 hours or two years URDGHQJLQHUHSDLUHVWDEOLVKPHQWRULQGLYLGXDOXVLQJFHUWL¿HGRIIURDGHQJLQHSDUWV7KHXVHUVKRXOGHQVXUHWKDW
such parts are equivalent in design and durability to genuine Cat parts. Use of non- genuine Cat parts does not
Constant speed 19 < kW < 37 3,000 rpm or higher 1,500 hours or two years invalidate the warranty. However, Caterpillar is not liable for parts that are not genuine Cat parts.
Constant speed 19 < kW < 37 Less than 3,000 rpm KRXUVRU¿YH\HDUV
Limitations
Variable speed 19 < kW < 37 Any speed KRXUVRU¿YH\HDUV
In addition to any other limitations stated herein, Caterpillar is not responsible for failures of emission related
Variable speed or constant speed kW > 37 Any speed KRXUVRU¿YH\HDUV components due to:
Any warranted part that is scheduled for replacement as required maintenance is warranted for the period of time ƒ Any use or installation that Caterpillar judges improper.
SULRUWRWKH¿UVWVFKHGXOHGUHSODFHPHQWSRLQWIRUWKDWSDUW
ƒ Attachments, systems, accessories, components or parts not sold nor approved by Caterpillar
Any part repaired or replaced under warranty is warranted for the remainder of the warranty period.
ƒ 7KHXVHRIDGGRQRUPRGL¿HGSDUWVWKDWDUHQRWH[HPSWHGE\WKH$5%
Warranty Coverage
ƒ Abuse, neglect, vandalism, or improper engine maintenance or repair, including the installation of parts or
This Emission Control Warranty covers: assembled components in contaminated systems.
ƒ All components whose failure would increase the engine’s emissions of any pollutant, including: ƒ )LUHDFFLGHQWDFWVRI*RGRURWKHUHYHQWVEH\RQGWKHFRQWURORI&DWHUSLOODU
• Fuel Metering System
ƒ 8VHU¶VGHOD\LQPDNLQJWKHSURGXFWDYDLODEOHDIWHUEHLQJQRWL¿HGRIDSRWHQWLDOSURGXFWSUREOHP
ƒ Fuel injection system
• Air Induction System ƒ Unauthorized repairs or adjustments and unauthorized fuel setting changes.
ƒ Controlled hot air intake system
ƒ Intake manifold &DWHUSLOODULVQRWUHVSRQVLEOHIRUGDPDJHVWRSDUWV¿[WXUHVKRXVLQJVDWWDFKPHQWVDQGDFFHVVRU\LWHPVWKDW
ƒ Turbocharger systems are not part of the engine (including any products of other manufacturers packaged and sold by Caterpillar).
ƒ Charge air cooling systems Notwithstanding the foregoing, Caterpillar will cover damages to other engine components proximately caused
‡ ([KDXVW*DV5HFLUFXODWLRQ(*56\VWHP by a failure under this warranty of any warranted part.
ƒ (*5YDOYHERG\ This warranty is in addition to Caterpillar’s standard warranty, applicable to the off-road diesel engine product
ƒ (*5UDWHIHHGEDFNDQGFRQWUROV\VWHP involved.
• Catalyst or Thermal Reactor System
ƒ Catalytic converter THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
ƒ Exhaust manifold ,1&/8',1* $1< :$55$17< 2) 0(5&+$17$%,/,7< 25 ),71(66 )25 $ 3$57,&8/$5 385326(
• Particulate Controls REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES,
ƒ 7UDSV¿OWHUVSUHFLSLWDWRUVDQGDQ\RWKHUGHYLFHXVHGWRFDSWXUHSDUWLFXODWHHPLVVLRQV AS SPECIFIED HEREIN. CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL
ƒ Regenerators, oxidizers, fuel additive devices, and any other device used to regenerate or aid in the '$0$*(6 (;&(37 '$0$*(6 72 27+(5 (1*,1( &20321(176 352;,0$7(/< &$86(' %< $
regeneration of the particulate control device )$,/85(81'(57+,6:$55$17<2)$1<:$55$17('3$57(;&(37'$0$*(67227+(5(1*,1(
ƒ Control device enclosures and manifolding COMPONENTS PROXIMATELY CAUSED BY A FAILURE UNDER THIS WARRANTY OF ANY WARRANTED
ƒ Smoke Puff Limiters PART.
• Advanced Oxides of Nitrogen (NOx) Controls Customer Assistance
ƒ Selective Catalyst Reduction
Caterpillar aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do
ƒ Reductant (urea/fuel) containers/dispensing systems not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, write:
• Positive Crankcase Ventilation (PCV) System Caterpillar Inc., 100 N. E. Adams St., Peoria, IL USA 61629.
ƒ PCV valve
ƒ 2LO¿OOHUFDS
DOCUMENT #: 1803659 Page 11 of 170 LAST UPDATE: 9/20/18
SELF9009-01 DATE
Effective for engines PRINTED:on9/20/18
manufactured or after 01 Jan 2015
Federal Emission Control Warranty appropriate hourly labor rate. An emission related component not being available within 30 days or a repair not
being complete within 30 days constitutes an emergency.
Caterpillar Inc. (Caterpillar) warrants to the ultimate purchaser and each subsequent purchaser that new nonroad
diesel engines and stationary diesel engines less than 10 liters per cylinder (including Tier 1 and Tier 2 marine User Responsibilities
engines < 37 kW, but excluding locomotive and other marine engines) operated and serviced in the United States During the warranty period the user is responsible for the following:
and Canada, including all parts of their emission control systems ("emission related components"), are:
ƒ 3URYLGLQJSURRIRIGDWHWKHHQJLQHZDV¿UVWSODFHGLQWRVHUYLFH
1. Designed, built, and equipped so as to conform, at the time of sale, with applicable emission standards
prescribed by the United States Environmental Protection Agency (EPA) by way of regulation. ƒ Parts shipping charges in excess of those that are usual and customary.
2. Free from defects in materials and workmanship in emission related components that can cause the engine ƒ Premium or overtime labor costs.
to fail to conform to applicable emission standards for the warranty period.
ƒ Local taxes, if applicable.
Warranty Period ƒ Costs to investigate complaints which are not caused by a defect in Caterpillar material or workmanship.
7KHZDUUDQW\SHULRGVKDOOEHWKHSHULRGRI\HDUVRUKRXUVRIRSHUDWLRQVSHFL¿HGLQWKHIROORZLQJWDEOHZKLFKHYHU
ƒ Providing timely notice of a warrantable failure and promptly making the product available for repair. The
RFFXUV¿UVWDIWHUWKHHQJLQHLV¿UVWSODFHGLQWRVHUYLFH
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If your engine is certified as: And its maximum And its rated Then its warranty period is ƒ Presenting replaced emission related components and validated invoices at a place of business of a Cat
power is: speed is: (whichever occurs first): dealer or other source approved by Caterpillar, as a condition of reimbursement.
Variable speed or constant speed kW < 19 Any speed 1,500 hours or two years
ƒ Proper maintenance of the engine, at the owner’s expense, including all recommended maintenance and
Constant speed 19 < kW < 37 3,000 rpm or higher 1,500 hours or two years ÀXLGFKDQJHVDWVFKHGXOHGLQWHUYDOVDQGXVHRISURSHUIXHORLOOXEULFDQWVFRRODQWDQG¿OWHUV&DWHUSLOODU
Constant speed 19 < kW < 37 Less than 3,000 rpm KRXUVRU¿YH\HDUV recommends that you retain all receipts and records covering the maintenance on your engine, but cannot
deny warranty solely for the lack of receipts and records or for your failure to ensure the performance of all
Variable speed 19 < kW < 37 Any speed KRXUVRU¿YH\HDUV scheduled maintenance.
Variable speed or constant speed kW > 37 Any speed KRXUVRU¿YH\HDUV Maintenance, replacement, or repair of the emission control devices and systems may be performed by any
QRQURDGHQJLQHUHSDLUHVWDEOLVKPHQWRULQGLYLGXDOXVLQJFHUWL¿HGQRQURDGHQJLQHSDUWV7KHXVHUVKRXOGHQVXUH
Any warranted part that is scheduled for replacement as required maintenance is warranted for the period of time
that such parts are equivalent in design and durability to genuine Cat parts. Use of non-genuine Cat parts does
SULRUWRWKH¿UVWVFKHGXOHGUHSODFHPHQWSRLQWIRUWKDWSDUW
not invalidate the warranty. However, Caterpillar is not liable for parts that are not genuine Cat parts.
Any part repaired or replaced under warranty is warranted for the remainder of the warranty period.
Limitations
Warranty Coverage
In addition to any other limitations stated herein, Caterpillar is not responsible for failures of emission related
This Emission Control Warranty covers: components due to:
ƒ All components whose failure would increase the engine’s emissions of any pollutant, including any engine ƒ Any use or installation that Caterpillar judges improper.
parts related to the following systems:
ƒ Attachments, systems, accessories, components or parts not sold nor approved by Caterpillar.
1. Air-induction system
2. Fuel system ƒ Abuse, neglect, vandalism, or improper engine maintenance or repair, including the installation of parts or
3. Ignition system assembled components in contaminated systems.
4. Exhaust gas recirculation systems
ƒ )LUHDFFLGHQWDFWVRI*RGRURWKHUHYHQWVEH\RQGWKHFRQWURORI&DWHUSLOODU
ƒ The following parts are also covered:
ƒ 8VHU¶VGHOD\LQPDNLQJWKHSURGXFWDYDLODEOHDIWHUEHLQJQRWL¿HGRIDSRWHQWLDOSURGXFWSUREOHP
1. Aftertreatment devices
2. Crankcase ventilation valves ƒ Unauthorized repairs or adjustments and unauthorized fuel setting changes.
3. Sensors
4. Electronic control units &DWHUSLOODULVQRWUHVSRQVLEOHIRUGDPDJHWRSDUWV¿[WXUHVKRXVLQJVDWWDFKPHQWVDQGDFFHVVRU\LWHPVWKDWDUH
not part of the engine (including any products of other manufacturers packaged and sold by Caterpillar).
Components whose only purpose is to reduce emissions or whose failure will increase emissions without
ƒ
VLJQL¿FDQWO\GHJUDGLQJHQJLQHSHUIRUPDQFH This Emission Control Warranty is in addition to Caterpillar’s standard warranty, applicable to the nonroad or
stationary diesel engine product involved. Caterpillar is not responsible for damages to other engine components
ƒ Components from any other system developed to control emissions.
caused by a failure of an emission related component, unless otherwise covered by standard warranty.
This Emission Control Warranty does not cover components whose failure would not increase the engine’s
emissions of any pollutant. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
,1&/8',1* $1< :$55$17< 2) 0(5&+$17$%,/,7< 25 ),71(66 )25 $ 3$57,&8/$5 385326(
Caterpillar Responsibilities REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES,
AS SPECIFIED HEREIN. CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL
During the warranty period, if a defect in materials or workmanship is found in an emission related component that
'$0$*(6
can cause the engine to fail to conform to applicable emission standards, Caterpillar will provide the following at
no charge through a Cat dealer or other source approved by Caterpillar: Customer Assistance
ƒ New, remanufactured, or repaired components (at Caterpillar’s choice) required to correct the defect. Note: Caterpillar aims to ensure that the Emission Control Warranty is properly administered. In the event that you do
emission related components replaced under warranty become the property of Caterpillar. not receive the warranty service to which you believe you are entitled under the Emission Control Warranty, write:
Caterpillar Inc., 100 N. E. Adams St., Peoria, IL USA 61629.
ƒ Reasonable or customary labor, during normal working hours, needed to correct the defect, including labor for
removal and installation when necessary to make the repair. Authorized dealers are recommended for maintenance and repair work as they are staffed with trained personnel,
proper tools, and are aware of the latest maintenance methods and procedures. Owners and others who desire
In an emergency, repairs may be performed at any service establishment, or by the user. Caterpillar will reimburse
to perform their own work should obtain current service information from their Cat dealer
the user for their expenses including diagnostic charges for such emergency repair. These expenses shall not
exceed Caterpillar’s suggested retail price for all warranted emission related components replaced, and labor
charges based on Caterpillar’s recommended time allowance for the warranty repair and the geographically

DOCUMENT #: 1803659 Page 12 of 170 LAST UPDATE: 9/20/18

SELF9009-01 DATE
Effective for engines PRINTED:on9/20/18
manufactured or after 01 Jan 2015
 2
Section

Placing Parts Orders

DOCUMENT #: 1803659 Page 13 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
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) 
 

DOCUMENT #: 1803659 Page 14 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 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 

DOCUMENT #: 1803659 Page 15 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 3
Section

Safety

DOCUMENT #: 1803659 Page 16 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
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.
DOCUMENT #: 1803659
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).
Page 17 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
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.
DOCUMENT #: 1803659 Page 18 of 170
 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.
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 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.
DOCUMENT #: 1803659 Page 19 of 170
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
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 .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
DOCUMENT #: 1803659
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.
Page 20 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 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
DOCUMENT #: 1803659
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.
Page 21 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 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.

DOCUMENT #: 1803659 Page 22 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 23 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
SECTION 1: IDENTIFICATION
1.1. Product Identifier
Product Form: Mixture
Product Name: Diamond Tooling
Synonyms: Diamond Core Bits, Diamond Blade, Cup Grinders, Diamond Wire, Grinding Discs & blocks and Diamond Segments.
Additional Information: These products in their manufactured state present a Skin Sensitization 1 hazard only. Operations such
as grinding, cutting, welding or brazing may release fumes and dust, which may present additional health and physical hazards.
Under normal conditions of use, this product may generate small amounts of dust which can pose a hazard to the user.
*This SDS encompasses the hazards of the product during use, when dust may be generated.
1.2. Intended Use of the Product
Use of the Substance/Mixture: Cutting, drilling and grinding.
1.3. Name, Address, and Telephone of the Responsible Party
Company
Diamond Products Limited
333 Prospect Street
Elyria, OH 44035
T: (440) 323-4616
1.4. Emergency Telephone Number
Emergency Number : (440) 323-4616
SECTION 2: HAZARDS IDENTIFICATION
2.1. Classification of the Substance or Mixture
Flam. Sol. 2 H228
Eye Irrit. 2 H319
Resp. Sens. 1 H334
Skin Sens. 1 H317
Carc. 1B H350
Repr. 2 H361
STOT RE 1 H372
Aquatic Acute 1 H400
Aquatic Chronic 1 H410
Comb. Dust
Full text of hazard classes and H-statements : see section 16
2.2. Label Elements
GHS-US Labeling
Hazard Pictograms (GHS-US) :

GHS02 GHS07 GHS08 GHS09

Signal Word (GHS-US) : Danger

Hazard Statements (GHS-US)
Precautionary Statements (GHS-US)
: May form combustible dust concentrations in air.
H228 - Flammable solid.
H317 - May cause an allergic skin reaction.
H319 - Causes serious eye irritation.
H334 - May cause an allergy or asthma symptoms or breathing difficulties if
inhaled.
H350 - May cause cancer (inhalation).
H361 - Suspected of damaging fertility or the unborn child.
H372 - Causes damage to organs (respiratory tract) through prolonged or repeated
exposure (inhalation).
H400 - Very toxic to aquatic life.
H410 - Very toxic to aquatic life with long lasting effects.
: P201 - Obtain special instructions before use.

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 P202 - Do not handle until all safety precautions have been read and understood.
P210 - Keep away from extremely high or low temperatures, ignition sources, and
incompatible materials. - No smoking.
P240 - Ground/Bond container and receiving equipment.
P241 - Use explosion-proof electrical, ventilating, and lighting equipment.
P260 - Do not breathe dust.
P264 - Wash hands, forearms, and other exposed areas thoroughly after handling.
P270 - Do not eat, drink or smoke when using this product.
P272 - Contaminated work clothing must not be allowed out of the workplace.
P273 - Avoid release to the environment.
P280 - Wear protective gloves, protective clothing, and eye protection.
P284 - [In case of inadequate ventilation] wear respiratory protection.
P302+P352 - If on skin: Wash with plenty of water.
P304+P341 - If inhaled: If breathing is difficult, remove person to fresh air and keep
comfortable for breathing.
P305+P351+P338 - If in eyes: Rinse cautiously with water for several minutes.
Remove contact lenses, if present and easy to do. Continue rinsing.
P308+P313 - If exposed or concerned: Get medical advice/attention.
P314 - Get medical advice/attention if you feel unwell.
P321 - Specific treatment (see section 4 on this SDS).
P333+P313 - If skin irritation or rash occurs: Get medical advice/attention.
P337+P313 - If eye irritation persists: Get medical advice/attention.
P342+P311 - If experiencing respiratory symptoms: Call a poison center or doctor.
P363 - Wash contaminated clothing before reuse.
P370+P378 - In case of fire: Use appropriate media (see section 5) to extinguish.
P391 - Collect spillage.
P405 - Store locked up.
P501 - Dispose of contents/container in accordance with local, regional, national,
and international regulations.
2.3. Other Hazards
Exposure may aggravate pre-existing eye, skin, or respiratory conditions. Hearing protection should be used to control noise
exposures from grinding.
2.4. Unknown Acute Toxicity (GHS-US)
No data available
SECTION 3: COMPOSITION/INFORMATION ON INGREDIENTS
3.1. Substance
Not applicable
3.2. Mixture
Name Product Identifier % GHS-US classification
Cobalt (CAS-No.) 7440-48-4 15 - 99.8 Flam. Sol. 2, H228
Eye Irrit. 2A, H319
Resp. Sens. 1B, H334
Skin Sens. 1, H317
Carc. 1B, H350
Repr. 2, H361
Aquatic Acute 1, H400
Aquatic Chronic 1, H410
Comb. Dust
Copper (CAS-No.) 7440-50-8 5 - 90 Aquatic Acute 1, H400
Aquatic Chronic 3, H412
Comb. Dust

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Nickel (CAS-No.) 7440-02-0 10 - 75 Skin Sens. 1, H317
Carc. 2, H351
STOT RE 1, H372
Aquatic Acute 1, H400
Aquatic Chronic 3, H412
Comb. Dust
Iron (CAS-No.) 7439-89-6 5 - 50 Comb. Dust
Tungsten carbide (CAS-No.) 12070-12-1 2 - 50 Comb. Dust
Diamond (CAS-No.) 7782-40-3 3 - 18 Not classified
Silver (CAS-No.) 7440-22-4 5 - 15 Aquatic Acute 1, H400
Aquatic Chronic 1, H410
Comb. Dust
Tin (CAS-No.) 7440-31-5 2 - 10 Comb. Dust
Manganese (CAS-No.) 7439-96-5 1-5 Comb. Dust
Titanium (CAS-No.) 7440-32-6 1-3 Flam. Sol. 1, H228
Comb. Dust
Chromium carbide (Cr3C2) (CAS-No.) 12012-35-0 1 - 2.9 Not classified
Zinc (CAS-No.) 7440-66-6 1 - 1.5 Aquatic Acute 1, H400
Aquatic Chronic 1, H410
Comb. Dust
Full text of H-phrases: see section 16
SECTION 4: FIRST AID MEASURES
4.1. Description of First-aid Measures
First-aid Measures General: Never give anything by mouth to an unconscious person. If you feel unwell, seek medical advice
(show the label where possible).
First-aid Measures After Inhalation: For particulates and dust: Using proper respiratory protection, move the exposed person to
fresh air at once. Encourage exposed person to cough, spit out, and blow nose to remove dust. Immediately call a poison center,
physician, or emergency medical service.
First-aid Measures After Skin Contact: For particulates and dust: Immediately drench affected area with water for at least 15
minutes. Obtain medical attention if irritation/rash develops or persists.
First-aid Measures After Eye Contact: Immediately rinse with water for at least 15 minutes. Remove contact lenses, if present
and easy to do. Continue rinsing. Obtain medical attention.
First-aid Measures After Ingestion: Rinse mouth. Do NOT induce vomiting. Obtain medical attention.
4.2. Most Important Symptoms and Effects Both Acute and Delayed
Symptoms/Injuries: In shipped form: May cause an allergic skin reaction. For particulates and dust generated during processing:
May cause cancer (inhalation). Suspected of damaging fertility or the unborn child. May cause allergy or asthma symptoms or
breathing difficulties if inhaled. Skin sensitization. Causes serious eye irritation. Causes damage to organs (respiratory tract)
through prolonged or repeated exposure (inhalation).
Symptoms/Injuries After Inhalation: Dust may be harmful or cause irritation. Exposure may produce cough, mucous secretions,
shortness of breath, chest tightness or other symptoms indicative of an allergic/sensitization reaction. Inhalation of dusts and
fumes can cause metal fume fever. Symptoms can include a metallic or sweet taste in the mouth, sweating, shivering, headache,
throat irritation, fever, chills, thirstiness, muscle aches, nausea, vomiting, weakness, fatigue, and shortness of breath.
Symptoms/Injuries After Skin Contact: May cause an allergic skin reaction. Direct contact may cause irritation by mechanical
abrasion.
Symptoms/Injuries After Eye Contact: For particulates and dust: Contact causes severe irritation with redness and swelling of
the conjunctiva. . May cause mechanical eye irritation.
Symptoms/Injuries After Ingestion: Ingestion may cause adverse effects.

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Chronic Symptoms: For particulates, dust, or fumes from processing: May cause cancer by inhalation. Suspected of damaging
fertility or the unborn child. Causes damage to organs (respiratory tract) through prolonged or repeated exposure (inhalation).
Chromium: Certain hexavalent chromium compounds have been demonstrated to be carcinogenic on the basis of
epidemiological investigations on workers and experimental studies in animals. Increased incidences of respiratory cancer have
been found in chromium (VI) workers. There is an increased incidence of lung cancer in industrial workers exposed to chromium
(VI) compounds. Please refer to IARC volume 23 for a more detailed discussion. Chronic exposure to cobalt-containing hard metal
(dust or fume) can result in a serious lung disease called "hard metal lung disease", which is a type of pneumoconiosis (lung
fibrosis). Copper: Overexposure to fumes may cause metal fume fever (chills, muscle aches, nausea, fever, dry throat, cough,
weakness, lassitude); metallic or sweet taste; discoloration of skin and hair. Tissue damage of mucous membranes may follow
chronic dust exposure. Nickel: May cause a form of dermatitis known as nickel itch and intestinal irritation, which may cause
disorders, convulsions and asphyxia. Nickel metal powder, when respirable, is a suspected human carcinogen, and is known to
cause damage to the lungs through inhalation. Manganese: Chronic exposure can cause inflammation of the lung tissue, scarring
the lungs (pulmonary fibrosis). Chronic exposure to excessive manganese levels can lead to a variety of psychiatric and motor
disturbances, termed manganism. Repeated inhalation of iron oxide dust can cause siderosis a benign condition. Silver: Chronic
skin contact or ingestion of silver dust, salts or fume can result in a condition known as Argyria, a condition with bluish
pigmentation of the skin and eyes. Tin: Has been shown to increase incidence of sarcoma in animal tests. Chronic exposure to
tin dusts and fume may result in "stannosis", a mild form of pneumoconiosis. Repeated or prolonged exposure to titanium
dioxide dust via inhalation is suspected of causing cancer of the respiratory tract. Zinc: Prolonged exposure to high
concentrations of zinc fumes may cause "zinc shakes", an involuntary twitching of the muscles.
4.3. Indication of Any Immediate Medical Attention and Special Treatment Needed
If exposed or concerned, get medical advice and attention. If medical advice is needed, have product container or label at hand.
SECTION 5: FIRE-FIGHTING MEASURES
5.1. Extinguishing Media
Suitable Extinguishing Media: For particulates and dust: Dry sand; Class D Extinguishing Agent (for metal powder fires). For
shipped form: Use extinguishing media appropriate for surrounding fire.
Unsuitable Extinguishing Media: Do not use a heavy water stream. Use of heavy stream of water may spread fire.
5.2. Special Hazards Arising From the Substance or Mixture
Fire Hazard: As shipped this product is not flammable, but contains substances that are flammable solids. If significant dust is
generated under normal use, the dust may exhibit these characteristics. If small particles are generated during further
processing, handling or by other means, may form combustible dust concentrations in air.
Explosion Hazard: Product itself is not explosive but if dust is generated, dust clouds suspended in air can be explosive.
Reactivity: Hazardous reactions may occur on contact with certain chemicals. Refer to incompatible materials. Contact with
concentrated acid or alkali can result in evolution of hydrogen gas.
5.3. Advice for Firefighters
Precautionary Measures Fire: Exercise caution when fighting any chemical fire.
Firefighting Instructions: Use water spray or fog for cooling exposed containers. In case of major fire and large quantities:
Evacuate area. Fight fire remotely due to the risk of explosion. Do not disturb burning metal. Do not breathe fumes from fires or
vapors from decomposition.
Protection During Firefighting: Do not enter fire area without proper protective equipment, including respiratory protection.
Hazardous Combustion Products: Metal oxides. Carbon oxides (CO, CO2). Chromium oxides. Oxides of cobalt. Oxides of copper.
Oxides of nickel. Oxides of iron. Oxides of manganese. Oxides of silver. Tin oxides. Titanium oxides. Oxides of tungsten. Oxides of
zinc.
Other Information: Do not allow run-off from fire fighting to enter drains or water courses. Risk of dust explosion.
SECTION 6: ACCIDENTAL RELEASE MEASURES
6.1. Personal Precautions, Protective Equipment and Emergency Procedures
General Measures: Avoid generating dust. For particulates and dust: Do not get in eyes, on skin, or on clothing. Do not breathe
dust. Keep away from heat, hot surfaces, sparks, open flames, and other ignition sources. No smoking. Remove ignition sources.
6.1.1. For Non-Emergency Personnel
Protective Equipment: Use appropriate personal protective equipment (PPE).
Emergency Procedures: Evacuate unnecessary personnel. Stop leak if safe to do so.
6.1.2. For Emergency Personnel
Protective Equipment: Equip cleanup crew with proper protection.
Emergency Procedures: Ventilate area. Eliminate ignition sources. Upon arrival at the scene, a first responder is expected to
recognize the presence of dangerous goods, protect oneself and the public, secure the area, and call for the assistance of trained
personnel as soon as conditions permit.

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6.2. Environmental Precautions
Prevent entry to sewers and public waters. Avoid release to the environment. Collect spillage.
6.3. Methods and Materials for Containment and Cleaning Up
For Containment: Contain solid spills with appropriate barriers and prevent migration and entry into sewers or streams. As an
immediate precautionary measure, isolate spill or leak area in all directions. Avoid generation of dust during clean-up of spills.
Methods for Cleaning Up: For product as shipped: Take up mechanically (sweeping, shoveling) and collect in suitable container
for disposal. For particulates and dust: Clean up spills immediately and dispose of waste safely. Use explosion proof vacuum
during cleanup, with appropriate filter. Do not mix with other materials. Vacuum clean-up is preferred. If sweeping is required
use a dust suppressant. Use only non-sparking tools. Contact competent authorities after a spill.
6.4. Reference to Other Sections
See Section 8 for exposure controls and personal protection and Section 13 for disposal considerations.
SECTION 7: HANDLING AND STORAGE
7.1. Precautions for Safe Handling
Additional Hazards When Processed: This product is physiologically inert in its massive form. However, user-generated dust
and/or fumes may pose a physiological hazard if inhaled or ingested. Avoid inhalation of metal dusts and fumes. May cause an
influenza-like illness. Avoid skin and eye contact with dusts to prevent mechanical irritation. User-generated dust is easily
ignited and difficult to extinguish. Accumulation and dispersion of dust with an ignition source can cause a combustible dust
explosion. Keep dust levels to a minimum and follow applicable regulations.
Precautions for Safe Handling: Do not handle until all safety precautions have been read and understood. Obtain special
instructions before use. Wash hands and other exposed areas with mild soap and water before eating, drinking or smoking and
when leaving work. For particulates and dust: Do not breathe dust. Do not get in eyes, on skin, or on clothing. Take precautionary
measures against static discharge. Use only non-sparking tools. Avoid creating or spreading dust. Keep away from heat, sparks,
open flames, hot surfaces. – No smoking. Use appropriate personal protective equipment (PPE).
Hygiene Measures: Handle in accordance with good industrial hygiene and safety procedures. Contaminated work clothing
should not be allowed out of the workplace. Wash contaminated clothing before reuse.
7.2. Conditions for Safe Storage, Including Any Incompatibilities
Technical Measures: Comply with applicable regulations. For particulates and dust: Take action to prevent static discharges.
Ground and bond container and receiving equipment. Use explosion-proof electrical, ventilating, and lighting equipment. Avoid
creating or spreading dust. Use explosion-proof electrical, ventilating, lighting equipment. Proper grounding procedures to avoid
static electricity should be followed.
Storage Conditions: Store in a dry, cool place. Keep/Store away from direct sunlight, extremely high or low temperatures and
incompatible materials. Store locked up/in a secure area.
Incompatible Materials: Strong acids, strong bases, strong oxidizers. Acetylene. Chlorine. Cupric nitrate. Ammonium nitrate.
Corrosive substances in contact with metals may produce flammable hydrogen gas.
7.3. Specific End Use(s)
Cutting, drilling and grinding.
SECTION 8: EXPOSURE CONTROLS/PERSONAL PROTECTION
8.1. Control Parameters
For substances listed in section 3 that are not listed here, there are no established exposure limits from the manufacturer,
supplier, importer, or the appropriate advisory agency including: ACGIH (TLV), AIHA (WEEL), NIOSH (REL), or OSHA (PEL).
Cobalt (7440-48-4)
USA ACGIH ACGIH TWA (mg/m³) 0.02 mg/m³
USA ACGIH ACGIH chemical category Confirmed Animal Carcinogen with Unknown Relevance to Humans
USA ACGIH Biological Exposure Indices (BEI) 15 μg/l Parameter: Cobalt - Medium: urine - Sampling time: end of
shift at end of workweek (nonspecific)
USA NIOSH NIOSH REL (TWA) (mg/m³) 0.05 mg/m³ (dust and fume)
USA IDLH US IDLH (mg/m³) 20 mg/m³ (dust and fume)
USA OSHA OSHA PEL (TWA) (mg/m³) 0.1 mg/m³ (dust and fume)
Copper (7440-50-8)
USA ACGIH ACGIH TWA (mg/m³) 0.2 mg/m³ (fume)
USA NIOSH NIOSH REL (TWA) (mg/m³) 1 mg/m³ (dust and mist)
0.1 mg/m³ (fume)
USA IDLH US IDLH (mg/m³) 100 mg/m³ (dust, fume and mist)
USA OSHA OSHA PEL (TWA) (mg/m³) 0.1 mg/m³ (fume)
1 mg/m³ (dust and mist)

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Nickel (7440-02-0)
USA ACGIH ACGIH TWA (mg/m³)
USA ACGIH ACGIH chemical category
USA NIOSH NIOSH REL (TWA) (mg/m³)
USA IDLH US IDLH (mg/m³)
USA OSHA OSHA PEL (TWA) (mg/m³)
Tin (7440-31-5)
USA ACGIH ACGIH TWA (mg/m³)
USA NIOSH NIOSH REL (TWA) (mg/m³)
USA IDLH US IDLH (mg/m³)
Silver (7440-22-4)
USA ACGIH ACGIH TWA (mg/m³)
USA NIOSH NIOSH REL (TWA) (mg/m³)
USA IDLH US IDLH (mg/m³)
USA OSHA OSHA PEL (TWA) (mg/m³)
Manganese (7439-96-5)
USA ACGIH ACGIH TWA (mg/m³)
USA ACGIH ACGIH chemical category
USA NIOSH NIOSH REL (TWA) (mg/m³)
USA NIOSH NIOSH REL (STEL) (mg/m³)
USA IDLH US IDLH (mg/m³)
USA OSHA OSHA PEL (Ceiling) (mg/m³)
Particulates not otherwise classified (PNOC) (Not applicable)
USA ACGIH ACGIH TWA (mg/m³)
USA OSHA OSHA PEL (TWA) (mg/m³)
8.2. Exposure Controls
Appropriate Engineering Controls
Personal Protective Equipment
Materials for Protective Clothing
Hand Protection
Eye and Face Protection
Skin and Body Protection
Respiratory Protection
Other Information
DOCUMENT #: 1803659
1.5 mg/m³ (inhalable particulate matter)
Not Suspected as a Human Carcinogen
0.015 mg/m³
10 mg/m³
1 mg/m³
2 mg/m³
2 mg/m³
100 mg/m³
0.1 mg/m³ (dust and fume)
0.01 mg/m³ (dust)
10 mg/m³ (dust)
0.01 mg/m³
0.02 mg/m³ (respirable particulate matter)
0.1 mg/m³ (inhalable particulate matter)
Not Classifiable as a Human Carcinogen
1 mg/m³ (fume)
3 mg/m³
500 mg/m³
5 mg/m³ (fume)
3
3 mg/m Respirable fraction
3
10 mg/m Total Dust
3
5 mg/m Respirable fraction
3
15 mg/m Total Dust
: For particulates and dust: Emergency eye wash fountains and safety showers
should be available in the immediate vicinity of any potential exposure. Ensure
adequate ventilation, especially in confined areas. Proper grounding procedures to
avoid static electricity should be followed. Use explosion-proof equipment. Use
local exhaust or general dilution ventilation or other suppression methods to
maintain dust levels below exposure limits. Power equipment should be equipped
with proper dust collection devices. It is recommended that all dust control
equipment such as local exhaust ventilation and material transport systems
involved in handling of this product contain explosion relief vents or an explosion
suppression system or an oxygen-deficient environment. Ensure all national/local
regulations are observed.
: Gloves. Protective clothing. Protective goggles. Insufficient ventilation: wear
respiratory protection.
: Chemically resistant materials and fabrics.
: Wear protective gloves.
: Chemical safety goggles.
: Wear suitable protective clothing.
: If exposure limits are exceeded or irritation is experienced, approved respiratory
protection should be worn. In case of inadequate ventilation, oxygen deficient
atmosphere, or where exposure levels are not known wear approved respiratory
protection.
: When using, do not eat, drink or smoke.
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DATE PRINTED: 9/20/18
SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES
9.1. Information on Basic Physical and Chemical Properties
Physical State : Solid
Appearance : Metallic- Silver Grey to Black
Odor : Odorless
Odor Threshold : No data available
pH : No data available
Evaporation Rate : No data available
Melting Point : 2719 °F (1492.78 °C)
Freezing Point : No data available
Boiling Point : No data available
Flash Point : No data available
Auto-ignition Temperature : No data available
Decomposition Temperature : No data available
Flammability (solid, gas) : Flammable solid
Vapor Pressure : No data available
Relative Vapor Density at 20°C : No data available
Relative Density : No data available
Specific Gravity : 8.5 - 15.0
Solubility : Not soluble in water.
Partition Coefficient: N-Octanol/Water : No data available
Viscosity : No data available
9.2. Other Information No additional information available
SECTION 10: STABILITY AND REACTIVITY
10.1. Reactivity: Hazardous reactions may occur on contact with certain chemicals. Refer to incompatible materials. Contact
with concentrated acid or alkali can result in evolution of hydrogen gas.
10.2. Chemical Stability: As shipped, product is stable. The following applies to the product if it is cut, sanded or altered in
such a way that excessive and/or significant particulates and/or dusts may be generated: Flammable solid.
10.3. Possibility of Hazardous Reactions: Hazardous polymerization will not occur.
10.4. Conditions to Avoid: Direct sunlight, extremely high or low temperatures, heat, hot surfaces, sparks, open flames,
incompatible materials, and other ignition sources. Dust accumulation (to minimize explosion hazard).
10.5. Incompatible Materials: Strong acids, strong bases, strong oxidizers. Acetylene. Chlorine. Cupric nitrate. Ammonium
nitrate. Corrosive substances in contact with metals may produce flammable hydrogen gas.
10.6. Hazardous Decomposition Products: Under normal conditions of storage and use, hazardous decomposition products
will not be produced.
SECTION 11: TOXICOLOGICAL INFORMATION
11.1. Information on Toxicological Effects
Acute Toxicity: Not classified
Cobalt (7440-48-4)
LD50 Oral Rat 6171 mg/kg
LC50 Inhalation Rat > 10 mg/l (Exposure time: 1 h)
Iron (7439-89-6)
LD50 Oral Rat 98.6 g/kg
Nickel (7440-02-0)
LD50 Oral Rat > 9000 mg/kg
LC50 Inhalation Rat > 10.2 mg/l (Exposure time: 1 h)
Silver (7440-22-4)
LD50 Oral Rat > 5000 mg/kg
LD50 Dermal Rat > 2000 mg/kg
Manganese (7439-96-5)
LD50 Oral Rat > 2000 mg/kg
LC50 Inhalation Rat > 5.14 mg/l/4h

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Skin Corrosion/Irritation: Not classified
Serious Eye Damage/Irritation: Causes serious eye irritation.
Respiratory or Skin Sensitization: May cause an allergy or asthma symptoms or breathing difficulties if inhaled. May cause an
allergic skin reaction.
Germ Cell Mutagenicity: Not classified
Carcinogenicity: May cause cancer.
Cobalt (7440-48-4)
IARC group 2B
National Toxicology Program (NTP) Status Evidence of Carcinogenicity, Reasonably anticipated to be Human
Carcinogen.
OSHA Hazard Communication Carcinogen List In OSHA Hazard Communication Carcinogen list.
Nickel (7440-02-0)
IARC group 2B
National Toxicology Program (NTP) Status Reasonably anticipated to be Human Carcinogen.
OSHA Hazard Communication Carcinogen List In OSHA Hazard Communication Carcinogen list.
Reproductive Toxicity: Suspected of damaging fertility or the unborn child.
Specific Target Organ Toxicity (Single Exposure): Not classified
Specific Target Organ Toxicity (Repeated Exposure): Causes damage to organs through prolonged or repeated exposure.
Aspiration Hazard: Not classified
Symptoms/Injuries After Inhalation: Dust may be harmful or cause irritation. Exposure may produce cough, mucous secretions,
shortness of breath, chest tightness or other symptoms indicative of an allergic/sensitization reaction. Inhalation of dusts and
fumes can cause metal fume fever. Symptoms can include a metallic or sweet taste in the mouth, sweating, shivering, headache,
throat irritation, fever, chills, thirstiness, muscle aches, nausea, vomiting, weakness, fatigue, and shortness of breath.
Symptoms/Injuries After Skin Contact: May cause an allergic skin reaction. Direct contact may cause irritation by mechanical
abrasion.
Symptoms/Injuries After Eye Contact: For particulates and dust: Contact causes severe irritation with redness and swelling of
the conjunctiva. May cause mechanical eye irritation.
Symptoms/Injuries After Ingestion: Ingestion may cause adverse effects.
Chronic Symptoms: For particulates, dust, or fumes from processing: May cause cancer by inhalation. Suspected of damaging
fertility or the unborn child. Causes damage to organs (respiratory tract) through prolonged or repeated exposure (inhalation).
Chromium: Certain hexavalent chromium compounds have been demonstrated to be carcinogenic on the basis of
epidemiological investigations on workers and experimental studies in animals. Increased incidences of respiratory cancer have
been found in chromium (VI) workers. There is an increased incidence of lung cancer in industrial workers exposed to chromium
(VI) compounds. Please refer to IARC volume 23 for a more detailed discussion. Chronic exposure to cobalt-containing hard metal
(dust or fume) can result in a serious lung disease called "hard metal lung disease", which is a type of pneumoconiosis (lung
fibrosis). Copper: Overexposure to fumes may cause metal fume fever (chills, muscle aches, nausea, fever, dry throat, cough,
weakness, lassitude); metallic or sweet taste; discoloration of skin and hair. Tissue damage of mucous membranes may follow
chronic dust exposure. Nickel: May cause a form of dermatitis known as nickel itch and intestinal irritation, which may cause
disorders, convulsions and asphyxia. Nickel metal powder, when respirable, is a suspected human carcinogen, and is known to
cause damage to the lungs through inhalation. Manganese: Chronic exposure can cause inflammation of the lung tissue, scarring
the lungs (pulmonary fibrosis). Chronic exposure to excessive manganese levels can lead to a variety of psychiatric and motor
disturbances, termed manganism. Repeated inhalation of iron oxide dust can cause siderosis a benign condition. Silver: Chronic
skin contact or ingestion of silver dust, salts or fume can result in a condition known as Argyria, a condition with bluish
pigmentation of the skin and eyes. Tin: Has been shown to increase incidence of sarcoma in animal tests. Chronic exposure to
tin dusts and fume may result in "stannosis", a mild form of pneumoconiosis. Repeated or prolonged exposure to titanium
dioxide dust via inhalation is suspected of causing cancer of the respiratory tract. Zinc: Prolonged exposure to high
concentrations of zinc fumes may cause "zinc shakes", an involuntary twitching of the muscles.
SECTION 12: ECOLOGICAL INFORMATION
12.1. Toxicity
Ecology - General : This product in its shipped form does not pose an aquatic toxicity hazard. If product
altered and powder, dust, fines, shavings, or small particles are generated this
product is considered very toxic to aquatic life and very toxic to aquatic life with
long lasting effects.
Cobalt (7440-48-4)
LC50 Fish 1 > 100 mg/l (Exposure time: 96 h - Species: Brachydanio rerio [static])

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Copper (7440-50-8)
LC50 Fish 1 0.0068 - 0.0156 mg/l (Exposure time: 96 h - Species: Pimephales promelas)
EC50 Daphnia 1 0.03 mg/l (Exposure time: 48 h - Species: Daphnia magna [Static])
EC50 Other Aquatic Organisms 1 0.0426 (0.0426 - 0.0535) mg/l (Exposure time: 72 h - Species: Pseudokirchneriella
subcapitata [static])
LC50 Fish 2 < 0.3 mg/l (Exposure time: 96 h - Species: Pimephales promelas [static])
EC50 Other Aquatic Organisms 2 0.031 (0.031 - 0.054) mg/l (Exposure time: 96 h - Species: Pseudokirchneriella
subcapitata [static])
Nickel (7440-02-0)
LC50 Fish 1 100 mg/l (Exposure time: 96 h - Species: Brachydanio rerio)
EC50 Daphnia 1 121.6 μg/l (Exposure time: 48h - Species: Ceriodaphnia dubia [static])
LC50 Fish 2 15.3 mg/l
EC50 Daphnia 2 1 mg/l (Exposure time: 48 h - Species: Daphnia magna [Static])
EC50 Other Aquatic Organisms 2 0.174 (0.174 - 0.311) mg/l (Exposure time: 96 h - Species: Pseudokirchneriella
subcapitata [static])
Silver (7440-22-4)
LC50 Fish 1 0.00155 (0.00155 - 0.00293) mg/l (Exposure time: 96 h - Species: Pimephales
promelas [static])
EC50 Daphnia 1 0.00024 mg/l (Exposure time: 48 h - Species: Daphnia magna [Static])
LC50 Fish 2 0.0062 mg/l (Exposure time: 96 h - Species: Oncorhynchus mykiss [flow-through])
Manganese (7439-96-5)
NOEC Chronic Fish 3.6 mg/l (Exposure time: 96h; Species: Oncorhynchus mykiss)
Zinc (7440-66-6)
LC50 Fish 1 2.16 - 3.05 mg/l (Exposure time: 96 h - Species: Pimephales promelas [flow-through])
EC50 Daphnia 1 0.139 - 0.908 mg/l (Exposure time: 48 h - Species: Daphnia magna [Static])
LC50 Fish 2 0.211 - 0.269 mg/l (Exposure time: 96 h - Species: Pimephales promelas [semi-static])
ErC50 (Algae) 0.15 mg/l
12.2. Persistence and Degradability
Diamond Tooling
Persistence and Degradability May cause long-term adverse effects in the environment.
Copper (7440-50-8)
Persistence and Degradability Not readily biodegradable.
12.3. Bioaccumulative Potential
Diamond Tooling
Bioaccumulative Potential Not established.
Cobalt (7440-48-4)
BCF Fish 1 (no bioaccumulation)
12.4. Mobility in Soil No additional information available
12.5. Other Adverse Effects
Other Information : Avoid release to the environment.
SECTION 13: DISPOSAL CONSIDERATIONS
13.1. Waste Treatment Methods
Waste Disposal Recommendations: Dispose of contents/container in accordance with local, regional, national, and international
regulations.
Ecology - Waste Materials: Avoid release to the environment. This material is hazardous to the aquatic environment. Keep out
of sewers and waterways.
SECTION 14: TRANSPORT INFORMATION
The shipping description(s) stated herein were prepared in accordance with certain assumptions at the time the SDS was
authored, and can vary based on a number of variables that may or may not have been known at the time the SDS was issued.
14.1. In Accordance with DOT Not regulated for transport
14.2. In Accordance with IMDG Not regulated for transport
14.3. In Accordance with IATA Not regulated for transport

DOCUMENT #: 1803659 Page 32 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
SECTION 15: REGULATORY INFORMATION
15.1. US Federal Regulations
Diamond Tooling
SARA Section 311/312 Hazard Classes Health hazard - Carcinogenicity
Health hazard - Reproductive toxicity
Health hazard - Specific target organ toxicity (single or repeated
exposure)
Health hazard - Respiratory or skin sensitization
Physical hazard - Flammable (gases, aerosols, liquids, or solids)
Health hazard - Serious eye damage or eye irritation
Physical hazard - Combustible dust
Cobalt (7440-48-4)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
SARA Section 313 - Emission Reporting 0.1 %
Iron (7439-89-6)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Copper (7440-50-8)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
CERCLA RQ 5000 lb no reporting of releases of this hazardous substance is
required if the diameter of the pieces of the solid metal released is
>100 µm
SARA Section 313 - Emission Reporting 1%
Tungsten carbide (12070-12-1)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Nickel (7440-02-0)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
CERCLA RQ 100 lb (only applicable if particles are < 100 µm)
SARA Section 313 - Emission Reporting 0.1 %
Titanium (7440-32-6)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Tin (7440-31-5)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Silver (7440-22-4)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
CERCLA RQ 1000 lb < 100 um CERCLA/SARA RQ CHANGE TITLE
SARA Section 313 - Emission Reporting 1%
Manganese (7439-96-5)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
SARA Section 313 - Emission Reporting 1%
Chromium carbide (Cr3C2) (12012-35-0)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Diamond (7782-40-3)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Zinc (7440-66-6)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Subject to reporting requirements of United States SARA Section 313
CERCLA RQ 454 kg no reporting of releases of this hazardous substance is
required if the diameter of the pieces of the solid metal released is
>100 µm

DOCUMENT #: 1803659 Page 33 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
SARA Section 313 - Emission Reporting 1 % (dust or fume only)
15.2. US State Regulations
Cobalt (7440-48-4)
U.S. - California - Proposition 65 - Carcinogens List WARNING: This product contains chemicals known to the State of
California to cause cancer.
Nickel (7440-02-0)
U.S. - California - Proposition 65 - Carcinogens List WARNING: This product contains chemicals known to the State of
California to cause cancer.
Cobalt (7440-48-4)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) List
Copper (7440-50-8)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) List
Tungsten carbide (12070-12-1)
U.S. - New Jersey - Right to Know Hazardous Substance List
Nickel (7440-02-0)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) - Special Hazardous Substances
U.S. - Pennsylvania - RTK (Right to Know) List
Titanium (7440-32-6)
U.S. - New Jersey - Right to Know Hazardous Substance List
Tin (7440-31-5)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) List
Silver (7440-22-4)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) List
Manganese (7439-96-5)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) List
Zinc (7440-66-6)
U.S. - Massachusetts - Right To Know List
U.S. - New Jersey - Right to Know Hazardous Substance List
U.S. - Pennsylvania - RTK (Right to Know) - Environmental Hazard List
U.S. - Pennsylvania - RTK (Right to Know) List
SECTION 16: OTHER INFORMATION, INCLUDING DATE OF PREPARATION OR LAST REVISION
Date of Preparation or Latest Revision : 05/25/2018

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DATE PRINTED: 9/20/18
Other Information : This document has been prepared in accordance with the SDS
requirements of the OSHA Hazard Communication Standard 29 CFR
1910.1200
These products in their manufactured state present a Skin
Sensitization 1 hazard only. Operations such as grinding, cutting,
welding or brazing may release fumes and dust, which may present
additional health and physical hazards. Under normal conditions of
use, this product may generate small amounts of dust which can
pose a hazard to the user. This SDS encompasses the hazards of the
product during use, when dust may be generated.
GHS Full Text Phrases:
------ Aquatic Acute 1 Hazardous to the aquatic environment - Acute Hazard Category 1
------ Aquatic Chronic 1 Hazardous to the aquatic environment - Chronic Hazard Category 1
------ Aquatic Chronic 3 Hazardous to the aquatic environment - Chronic Hazard Category 3
------ Carc. 1B Carcinogenicity Category 1B
------ Carc. 2 Carcinogenicity Category 2
------ Comb. Dust Combustible Dust
------ Eye Irrit. 2 Serious eye damage/eye irritation Category 2
------ Eye Irrit. 2A Serious eye damage/eye irritation Category 2A
------ Flam. Sol. 1 Flammable solids Category 1
------ Flam. Sol. 2 Flammable solids Category 2
------ Repr. 2 Reproductive toxicity Category 2
------ Resp. Sens. 1 Respiratory sensitization, Category 1
------ Resp. Sens. 1B Respiratory sensitization, Category 1B
------ Skin Sens. 1 Skin sensitization, Category 1
------ STOT RE 1 Specific target organ toxicity (repeated exposure) Category 1
------ H228 Flammable solid
------ H317 May cause an allergic skin reaction
------ H319 Causes serious eye irritation
------ H334 May cause an allergy or asthma symptoms or breathing difficulties if inhaled
------ H350 May cause cancer
------ H351 Suspected of causing cancer
------ H361 Suspected of damaging fertility or the unborn child
------ H372 Causes damage to organs through prolonged or repeated exposure
------ H400 Very toxic to aquatic life
------ H410 Very toxic to aquatic life with long lasting effects
------ H412 Harmful to aquatic life with long lasting effects
This information is based on our current knowledge and is intended to describe the product for the purposes of health, safety and
environmental requirements only. It should not therefore be construed as guaranteeing any specific property of the product.

SDS US (GHS HazCom)

False

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 4
Section

Operator
Orientation

DOCUMENT #: 1803659 Page 36 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
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 
Series and the TBG130C DO 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 and 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 Series, 
and PC4500 Series are not to be driven, loaded on or unloaded from trailer  with the 
equipment (PC1500 Series) or engine frame (PC4500 Series, and PC6000 Series) 
PINNED UP. Equipment may tip due to high center of gravity. The cutting head frame 
on the TBG130C should be pinned up when loading and unloading the equipment. 
4. CAUTION: The Loading or unloading of all equipment models must be done on a level 
pavement surface. The TBG130C, PC1500 Series, and PC4500 Series are transported on 
trailers. When loading or unloading trailer deck must be clean, dry and level. The 
PC6000 Series are transported by connecting via fifth wheel to a semi tractor. 
Operator must be familiar with hooking up air and electrical connections, fifth wheel, 
PC6000 Series 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: The TBG130C and 
the PC1500 have one operator station located on the right side of the equipment. 
PC1504, PC4500 Series, and PC6000 Series 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. 
 

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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, NOTE: panel is not adjustable on TBG130C, to 
comfortable location. WARNING: Never operate the equipment with the operator 
adjacent to live traffic.  
3. Verify: clutch lever (PC1500 Series) is disengaged, TBG130C cutting head ON/OFF 
switch, OFF, clutch ON/OFF switch (PC4500 Series, and PC6000 Series) 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 TBG130C, PC 
1500 Series, and PC4500 Series. Two diesel engines are used on the PC6000 Series. A 
small diesel engine is used to power all systems and a large diesel engine is used to 
power the grinding head.  
3. Starting the TBG130C, PC1500 Series, PC4500 Series. Operator MUST be in seat. NOTE: 
refer to engine manual for specific starting instructions. Brake ON/OFF switch must be 
in ON position to start engine. 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 reset E‐STOP, 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 Series, 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 reset E‐STOP, 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. 
  
 
 

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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, except when loading and unloading the TBG130C. 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 
Series, and PC6000 Series 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 cutting head frame (TBG130C, PC4500 Series, 
and PC6000 Series) until vacuum skirt touches pavement. 
7. To check equipment brake, brake switch in ON position (TBG130C, PC1500 Series, and 
PC4500 Series) move joystick slowly forward and reverse. Equipment should not 
move.  
8. To check equipment brake (PC6000 Series) 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. Once drive tires contact 
pavement move joystick slowly forward and reverse. Equipment should not move.  
9.  A Water alarm will sound when lowering equipment when no water pressure is 
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 Series: Blower on PC1500 Series is driven by belts from 
the gearbox that drives the grinding head. Operator will have to set the brake then get 
out of seat and engage clutch to run blower. Disengage clutch after test. 
13.  Vacuum System check: TBG130C, PC4500 Series and PC6000 Series: Blower is 

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DATE PRINTED: 9/20/18
 hydraulically driven on these models. Operator to stay in seat. Switch blower switch 
to ON. Blower may take several seconds to start. If blower does not start switch to 
OFF and trouble shoot/repair. 
14. Slurry Pump checks: Switch slurry pump switch to ON. On PC6000 Series 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 (TBG130C, PC4500 Series, and PC6000 Series) and adjustments. 
Discuss/demonstrate adjustment and purpose. 
17. Check profile wheel (PC1500 Series, PC4500 Series, and PC6000 Series) raise/lower 
function and purpose. Discuss/demonstrate setting the grinding head to “ZERO” and 
matching adjacent passes. 
18. Check depth control wheel TBG130C adjustment and setting procedure. 
Demonstrate/discuss how to adjust. 
19. Check clutch engagement function. PC1500 Series, PC4500 Series, and PC6000 Series. 
20.  PC1500 Series and PC6000 Series: Check front bogey slide operation and discuss 
purpose of same. 
21. PC6000 Series: Check load leg operation and discuss use and purpose.  
22. With brakes set, clutch disengaged check engine throttle adjustment function. Run 
engine(s) up to full RPM and back to low idle. 
23. 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. 
 
All personnel that are in attendance MUST sign and print name and date on attached page.  
 
 
   

DOCUMENT #: 1803659 Page 40 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Grinder/Groover Operator Orientation:
Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Signature: ___________________ Print Name: ___________________ Date: __________

Diamond Products 
___________________ Print Name: ___________________ Date: __________
Representative:

Diamond Products 
___________________ Print Name: ___________________ Date: __________
Representative:

Diamond Products 
___________________ Print Name: ___________________ Date: __________
Representative:

Diamond Products 
___________________ Print Name: ___________________ Date: __________
Representative:

DOCUMENT #: 1803659 Page 41 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 5
Section

Daily Equipment
Inspection

DOCUMENT #: 1803659 Page 42 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
                       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. Verify: Clutch lever PC1500 series must be disengaged; cutting 
head ON/OFF switch TBG130C is OFF; clutch ON/OFF switch is in 
OFF position PC4500 Series and PC6000 Series. 
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 

DOCUMENT #: 1803659 Page 43 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 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.  
     12. Disengage clutch. 
     13. Load equipment. 

DOCUMENT #: 1803659 Page 44 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 
 
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.  
 
 
 
 
 
 
 

DOCUMENT #: 1803659 Page 45 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 6
Section

Lubrication and
Maintenance  

DOCUMENT #: 1803659 Page 46 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6000 LUBRICATION SCHEDULE
FUEL TANK, DIESEL
WATER TANK DEMISTER SILENCER
BLOWER

ENGINE,
C4.4

B ENGINE, C18
TORQUE HUBS TRANSFLUID CLUTCH
RIGHT SIDE VIEW RIGHT ANGLE DRIVE

A
PIVOT LEFT SIDE VIEW PIVOT TANK SLIDE
*Do not attempt to perform maintenance,
repair, or installation on machine until the
machine and engine are stopped and secured

ITEM # LUBRICATION SCHEDULE

1 DAILY 2-3 PUMPS
2 DAILY 2-5
3 DAILY 15-20 PUMPS
4 WEEKLY 5 PUMPS
5 WEEKLY 1-2 PUMPS
6 MONTHLY 1 PUMPS
*REFER TO OWNERS
MANUAL FOR ENGINE,
GEARBOX, TRANSFLUID
CLUTCH, AND BLOWER
MAINTENANCE
*Check pivot point bolts daily

FRONT VIEW

DOCUMENT #: 1803659 Page 47 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
DEPTH CONTROL ASSEMBLY BLADESHAFT BEARINGS

6 3

DETAIL A
SCALE 1:16

SLURRY PUMP
TANK SLIDE
6
4

4
DETAIL B
SCALE 1:12

ITEM # LUBRICATION SCHEDULE

1 DAILY 2-3 PUMPS
2 DAILY 2-5 PUMPS
3 DAILY 15-20 PUMPS
4 WEEKLY 5 PUMPS
5 WEEKLY 5 PUMPS
6 MONTHLY 1 PUMPS

DOCUMENT #: 1803659 Page 48 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 BOGEY STEERING
1 1

1 1

1 1

1 1

RIGHT SIDE
FRONT

1 1

LEFT SIDE

ITEM # LUBRICATION SCHEDULE

1 DAILY 2-3 PUMPS
2 DAILY 2-5 PUMPS
3 DAILY 15-20 PUMPS
4 WEEKLY 5 PUMPS
5 WEEKLY 1-2 PUMPS
6 MONTHLY 1 PUMPS

DOCUMENT #: 1803659 Page 49 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 OPERATOR ASSEMBLY

AIR FILTER

5*
5*

ITEM # LUBRICATION SCHEDULE

1 DAILY 2-3 PUMPS
2 DAILY 2-5 PUMPS
3 DAILY 15-20 PUMPS
4 WEEKLY 5 PUMPS
5 WEEKLY 1-2 PUMPS
6 MONTHLY 1 PUMPS

5*

DETAIL C
SCALE 1:12
*APPLIES TO BOTH SIDES OF THE MACHINE

DOCUMENT #: 1803659 Page 50 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 TORQUE HUBS

*FILL/DRAIN PORTS *FILL/DRAIN PORTS

ENGINE, QSX 15L

*WATER FILTER
*OIL FILTER *FUEL/WATER
SEPARATOR

* REFER TO OWNERS MANUAL FOR REPLACEMENT

DOCUMENT #: 1803659 Page 51 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6000 MAINENANCE, DAILY
OR MORE OFTEN AS NEEDED
*Before cleaning the machine with water 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.
V

II

DAILY MAINTENANCE
I *DEMISTER CLEAN
II *LOBSTER POT CLEAN
III *WATER FILTER CLEAN
IV *SPRAY BAR AND CLEAN
TIPS
V *SLURRY PUMP CLEAN
VI *SEPERATOR CLEAN

*REFER TO OWNERS MANUAL

FOR ENGINE, GEAR BOX,
TRANSFLUID CLUTCH, AND
BLOWER MAINTENANCE *CLEAN SILENCER AS NEEDED

VI

III

IV

DOCUMENT #: 1803659 Page 52 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Recommended Oils, Lubricants, and Filters
Oils & Lubricants
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 & 
 Lubriplate EMB
Pivot
Right Angle Drive Refer to manual
TRANSFLUID CLUTCH Refer to Manual
Trailer Axels Refer to manual
Engine Cummins QSX 15L Filters
Cummins QSX 15L Refer to manual
Engine Cummins 4.5L Filters
Cummins QSB 4.5L Refer to manual
Vacuum System
De‐Mister Element 2504421
Blower Filter Element 2703380
Hydraulic System
Functions System Filter 2703304
Ground Drive Pump 2706897
Water System
Water Filter 2703907
*CHANGE HYDRAULIC OIL EVERY 1000 HOURS

DOCUMENT #: 1803659 Page 53 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6000 Wear Parts for Operator to Carry
ITEM #  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
14 7600393 4" SLURRY PUMP FLAP VALVE WEIGHT 2

DOCUMENT #: 1803659 Page 54 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6000 Replacement and Wear Parts for Shop to Carry
ITEM #  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
30 7600392 4" SLURRY PUMP FLAP VALVE WEIGHT 2
31 7600393 4" SLURRY PUMP FLAP VALVE WEIGHT 2
32 2504610 SPRAY BAR NOZZLES 80/30 4
33 2502263 SPRAY BAR NOZZLES 80/15 27

DOCUMENT #: 1803659 Page 55 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
OM -- 01505 SLURRY PUMP MAINTENANCE D SERIES

SECTION DRAWING

Figure 1. Pump Model 4D-B

PAGE E -- 2 MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 56 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES OM -- 01505

PARTS LIST
Pump Model 4D-B
(From S/N 461594 up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact
the Gorman-Rupp Company to verify part numbers.

ITEM PART NAME PART MAT’L QTY ITEM PART NAME PART MAT’L QTY
NO. NUMBER CODE NO. NUMBER CODE

1 COUPLING DRIVE SHAFT 34355--- 105 --- --- --- 1 28 HEX HD CAPSCREW B1211 15991 4
2 COUPLING MTR SHAFT 24355--- 112 --- --- --- 1 29 LOCKWASHER J12 15991 4
3 SPIDER 24355--- 267 --- --- --- 1 30 HEX NUT D12 15991 4
4 COUPLING GUARD 34613--- 045 15020 1 31 DIAPHRAGM POT ASSY 46475--- 702 --- --- --- 1
5 KEY N0405 15990 1 32 U--- BOLT 5495 15991 2
6 MOTOR NOT FURNISHED 33 HEX NUT D06 15991 4
7 BASE 13485 24000 1 34 LOCKWASHER J06 15991 4
8 AXLE 6619 15990 1 35 HEX HD CAPSCREW B0402 1/2 15991 2
9 SPACER 6619A 15070 2 36 T TYPE LOCK WASHER AK04 15991 2
10 COTTER PIN M0306 15990 2 37 FLAT WASHER K04 15991 2
11 FLAT WASHER S1532 --- --- --- 4 38 LUBE DECAL 38817--- 066 --- --- --- 1
12 PNEUMATIC WHEEL S263 --- --- --- 2 39 ECCENTRIC GUARD 38861--- 504 23200 1
13 U--- BOLT 6945 15000 2 40 NYLOCK CAP SCREW BT0403 15991 1
14 HEX NUT D06 15991 4 41 WASHER S157 --- --- --- 1
15 LOCKWASHER J06 15991 4 42 FLAT WASHER K04 15991 1
16 HEX HD CAPSCREW B0404 15991 2 43 GUARD WARNING STKER 38816--- 063 --- --- --- 1
17 FLAT WASHER K04 15991 2
18 LOCKWASHER J04 15991 2 NOT SHOWN:
19 HEX NUT D04 15991 2 NAME PLATE 2613BP 13990 1
20 DIAPHRAGM RING 6621 13010 1 DRIVE SCREW BM#04--- 03 17000 4
21 DRAW BAR 5438 15990 1 STRAINER 4917 24001 1
22 PLUNGER ROD ASSY 6959 --- --- --- 1 DISCHARGE STICKER 6588BJ --- --- --- 1
23 LUB FITTING S191 --- --- --- 1 SUCTION STICKER 6588AG --- --- --- 1
24 END CAP 6643 10010 1 INSTRUCTION TAG 38817--- 031 --- --- --- 1
25 GEARBOX ASSY 44161--- 009 --- --- --- 1
26 HEX HD CAPSCREW B1010 15991 4 OPTIONAL:
27 LOCKWASHER J10 15991 4 STATIONARY BASE 8283 24000 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E -- 3

DOCUMENT #: 1803659 Page 57 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
OM -- 01505 D SERIES

SECTION DRAWING

NOTE:
FLAP VALVE ASSEMBLY SHOWN IN POSI-
TION ON DISCHARGE SIDE. SUCTION SIDE
TO OPEN IN SAME DIRECTION.

DISCHARGE

30
29
28
25 37
36 SUCTION
27
35
32
26 34

33
24
31

2 3

23

22
21
20

19 18 17,16 15 ,14 ,13 12 11 10 9 ,8 ,7 6, 5 4

Figure 2. 46475---702 Diaphragm Pot Assembly

PAGE E -- 4 MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 58 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES OM -- 01505

PARTS LIST
46475---702 Diaphragm Pot Assembly

ITEM PART MAT’L

NO. PART NAME NUMBER CODE QTY

1 DIAPHRAGM POT 6622 13010 1

2 SUCT ACCUMULATOR PLUG AND GASKET S591A --- --- --- 1
3 SUCTION ACCUMULATOR 6625 13010 1
4 REDUCER PIPE BUSHING AP6448 11990 1
5 HEX HD CAPSCREW B0504 15991 2
6 LOCKWASHER J05 15991 2
7 STUD C1013 15991 2
8 FLAT WASHER KE10 15991 2
9 HEX NUT D10 15991 2
10 SUCTION ACCUMULATOR GASKET 6625G 19100 1
11 DIAPHRAGM POT DRAIN PLUG P06 11990 1
12 DISCHARGE FLANGE GASKET 6625G 19100 1
13 STUD C1010 15991 2
14 FLAT WASHER KE10 15991 2
15 HEX NUT D10 15991 2
16 HEX HD CAPSCREW B0504 15991 2
17 LOCKWASHER J05 15991 2
18 DISCHARGE FLANGE 6627 13040 1
19 DISCHARGE ELBOW GASKET 6625G 19100 1
20 STUD C1013 15991 2
21 FLAT WASHER KE10 15991 2
22 HEX NUT D10 15991 2
23 DISCHARGE ELBOW 6626 13040 1
24 VALVE SEAT 6635 10010 1
25 DISCHARGE FLAP VALVE ASSY 46413---007 --- --- --- 1
26 ---VALVE WEIGHT 6801 15990 1
27 ---FLAP VALVE 6925 19100 1
28 ---VALVE WEIGHT 6642 15990 1
29 ---RD HD MACHINE SCREW X0402 1/2 17090 4
30 ---LOCKWASHER J04 17090 4
31 VALVE SEAT 6635 10010 1
32 SUCTION FLAP VALVE ASSY 46413---007 --- --- --- 1
33 ---VALVE WEIGHT 6642 15990 1
34 ---VALVE WEIGHT 6801 15990 1
35 ---RD HD MACHINE SCREW X0402 1/2 17090 4
36 ---LOCKWASHER J04 17090 4
37 ---FLAP VALVE 6925 19100 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E -- 5

DOCUMENT #: 1803659 Page 59 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
OM -- 01505 D SERIES

SECTION DRAWING

2 ,3 ,4

13

12

8.00 REF

10.78 HOLD

11

10

9 8 7 6

Figure 3. 6959 Plunger Rod Assembly

PAGE E -- 6 MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 60 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES OM -- 01505

PARTS LIST
6959 Plunger Rod Assembly

ITEM PART MAT’L

NO. PART NAME NUMBER CODE QTY

1 BEARING CAP 6560 10010 1

2 ---HEX HD CAPSCREW B0813S 15991 2
3 ---HEX NUT D08S 15991 2
4 ---LOCKWASHER J08 15991 2
5 PLUNGER ROD ASSEMBLY 6633 15990 1
6 DIAPHRAGM S1017 --- --- --- 1
7 LUBRICATION FITTING S194 --- --- --- 1
8 DIAPHRAGM PLATE 6629 15990 1
9 DIAPHRAGM PLATE 6628 10010 1
10 HEX NUT D08 15991 4
11 SPRING WASHER 6639 15000 1
12 SPRING 6547 16080 1
13 SPRING RETAINING NUT 6638 11000 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E -- 7

DOCUMENT #: 1803659 Page 61 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
OM -- 01505 D SERIES

SECTION DRAWING

Figure 4. 44161---009 Gearbox Assembly

PAGE E -- 8 MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 62 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES OM -- 01505

PARTS LIST
44161---009 Gearbox Assembly
ITEM PART NAME PART MAT’L QTY ITEM PART NAME PART MAT’L QTY
NO. NUMBER CODE NO. NUMBER CODE

1 GEAR HOUSING 6624 13040 1 26 SNAP RING S1004 --- --- --- 1
2 CRANKSHAFT BEARING S374 --- --- --- 1 27 INTERNAL GEAR S1014 --- --- --- 1
3 CRANKSHAFT GEAR 6641 15060 1 28 PINION SHAFT 6634 16070 1
4 GEAR HOUSING GSKT 6624G 18000 1 29 GEAR HOUSING PLUG S1054 --- --- --- 1
5 AIR VENT FITTING S2162 --- --- --- 1 30 PINION SHAFT BUSHING S1015 --- --- --- 1
6 HEX HD CAPSCREW B0803 15991 1 31 WASHER 6636 15990 1
7 GEAR COVER 6623 13010 1 32 SNAP RING S244 --- --- --- 1
8 CRANKSHAFT GEAR KEY N0605 15990 1 33 CRANKSHAFT ROLLER S1011 --- --- --- 1
9 CRANKSHAFT BEARING S1080 --- --- --- 1 BEARING
10 HEX HD CAPSCREW B1004 15991 1 34 RETAINING RING S442 --- --- --- 1
11 FLAT WASHER 21161--- 442 --- --- --- 1 35 CRANKSHAFT 6550 11000 1
12 WASHER 6637 15000 1
36 SNAP RING S1010 --- --- --- 1
13 PINION BUSHING S1016 --- --- --- 1 37 HEX HD CAPSCREW B0511 15991 5
14 GEAR COVER PLUG S1053 --- --- --- 1 38 LOCKWASHER J05 15991 5
15 HEX HD CAPSCREW B0504 15991 4 39 HEX NUT D05 15991 5
16 LOCKWASHER J05 15991 4 40 SHOULDER BOLT S1018 --- --- --- 1
17 DRIVE SHAFT KEY N0304 15990 1 41 LOCKWASHER J05 15991 1
18 DRIVE SHAFT 6631 15010 1 42 HEX NUT D05 15991 1
19 OIL SEAL S1012 --- --- --- 1 43 HEX HD CAPSCREW B0518 15991 3
20 ECCENTRIC HOUSING 6632 10010 1 44 LOCKWASHER J05 15991 3
21 ECC HOUSING GSKT 6632G 18000 1 45 HEX NUT D05 15991 3
22 DRAIN PLUG P04 15079 1 46 OIL CUP S617 --- --- --- 1
23 DRIVE SHAFT BEARING S1044 --- --- --- 2 47 SHOULDER BOLT S1019 --- --- --- 1
24 RETAINING RING S204 --- --- --- 1 48 LOCKWASHER J05 15991 1
25 DRIVE GEAR 6558 16040 1 49 HEX NUT D05 15991 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E -- 9

DOCUMENT #: 1803659 Page 63 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 OM -- 01505
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de-
cals attached to the pump.
This pump requires little service due to its rugged,
minimum-maintenance design. However, if it be-
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1, 2, 3 and 4) and
the accompanying parts lists.
Most service functions may be performed without
separating the pump and gearbox from the motor.
If major repair is required, the pump, gearbox and
motor must be disconnected.
Before attempting to service the pump, shut off in-
coming power to the motor and lock it out to ensure
that it will remain inoperative. Close all valves in the
suction and discharge lines.
For motor disassembly and repair, consult the lit-
erature supplied with the motor, or contact your lo-
cal motor representative.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man-
ual.
2. Shut off incoming power to the mo-
tor and lock it out to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
5. Drain the pump.
Before attempting to service the pump, drain the
pump by removing the drain plug (11, Figure 2).
Clean and reinstall the drain plug.
PAGE E -- 10
DOCUMENT #: 1803659 Page 64 of 170
D SERIES
Suction And Discharge Check Valve Removal
(Figure 2)
To service the suction and discharge check valves,
remove the suction and discharge piping.
To service the suction check valve assembly (32),
remove the suction accumulator (3) by disconnect-
ing the hardware (8 and 9) securing it to the dia-
phragm pot (1). Remove the hardware (5 and 6) se-
curing the valve seat (31) and check valve assem-
bly to the diaphragm pot. Pull the check valve as-
sembly from the suction port.
To service the discharge check valve assembly
(25), loosen the hardware (21 and 22) and remove
the assembled outboard discharge elbow (23),
check valve, and seat (24). Remove the gasket
(19).
Remove the hardware (16 and 17) securing the
valve seat (24) and discharge check valve assem-
bly to the discharge elbow.
To remove the inboard discharge flange (18), loos-
en the hardware (14 and 15) securing the flange to
the diaphragm pot. Remove the gasket (12).
The suction and discharge check valve assemblies
are identical parts and operate in the same direc-
tion. For removal and/or replacement, remove the
hardware (29, 30, 35 and 36) securing the check
valve weights (26, 28, 33 and 34) to the check
valves (27 and 37). Inspect and replace as re-
quired.
If no further disassembly is required, see Suction
And Discharge Check Valve Installation.
Diaphragm Removal
(Figure 1)
To remove the diaphragm (6, Figure 3), disengage
the hardware (28, 29 and 30) and remove the dia-
phragm pot assembly (31). Inspect the diaphragm
ring (20) for wear or damage. If replacement is re-
quired, the gearbox assembly (25) and the eccen-
tric guard (39) must be removed.
(Figure 3)
Remove the nuts (10). Separate the lower dia-
phragm plate assembly (8) from the diaphragm (6)
MAINTENANCE & REPAIR
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES
and the upper diaphragm plate (9). Inspect the dia-
phragm and replace a required.
If no further disassembly is required, see Dia-
phragm Installation.
Plunger Rod Removal And Disassembly
(Figure 3)
With the diaphragm pot assembly and diaphragm
removed, disengage the hardware (35, 36, 37, 40,
41, and 42, Figure 1) and remove the eccentric
guard (39, Figure 1).
Loosen the hardware (2, 3 and 4) and remove the
end cap (24, Figure 1). Slide the bearing cap (1) off
the crankshaft roller bearing (33, Figure 4), and re-
move the plunger rod assembly.
Use a socket wrench to hold the plunger rod (5) se-
curely, and unscrew the bearing cap assembly (1).
Unscrew the spring retaining nut (13). Use caution
when unscrewing the retaining nut; tension on the
spring (12) will be released.
Remove the spring (12) and spring washer (11).
Slide the plunger rod assembly (5) out of the upper
diaphragm plate (9).
Inspect the component parts for excessive wear
and replace as required.
Gearbox Removal And Disassembly
(Figure 1)
When properly operated and maintained, the gear-
box assembly (25) should not require disassembly.
Disassemble the gearbox only when there is evi-
dence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly
equipped shop by qualified personnel.
Support the diaphragm ring (20) with wooden
blocks. Disengage the hardware (26 and 27), and
MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 65 of 170
OM -- 01505
remove the diaphragm ring. Inspect the dia-
phragm ring for wear or damage and replace as
necessary. It is not necessary to remove the draw-
bar (21) from the diaphragm ring unless replace-
ment is required. Disengage the hardware (33 and
34) from the U-bolts (32) to remove the drawbar.
Disengage the hardware (16, 17, 18 and 19) and
remove the coupling guard (4). Loosen the hard-
ware securing the coupling (1). Separate the gear-
box assembly from the coupling by pulling straight
away. Remove the shaft key (17, Figure 4).
(Figure 4)
Before attempting to disassemble the gearbox as-
sembly, drain the lubricant by removing the drain
plug (22) and turning the gearbox on its side. Clean
and reinstall the drain plug.
Remove the hardware (15 and 16) securing the ec-
centric housing (20) and housing gasket (21) to the
gear cover (7). Pull the complete drive shaft sub-
assembly from the gear cover.
To disassemble the drive shaft subassembly, re-
move the snap ring (26) and slide the drive gear
(25) off the drive shaft (18). Remove the retaining
ring (24), and press the drive shaft and assembled
bearings (23) out of the eccentric housing. Press
the oil seal (19) from the housing bore. Cover the
shaft and bearing with a clean cloth until ready to
clean and inspect the gearbox components.
For access to the remaining gearbox drive compo-
nents, the gear cover (7) and gear housing gasket
(4) must be separated from the gear housing (1) by
removing the two close-tolerance shoulder bolts
(40 and 47), which act as pilots to ensure accurate
concentric positioning of the cover, and the re-
maining hardware (37, 38, 39, 41, 42, 43, 44, 45, 48
and 49).
NOTE
The shoulder bolts and capscrews securing the
gearbox cover to the gearbox housing are of differ-
ent lengths. For ease of reassembly, record the
positions of the shoulder bolts and capscrews at
the time of removal.
Remove the gear housing gasket and clean all the
mating surfaces.
NOTE
If the gear cover does not readily separate from the
PAGE E -- 11
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 OM -- 01505
housing, remove the hardware (10 and 11), install a
5/8-11 UNC by 4-inch long capscrew, and jack the
cover from the housing. Remove the jacking screw
and replace the hardware (10 and 11).
After the gear cover has been removed, inspect the
pinion shaft bushing (13). If replacement is re-
quired, remove the cover plug (14) and press the
pinion shaft bushing (14) from the cover bore. Slide
the pinion shaft washer (12) off the pinion shaft (28)
and tag it for reference during reassembly.
Use a bearing puller to remove the crankshaft
bearing (9) from the crankshaft (35). Remove the
spacer (31).
Install two 5/8-11 UNC capscrews in the tapped
holes in the crankshaft gear (3), and use a gear
puller to slide the gear off the crankshaft. Retain the
crankshaft gear key (8). Remove the capscrews
from the gear.
Remove the snap ring (36) and slide the crankshaft
and crankshaft bearing (2) out of the gearbox
housing.
To disassemble the pinion shaft and components,
slide the shaft and assembled pinion gear (27) out
of the shaft bushing (30). The pinion gear is re-
tained on the shaft by tight friction fit and does not
normally require removal. If removal is required,
press the pinion gear from the shaft.
Inspect the pinion shaft bushing and, if replace-
ment is required, remove the plug (29) and press
the bushing from the gear housing bore.
After removing the shafts and bearings, clean and
inspect the bearings in place as follows.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear-
ings are removed.
Clean the gear housing, shaft and all component
parts (except the bearings) with a soft cloth soaked
PAGE E -- 12
DOCUMENT #: 1803659 Page 66 of 170
D SERIES
in cleaning solvent. Inspect the parts for wear or
damage and replace as necessary.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven-
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain-
ers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great-
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail-
ure.
Rotate the bearings by hand to check for rough-
ness or binding and inspect the bearing balls. If ro-
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shafts and a snug slip fit into the gear
housing. Replace the bearings, shafts, eccentric
housing, or gear housing if the proper bearing fit is
not achieved.
If the bearings require replacement, remove the
bearing retaining ring (34). Remove the bearing
snap ring (32) and use a bearing puller to remove
the bearings (2, 23, and 33).
Gearbox Reassembly And Installation
(Figure 4)
Inspect the shafts (18, 28 and 35) for distortion,
nicks or scratches. Dress small nicks and burrs
with a fine file or emery cloth. Replace the shafts if
defective.
MAINTENANCE & REPAIR
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and and
bearings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear-
ings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor-
oughly filtered.
Heat the bearings to a uniform temperature no
higher than 250EF (120EC), and slide the bearings
onto the shafts, one at a time, until they are fully
seated. This should be done quickly, in one con-
tinuous motion, to prevent the bearings from cool-
ing and sticking on the shaft.
Use caution when handling hot bear-
ings to prevent burns.
NOTE
The crankshaft bearing (9) must be installed after
the crankshaft gear (3).
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
out of position in shrinking. If movement has oc-
curred, use a suitable sized sleeve and a press to
reposition the bearings.
If heating the bearings is not practical, use a suit-
able sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.
MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 67 of 170
OM -- 01505
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
Secure the bearing (2) with the snap ring (36). Se-
cure the crankshaft roller bearing (33) with the
snap ring (32).
If removed, press the pinion shaft bushing (30) into
the gear housing until fully seated.
Use a hydraulic press to install the pinion gear (27)
onto the pinion shaft (28).
NOTE
The pinion gear is a tight interference fit on the pin-
ion shaft. To ease installation, the gear may be
heated (and the shaft cooled) to a temperature dif-
ferential of 350EF (177EC). If the gear is heated, use
caution when handling the gear to prevent burns.
Slide the assembled pinion shaft and gear into the
pinion shaft bushing until fully seated.
Slide the crankshaft and assembled bearing (2)
into the gear housing and secure with the snap ring
(36).
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Install the crankshaft gear key (8) in the shaft key-
way. Align the crankshaft gear teeth with those on
the pinion shaft, and press the gear onto the crank-
shaft until fully seated against the shoulder. Install
the spacer (31), and press the bearing (9) onto the
shaft until fully seated against the spacer.
Tap the end of the crankshaft with a soft-faced mal-
let to ensure that all components are fully seated.
If removed, press the pinion shaft bushing (13) into
the gear cover (7). Slide the pinion shaft washer
(12) onto the pinion shaft (28). Install the gear
PAGE E -- 13
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 OM -- 01505
housing gasket (4). Position the gear cover so that
the respective bores slip over the crankshaft bear-
ing and pinion shaft. Tap the cover into place with a
soft-faced mallet.
Install the two close-tolerance shoulder bolts (40
and 47) (which act as pilots to ensure accurate
concentric positioning of the cover) through their
respective holes, and secure them with the hard-
ware (41, 42, 48 and 49). Secure the gear cover to
the gear housing by tightening the remaining hard-
ware (37, 38, 39, 43, 44, and 45) evenly.
Install the gear cover plug (14) and the gear hous-
ing plug (29).
Press the drive shaft and assembled bearings into
the eccentric housing (20), and secure with the re-
taining ring (24).
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Lubricate the lip of the oil seal (19) with light oil, and
position it on the drive shaft with the lip positioned
as shown in Figure 4. Press the oil seal into the ec-
centric housing bore until the face of the oil seal is
just flush with the face of the eccentric housing.
Be careful not to roll or cut the lip of the oil seal on
the shaft keyway.
Install the drive gear (27) on the drive shaft, and se-
cure with the snap ring (26).
Clean the mating surface of the eccentric housing
and replace the eccentric housing gasket (21). Po-
sition the assembled eccentric housing and drive
shaft in the gear cover bore with the word “top” on
the eccentric housing flange facing up. Slide the
housing and drive shaft into the gearbox, making
certain the drive gear teeth fully engage those of
the pinion gear. Secure the eccentric housing to
the gear housing with the hardware (15 and 16).
Install the drive shaft key (17).
PAGE E -- 14
DOCUMENT #: 1803659 Page 68 of 170
D SERIES
(Figure 1)
Position the gearbox on the base (7). Position the
diaphragm ring (20) under the base, and secure
the gearbox and diaphragm ring with the hardware
(26 and 27).
If the drawbar (21) was removed, secure it to the
diaphragm ring with the U-bolts (32) and hardware
(33 and 34).
Reinstall the drive coupling (1), and connect the
halves. Check the coupling alignment as de-
scribed in ALIGNMENT, Section B.
Lubricate the gearbox as described in LUBRICA-
TION.
Plunger Rod Reassembly And Installation
(Figure 3)
Slide the plunger rod (5) through the upper dia-
phragm plate (9). Slide the spring washer (11) and
spring (12) down over the plunger rod. Install the
spring retaining nut (13), and tighten it to obtain the
dimension shown in Figure 3.
Clean the bearing cap (1) with a cloth soaked in
cleaning solvent.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven-
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain-
ers.
Inspect the bearing cap for wear or damage and
replace if necessary.
NOTE
The bearing cap consists of an upper and lower half
secured with the hardware (2, 3 and 4). The cap is
machined as one piece before being split to ensure
concentricity of the bore, and is available only as an
assembly.
MAINTENANCE & REPAIR
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
D SERIES
Screw the bearing cap assembly onto the plunger
rod until fully seated against the spring retaining
nut.
Loosen the hardware (2, 3 and 4), and position the
bearing cap over the crankshaft roller bearing (33,
Figure 4). Secure the plunger rod assembly by
tightening the hardware (2, 3 and 4).
Secure the eccentric guard (39, Figure 1) with the
hardware (35, 36, 37, 40, 41, and 42, Figure 1).
Lubricate the plunger rod assembly as described
in LUBRICATION, Section E.
Diaphragm Installation
(Figure 3)
Position the diaphragm (6) on the upper dia-
phragm plate (9), making sure the lip is properly
seated. Slide the studs in the lower diaphragm
plate (8) through the holes in the upper diaphragm
plate, and secure with the nuts (10).
(Figure 1)
Secure the diaphragm pot assembly (31) to the di-
aphragm ring (20) with the hardware (28, 29 and
30).
Suction And Discharge Check Valve Installation
(Figure 2)
Inspect the check valve components and replace
as required. Subassemble the check valve weights
(26, 28, 33 and 34) and check valves (27 and 37)
with the hardware (29, 30, 35 and 36).
If the inboard discharge flange (18) was removed,
clean the mating surfaces and install the gasket
(12). Secure the flange to the diaphragm pot (1)
with the hardware (14 and 15).
Subassemble the valve seat (24) and discharge
check valve (25) to the discharge elbow (23) with
the weights positioned as shown in Figure 2, and
secure with the hardware (16 and 17).
MAINTENANCE & REPAIR
DOCUMENT #: 1803659 Page 69 of 170
OM -- 01505
Clean the mating surfaces of the valve seat and dis-
charge flange. Install the gasket (19) and secure
assembled discharge elbow, check valve, and seat
to the discharge flange with the hardware (21 and
22).
Check the operation of the check valve to ensure
proper seating and free movement.
Subassemble the suction check valve (32). Clean
the mating surfaces, and position the gasket (10),
check valve assembly, and valve seat (31) against
the diaphragm pot with the weights positioned as
shown in Figure 2. Secure with the hardware (5
and 6).
Check the operation of the check valve to ensure
proper seating and free movement.
Secure the suction accumulator (3) to the dia-
phragm pot with the hardware (8 and 9).
Connect the suction and discharge piping as de-
scribed in INSTALLATION, Section B.
Refer to OPERATION, Section C before starting
the pump.
LUBRICATION
Plunger Rod Assembly
(Figure 1)
The crankshaft roller bearing (33, Figure 4)
should be lubricated thoroughly after each
8 hours of operation. Failure to do so may
cause the bearing to overheat and fail.
Apply No. 2 lithium base grease to the upper lubri-
cation fitting (23) until grease escapes from the end
cap (24).
Apply No. 2 lithium base grease to the lower fitting
(7, Figure 3) until grease escapes from the top of
the upper diaphragm plate inside the spring.
PAGE E -- 15
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 OM -- 01505
Gearbox
(Figure 4)
The gearbox was fully lubricated when shipped
from the factory. Check the oil level regularly at the
oil cup (46), and keep the oil cup full. Lubricate with
SAE No. 30 non-detergent when lubrication is re-
quired. Do not over-lubricate. Over-lubrication can
cause the bearings to overheat, resulting in prema-
ture bearing failure.
Under normal conditions, change the oil after each
5000 hours of operation, or at 12 month intervals,
whichever occurs first. Change the oil more fre-
quently if the pump if operated continuously or in-
stalled in a dirty or humid environment with rapid
temperature change.
PAGE E -- 16
DOCUMENT #: 1803659 Page 70 of 170
D SERIES
Monitor the condition of the bearing lubri-
cant regularly for evidence of rust or mois-
ture condensation. This is especially im-
portant in areas where variable hot and
cold temperatures are common.
When lubricating a dry (or overhauled) gearbox,
add one ounce of ‘Molykote M Gear Guard’ and
‘top off’ with clean oil.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Motor
Refer to the motor manufacturer’s recommenda-
tions or contact your local motor representative.
MAINTENANCE & REPAIR
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 BLOWER MAINTENANCE
SECTION 3
LUBRICATION

All DuroFlow blowers are splash oil lubricated at both

the gear and drive ends. Oil is distributed around the
gear housing and drive end chamber by the gears and
specially designed oil flingers.

Series Vertical Horizontal

Oil Fill Ports Mounting Mounting

One Port -- LUBRICATION INSTRUCTIONS

45 Shaft & Gear Ends 29 oz. 55 oz.
Interconnected For 45 series models, the oil fill port is located on the
top of the blower at the driveshaft end (see
FIGURE 1-- 2, page 5). The two oil sumps are
connected by a passageway through the housing
FIGURE 3-- 1 - APPROXIMATE OIL CAPACITIES
Add oil until the level stabilizes at the center of the sight-
glass(es). Oil level at the sight glass must be
established when the blower is not operating.
RECOMMENDED LUBRICANT
Add fresh oil as required to maintain proper level.
The factory recommended lubricant is AEON PD
Synthetic Lubricant. AEON PD is formulated
especially for positive displacement blowers to provide
maximum protection at any temperature. One filling of
AEON PD will last a minimum of 4 times longer than a
premium mineral oil, depending on actual operating Do not overfill as this will tend to
conditions. AEON PD contains a special additive cause excessive heating of the gears,
package designed for greater rust and corrosion
protection.
oil to leak through the vent holes, and
may damage the unit.

AEON PD Lubricant
AEON PD Synthetic Lubricant should be drained after
Description Part Number 6000 hours of operation. Re--fill with fresh AEON PD
1 Quart 28G23 oil. If mineral oil is used, perform the above oil--change
Case/12Quarts 28G24 maintenance every 1500 hours. Recommended
service intervals are for normal blower operating condi-
5 Gallon Pail 28G25
tions. Severe operating conditions may warrant more
55 Gallon Drum 28G28 frequent oil changes. Laboratory analysis of lubricant
should be used to help determine the optimum oil
AEON PD Food Grade Lubricant change interval.
Description Part Number
For best performance and equipment protection, use
1 Quart 28H97 AEON PD Synthetic Lubricant, which has been specifi-
Case/12Quarts 28H98 cally formulated for positive displacement blowers. If
5 Gallon Pail 28H99 you choose not to use AEON PD Synthetic Blower
55 Gallon Drum 28H100 Lubricant, select an oil with rust and oxidation inhibi-
tors, anti--foam additives, and the viscosities listed in
FIGURE 3--3, page 12. Do not use an oil that
FIGURE 3-- 2 - AEON PD SYNTHETIC LUBRICANT contains EP additives.

DOCUMENT #: 1803659 D--9-Page

-61171 of
Page
170 10 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
SECTION 5
MAINTENANCE AND TROUBLESHOOTING

Your DuroFlow blower has been designed, manufac-
tured and tested to precise specifications. Every
DuroFlow blower is backed by over 70 years of proven
performance in the most demanding applications that
modern industry can produce. DuroFlow blowers have
been designed specifically for long, trouble--free
service. Minimal maintenance is required to keep your
DuroFlow blower in top operating condition. Your
attention to the following key points will insure years of
dependable DuroFlow blower performance.
Key Points for Long Blower Life
1. Use AEON PD Synthetic Blower Lubricant to
assure maximum blower protection.
2. The oil level must be checked periodically.
3. Drain and refill the blower with fresh AEON PD
Lubricant every 6000 hours of operation, 1500
hours if using mineral based lubricant.
4. Clean the breather filters at every oil change or
more often if dust conditions are severe.
5. Service the intake and in--line filters regularly to
make sure that air flow restriction does not occur
and that foreign material does not enter the
blower.
6. If the blower is taken out of service for any reason,
be sure to protect all interior surfaces from rusting.

TROUBLE SHOOTING
No matter how well the equipment is designed and equipment needs attention, the operator or service
manufactured, there may be times when servicing will technician should be able to locate the cause and
be required due to normal wear, the need for correct the trouble quickly by following the Trouble-
adjustment, or various external causes. Whenever shooting Chart given below:

PROBLEM POSSIBLE CAUSES SOLUTION

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

Knocking and 2. Distortion due to improper 2. Check mounting alignment and
excessive mounting or pipe strains. relieve pipe strains.
mechanical noise.
3. Excessive pressure differential. 3. Reduce to manufacturer’s recom--
mended pressure or vacuum. Exam--
ine relief valve, re-set if necessary.
4. Worn gears. 4. Replace timing gears. (See page 18.)
5. Worn bearings. 5. Replace bearings. (See page 18.)

1. Too much oil in gear case. 1. Reduce oil level.

2. Too low operating speed. 2. Increase blower speed. Check
Excessive blower sheave set
temperature.
3. Plugged filter or silencer. 3. Remove cause of obstruction.
4. Excessive pressure differential. 4. Reduce pressure differential
across the blower.
5. Worn rotors clearances. 5. Replace rotors. (See page 18.)
6. Internal contact. 6. Correct clearances. (See page 18.)
7. Excessive inlet temperature. 7. Relocate intake to cooler area.

DOCUMENT #: 1803659
D--9-Page
-61172 of
Page
170
16
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 NORME D’INSTALLAZIONE E MANUTENZIONE
PRIMA DI MONTARE E METTERE IN FUNZIONE IL PRODOTTO, LEGGERE
ATTENTAMENTE TUTTE LE ISTRUZIONI SULLA SICUREZZA ED IL
FUNZIONAMENTO RIPORTATE NEL PRESENTE MANUALE.
SEGUIRE SEMPRE TUTTE LE AVVERTENZE ED ASSICURARSI CHE G L I
O P E R ATO R I P R E S E N T I I N P RO S S I M I TA ’ DELL’APPARECCHIATURA
INDOSSINO TUTTI I DISPOSITIVI DI PROTEZIONE RICHIESTI PER LA
SICUREZZA NELL’ AMBIENTE DI LAVORO.
NON UTILIZZARE L’APPARECCHIATURA SE LE PRESENTI ISTRUZIONI NON
DOVESSERO RISULTARE CHIARE, E CONTATTARE IMMEDIATAMENTE IL
COSTRUTTORE O IL DISTRIBUTORE PER L’ASSISTENZA NECESSARIA.
IL PRODOTTO DEVE ESSERE PROTETTO DA UNA COPERTURA ADEGUATA
PER EVITARE DANNI ALLE PERSONE.
LO SCHERMO DEVE SEMPRE PREVEDERE APERTURE ASSIALI E RADIALI
PER LA VENTILAZIONE DEL GIUNTO.
SE FOSSE MONTATO IL TAPPO FUSIBILE, LE SUDDETTE APERTURE NON
DEVONO ESSERE ORIENTATE VERSO GLI OPERATORI, PARTI CALDE O
COLLEGAMENTI ELETTRICI.

INSTALLATION AND MAINTENANCE

BEFORE ASSEMBLING AND OPERATING THE PRODUCT, CAREFULLY READ
ALL THE SAFETY AND OPERATING INSTRUCTIONS REPORTED IN THIS
MANUAL.
ALWAYS FOLLOW ALL THE INSTRUCTIONS AND ASSURE THAT ALL THE
OPERATORS STANDING BY THE MACHINERY ARE WEARING ALL THE
PROTECTIVE EQUIPMENT NECESSARY FOR THE JOB TYPE AND
APPLICATION BEING PERFORMED.
DO NOT USE THE MACHINERY IF YOU DO NOT UNDERSTAND THESE
INSTRUCTIONS, AND IMMEDIATELY REFER TO THE MANUFACTURER OR
THE CUSTOMER SERVICE DESK FOR ASSISTANCE.
THE PRODUCT MUST BE PROTECTED BY A CONVENIENT COVER GUARD
TO AVOID PERSONAL INJURY TO PEOPLE.
AXIAL AND RADIAL VENTILATION OPENINGS SHOULD BE INCORPORATED
IN THE GUARD FOR HEAT EXCHANGE.
IF THE PRODUCT IS FITTED WITH FUSIBLE PLUGS, THE SAID OPENINGS
SHOULD NOT BE DIRECTED TOWARDS OPERATORS OR ANY HOT OR
ELECTRICAL INSTALLATION.

24 KPTO

SPEC. NR. 2474-C

SERIE / SERIAL NR. KP -

DOCUMENT #: 1803659 Page 73 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 24 KPTO
trasmissioni industriali SPEC. 2474-C

SERIAL N. KP -

DOCUMENT REV DESCRIPTION

TF 6113 6 Features-use and maintenance
TF 6231 1 Procedures for conservation
TF 6093-A 2 Radial load (N / lb)
TF 6042 2 Torsional vibration calculation data
TF 6114 1 Arcusaflex technical data
TF 6115 Recommended oil
TF 6014 2 Hydraulic scheme
TF 6007-Q 1 Electric connection
TF 5938-E 2 Filter
TF 6051 2 Solenoid valve spares
TB 1066-C 3 Spare sparts: fluid coupling
TB 1070-B 6 Spare parts: fluid coupling carter
TB 1071-A 4 Spare parts: std. accessories
TB 1072-B 11 Spares description
TF 6119/1 4 Trouble shooting
A 6468-B 1 Installation drawing

DOCUMENT #: 1803659 Page 74 of 170 LAST UPDATE: 9/20/18

INDEX GB-24KPTO-std.doc
DATE PRINTED: 9/20/18
 ISTRUZIONI di USO e MANUTENZIONE per
GIUNTI KPTO
WORKING and MAINTENANCE INSTRUCTIONS
trasmissioni industriali for KPTO FLUID COUPLINGS
CARATTERISTICHE
1 - Il KPTO per motori endotermici è un giunto idrodinamico a
svuotamento. Quando è vuoto lavora come una frizione
disinnestata; se progressivamente riempito, lavora come
un avviatore graduale (soft starter).
2 - Il KPTO può essere flangiato a qualunque tipo di motore
endotermico che abbia una flangia SAE ed un volano. Il
KPTO è dotato di un giunto ad elevata elasticità. Si
raccomanda in ogni caso l’esecuzione di una verifica
torsionale della catena cinematica in modo da garantire la
compatibilità tra i vari elementi che compongono la
trasmissione.
3 - Il KPTO è fornito di una pompa incorporata.
Tale pompa serve a riempire il giunto, a lubrificare i
cuscinetti e a dissipare il calore generato durante
l’avviamento ed a regime.
4 - Il KPTO ha alcuni fori, situati sulla periferia della parte
rotante, che continuamente scaricano l’olio fornito dalla
pompa.
Questi fori hanno un diametro calcolato in funzione
dell’applicazione. Poiché i fori sono ricavati su dei tappi
filettati, possono essere facilmente sostituiti per
ottimizzare le prestazioni.
5 - Per mezzo di una elettrovalvola (TF5937… 24 Vdc
[standard] o 12 Vdc, 110 Vac, 220 Vac) la portata della
pompa può essere deviata nel carter. In tal modo il giunto
viene svuotato (il tempo di svuotamento dipende da: il
diametro dei fori periferici e dalla velocità di entrata)
mentre la portata di olio continua ad assicurare il
raffreddamento del carter e la lubrificazione dei cuscinetti.
6 - L’olio è mantenuto pulito attraverso un filtro da 25 μm con
cartuccia sostituibile. L’intasamento del filtro è indicato dal
manometro-pressostato (N9404AB-N9504AC) quando la
pressione supera di 1.7 bar il valore con cartuccia nuova;
il contatto è regolato durante il collaudo, controllare che il
valore sia conforme (tale valore viene stabilito al primo
avviamento e non appena la temperatura ha raggiunto il
valore di normale funzionamento). Il pressostato fornito
già tarato da TRANSFLUID (verificare che la taratura sia
coerente con le reali condizioni d’impiego quali lunghezza
tubazioni e temperatura olio) deve essere usato come
segnale d’allarme intasamento filtro.
7 - Il termostato (vedere N9404AB-N9504AC) è già
impostato (vedere il Certificato di collaudo) e deve essere
utilizzato come segnale di allarme quindi deve essere
collegato ad un dispositivo che consenta di prevenire
surriscaldamenti e danni al KPTO nel rispetto delle norme
di sicurezza.
Come suggerimento, può disinserire la valvola solenoide
o fermare il motore.
Se il KPTO è raffreddato dall’acqua del motore, il
termostato deve essere tarato a max 95 °C.
DOCUMENT #: 1803659 Page 75 of 170
TF6113_GB+IT.doc
TF6113
Rev. 12
pag. 1/6
FEATURES
1 - KPTO for internal combustion engine is a drain type fluid
coupling.
If drained out it works as a disconnected clutch.; if
progressively filled up it works as a soft starter.
2 - KPTO can be flanged to any internal combustion engine
having a SAE housing and flywheel.
The KPTO is equipped with a torsional elastic coupling. It
is recommended to perform a transmission line torsional
analysis in order to grant full compatibility among each
single transmission element.
3 - KPTO has a incorporated feed oil pump. This oil flow is
used to fill up the fluid coupling, to lubricate bearing, and
to dissipate the heat generated during start up and steady
running.
4 - KPTO has some calibrated nozzles, fitted on peripheral
part, which continuously drain the oil supplied by feed oil
pump. Nozzles have calculated diameter depending on
application. Because nozzles are made in threaded plugs,
they can be replaced to optimise performances. Quick
release valves, supplied as optional, drain oil in few
seconds.
5 - Through an solenoid valve (TF5937… 24 Vdc [standard]
or 12 Vdc, 110 Vac, 220 Vac) the pump oil flow can be
diverted to the oil tank.
In such a way the fluid coupling is drained out (time
required depends by nozzles diameter and input speed)
while oil flow continues to assure the tank cooling and
bearings lubrication.
6 - Oil is cleaned through a 25 μm filter with replace paper
cartridge.
Filter clogging is indicated on pressure switch-gauge dial
(see N9404AB-N9504AC) when is 1.7 bar over the rated
pressure (rated pressure is established during first start
up as soon as oil temperature has reached the working
value).
Pressure switch, already set during workshop test (be
careful to check if setting was correct according to actual
working condition like pipes length and oil temperature)
must be used as alarm signal for filter clogging.
7 - Temperature switch (see N9404AB-N9504AC), already set
(see the test Certificate), must be used as alarm signal
therefore should be connected to any protection device in
order to avoid overheating and damages to KPTO unit
granting also a safe operation.
Just as suggestion, it could switch off solenoid valve or
shut down the engine.
When KPTO is cooled by engine jacket water,
temperature switch setting could be max 95 °C.
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 ISTRUZIONI di USO e MANUTENZIONE per
GIUNTI KPTO
TF6113
WORKING and MAINTENANCE INSTRUCTIONS Rev. 12
trasmissioni industriali for KPTO FLUID COUPLINGS
pag. 4/6

AVVIAMENTO
IMPORTANTE
- Controllare il senso di rotazione della pompa. Una volta in
moto, se non si dovesse leggere nessuna pressione sul
manometro, controllare i collegamenti dei tubi ed il livello
dell’olio (vedere cap. MANUTENZIONE in questo
manuale).
START UP
IMPORTANT
- Check rotation direction of the pump. Once the pump is
running, if no pressure is read on filter pressure gauge,
check pipes connection and oil level (see MAINTENANCE
for correct level).

- Controllare che la pressione rientri nel valore corretto, con - Check pressure be within correct value at steady running
temperatura a regime (vedere il Certificato di collaudo). temperature (see Test Certificate).

- Mettere in OFF l’elettrovalvola. - Switch OFF solenoid valve.

- Mettere in ON l’elettrovalvola. - Switch ON solenoid valve.

DISINNESTO (FERMATA) DISENGAGEMENT (STOP)

Mettere in OFF l’elettrovalvola. Switch OFF solenoid valve.

Quando il motore principale è in funzione, disconnettere
l’elettrovalvola per disinnestare il giunto.
La lubrificazione dei cuscinetti è garantita dalla pompa di
alimento. La pompa riceve moto dal motore tramite
collegamento meccanico.
While main engines is running, switch off solenoid valve to
disengaged (load stop) fluid coupling.
Bearings lubrication, is assured by feed pump that is
mechanically driver by the engine.

Il motore endotermico deve essere The Diesel engine must be always running
mantenuto in funzione fino al completo until the driven machines comes to a full
arresto della macchina condotta per stop.
garantire la corretta lubrificazione dei This is to grant KPTO bearings lubrication
cuscinetti del KPTO

MANUTENZIONE MAINTENANCE
PER POSIZIONI ED ELENCO PARTI DI RICAMBIO TO LOOK FOR POSITION AND SPARE PARTS SEE
VEDERE TB1066…, TB1070…, TB1071.. e TB1072... TB1066…, TB1070…, TB1071… and TB1072...

Dopo le prime 100 ore di funzionamento:
smontare il coperchio di ispezione (pos. 42) e rimuovere i 4
tappi di perdita (pos. 10).
Riposizionare il portello di ispezione con il tappo di sfiato.
Far funzionare il KPTO a piena velocità per 2-3 minuti
innestando e disinnestando l’elettrovalvola alcune volte.
Rimontare i 4 tappi di perdita.
Scaricare l’olio e pulire i tappi magnetici (pos. 40).
Riempire con nuovo olio fino a raggiungere la linea blu sui
livelli visivi dell’indicatore di livello olio (pos. 37).
After the first 100 working hours:
remove the inspection cover (item 42) and then remove the 4
nozzle calibrated plugs (item 10).
Mount inspection cover with the breather.
Run for 2-3 minutes the KPTO at full speed engaging and
disengaging few times the solenoid valve.
Mount again the 4 nozzle calibrated plug.
Drain the oil and clean the magnetic plugs (item 40).
Fill again with new oil up to the blue line on the sight glasses
off the oil level indicator (item 37).

DOCUMENT #: 1803659 Page 76 of 170 LAST UPDATE: 9/20/18

TF6113_GB+IT.doc
DATE PRINTED: 9/20/18
 ISTRUZIONI di USO e MANUTENZIONE per
GIUNTI KPTO
TF6113
WORKING and MAINTENANCE INSTRUCTIONS Rev. 12
trasmissioni industriali for KPTO FLUID COUPLINGS
pag. 5/6

Cambiare l’olio ogni 4000 ore di funzionamento, a meno di
un evidente cambiamento del colore. Il livello corretto
dell’olio è la linea blu sull’indicatore di livello (prima riempire
il KPTO, poi avviare la pompa di alimento per riempire lo
scambiatore di calore, valvola in OFF, quindi controllare
nuovamente il livello quando il motore principale è fermo).
Change oil every 4000 working hours unless evident oil
colour change.
Correct oil level is the blue line on oil level indicators (first fill
KPTO, then run the pump, solenoid valve OFF, to completely
fill heat exchanger, hence check level again, while engine is
stopped).

Cambiare la cartuccia del filtro (25 μm) quando la pressione Change oil filter cartridge (25 μm) when pressure is 1.7 bar
supera di 1.7 bar il valore di normale funzionamento. over rated value and/or pressure switch is ON.

Cambiare le tenute rotanti (pos.46 e 58) in caso di perdite di Change rotating seals (items 46 and 58) in case of
olio considerevoli. considerable oil leakage.
Le parti di ricambio consigliate sono disponibili presso Recommended spare parts are supplied from
TRANSFLUID srl o presso il Distributore di zona (vedere - TRANSFLUID srl or local Distributor (see - SALES
RETE DI VENDITA - su www.kraftpower.com o sul retro del NETWORK - on www.kraftpower.com
catalogo 176 I).

OIL ANALYSIS AND CONTAMINATION LEVEL

ANALISI DELL'OLIO E LIVELLO DI
CONTAMINAZIONE
On first oil filling an hydraulic circuit flushing is recommended
Al primo riempimento si raccomanda di flussare il circuito to grant a contamination level within ISO4406:1999 class
idraulico fino a garantire un livello di contaminazione 19/17/14 NAS 1638 Class 8.
conforme all normativa ISO4406:1999 classe 19/17/14 NAS During operation oil should be replaced when contamination
1638 Classe 8. level rises above
Durante il funzionamento l'olio dovrebbe essere sostituito non ISO4406:1999 class 20/18/15 NAS 1638 Class 9
appena il livello di contaminazione sia salito oltre il valore
indicato dalla ISO4406:1999 classe 20/18/15 NAS 1638
Classe 9. FOR MORE INFORMATION ASK FOR DOCUMENT
PER ULTERIORI INFORMAZIONI, RICHIEDERE TF6817
DOCUMENTO TF6817.

- Controllare periodicamente, possibilmente ogni 1000 ore, - Check periodically, possibly every 1000 hours, that pump
l’allungamento della catena della pompa (appendere alla chain be of correct length (hang 20 kg weight to stretch
catena un carico di 20 kg e quindi misurare la lunghezza chain):
totale):

Lunghezza Max
KPTO
Max Length

15 1265 mm

17 - 19 1362 mm

21 - 24 1556 mm

27 1914 mm

- Verificare il serraggio delle viti/dadi pos. 20 specialmente se - Check screws/nuts item 20 tightening torque especially
il giunto ha subito surriscaldamenti. when the unit was overheated.

- Controllare, periodicamente, le condizioni del giunto elastico - Check, periodically, elastic coupling condition.

DOCUMENT #: 1803659 Page 77 of 170 LAST UPDATE: 9/20/18

TF6113_GB+IT.doc
DATE PRINTED: 9/20/18
 ISTRUZIONI di USO e MANUTENZIONE per
GIUNTI KPTO
TF6113
WORKING and MAINTENANCE INSTRUCTIONS Rev. 12
trasmissioni industriali for KPTO FLUID COUPLINGS
pag. 6/6

PROCEDURA PER LA SOSTITUZIONE DEI PROCEDURE FOR THE REPLACEMENT OF

SEGUENTI PARTICOLARI: THE FOLLOWING PARTS:
- mozzo dentato del giunto elastico (pos. 64) - splined hub of the elastic coupling (item 64)
- albero di entrata (pos. 4) - input shaft (item 4)
- rondella (pos. 23). - washer (item 23).

E’ necessario spessorare il gioco tra la rondella e l’albero, in
modo che sia compreso tra 0.05 mm e 0.15 mm.
Assicurarsi di collocare il mozzo correttamente contro il
cuscinetto prima di misurare lo spazio da spessorare tra il
fondo dell’albero e la superficie del mozzo per l’appoggio
della rondella di bloccaggio . A tale scopo utilizzare gli
spessori forniti da TRANSFLUID od equivalenti (richiedere
tabella N2912).
Le viti (pos. 24) devono essere rimontate con LOCTITE e
serrate con una coppia di 50 Nm.
It is necessary to shim the gap between washer and input
shaft ; the gap must be within 0.05 mm and 0.15 mm.
Be sure to seat hub tightly against bearing before measuring
the shim gap between the end of the input shaft and retainer
washer clamping surface in the hub. Use shims provided by
TRANSFLUID or equivalent (ask for table N2912).
Screws (item 24) must be refitted with LOCTITE and
tightened at 50 Nm.

IMPORTANTE IMPORTANT
QUALUNQUE MODIFICA DEI FORI DI PERDITA ANY MODIFICATION OF NOZZLES DIAMETER
DEVE ESSERE APPROVATA DA TRANSFLUID srl. MUST BE APPROVED BY TRANSFLUID srl NOT TO
SENZA APPROVAZIONE, VERREBBE PENALIZE WARRANTY VALIDITY.
PENALIZZATA LA VALIDITÀ DELLA GARANZIA.

DOCUMENT #: 1803659 Page 78 of 170 LAST UPDATE: 9/20/18

TF6113_GB+IT.doc
DATE PRINTED: 9/20/18
 PROCEDURES FOR CONSERVATION
OF VARIABLE FILL FLUID COUPLING TF 6231
Rev. 1
trasmissioni industriali KPT - KSL

Following procedures are valid for unit in its original packaging, stored in dry, clean, dust
free indoor ambient.

CHECK CONTROL

1 - INTERNAL PARTS

1.1 - Spray inside housing 0,25 l of oil TECTYL 930 SAE 30.

1.2 - Put inside housing suitable amount of dryer packs (g/m3 according to packs
instructions). attach, externally, a warning signal like “REMOVE BEFORE
OPERATION”.

1.3 - Seal all openings and passes between housing and ambient (i.e. breather,
input/output for cooler).

2 - EXTERNAL PARTS

2.1 - Wet with protective fluid CRC 3.36 (or equivalent) all steel parts not already
painted or phosphated.
In case of marine enviroment, use protective fluid CRC 6.66 MARINE (or
equivalent) for 3 months protection, or CRC PROTECTIVE MARINE for 6
months protection.
After the 3 or the 6 months period, operation must be repeated first cleaning
CRC.
CRC is cleanable by means of CRC MARIN ELMEC CLEAN diluent.

2.2 - Rotating seals or labyrinths must be protected with grease AGIP 33 FD or

SHELL ALVANIA R3 or equivalent.

2.3 - Check that connection wiring box be well sealed.

2.4 - For motors, pumps, instruments, preserve the original packaging, if any.

TF6231-GB-REV.1
DOCUMENT #: 1803659 Page 79 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 KPTO & KPTE TF 6093-A
PERMISSIBLE SIDE LOAD (N) Rev. 2
trasmissioni industriali AND SUGGESTED PULLEY TRANSMISSION

- Calculated bearings life over 10.000 hours.

- Engine speed over the max listed below, needs approval by Transfluid.
- Pulley diameter is the minimum permissible. (Over 35 m/s, dynamic balancing is recommended).
- Belts nr. is maximum permissible.
- Timing belts must be approved by Transfluid.
- “X” distance is according to belts type & number.
- Side load includes 2.5 belt tensioning factor.

15
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
200 / 2600 91 / 17.000 10 x 5V - 220 mm
17 - 19
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
95 / 20.000 10 x 5V - 335 mm
250 / 1800 91 / 20.000 6 x 8V - 335 mm
95 / 20.000 7 x SPC - 335 mm
102 / 18.000 11 x 5V - 355 mm
300 / 2200 105 / 18.000 7 x 8V - 355 mm
107 / 18.000 8 x SPC - 355 mm
21
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
150 / 31.000 10 x 8 V - 335 mm
400 / 1800
160 / 31.000 12 x SPC - 335 mm
165 / 29.000 11 x 8 V - 355 mm
470 / 2200
170 / 29.000 13 x SPC - 355 mm
24
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
88 / 40.000 12 x 8 V - 355 mm
545 / 1800
95 / 40.000 14 x SPC - 355 mm
117 / 35.000 14 x 8 V - 380 mm
620 / 2200
120 / 35.000 16 x SPC - 380 mm
Pulley must be installed overlapping bearing carrier by 89 mm.
27
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
800 / 1800 133 / 55.000 17 x 8V - 380 mm
Pulley must be installed overlapping bearing carrier by 115 mm.

ASK TRANSFLUID FOR ANY APPLICATION DIFFERENT THAN ABOVE.

tf6093-a 02-00#: 1803659

DOCUMENT Page 80 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 GIUNTO ELASTICO RBD o AC + KPT LATO ENTRATA
(per calcolo vibrazioni torsionali) TF 6042
RBD or AC ELASTIC COUPLING + KPT INPUT SIDE Rev.2
trasmissioni industriali (for torsional vibration calculation)

Dim.
TKN TKmax T
± KW
CT CTdyn ψ VR J1 JL
rpm T (°C)
Size (10Hz) max max
15/11S 860 2150 430 93 100 0.726 8.65 0.035 0.736 2600 120
15/11D 2060 6530 1030 461 691 0.726 8.65 0.082 0.782 2600 120
15/14S 1690 4220 845 206 309 0.726 8.65 0.180 0.836 2600 120

17/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.215 2600 120
17/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.276 2600 120

19/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.773 2600 120
19/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.833 2600 120
19/AC5-11 2500 7500 1250 13 1.25 5.03 0.065 1.832 2600 80
19/AC5-14 2500 7500 1250 13 1.25 5.03 0.179 1.830 2600 80

21/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 2.869 2200 120
21/AC6-14 4200 12600 2100 45 1.25 5.03 0.220 2.999 2600 80

24/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 5.332 2200 120
24/14D18 3490 11040 1745 1010 1515 0.726 8.65 0.870 5.332 2200 120
24/AC7-14 6300 18900 3100 100 1.25 5.03 0.312 5.742 2600 80
24/AC7-18 6300 18900 3100 100 1.25 5.03 0.519 5.742 2300 80

27/18D 5300 16720 2650 1885 2827 0.726 8.65 0.652 8.805 1800 120
27/AC8-18 7800 23400 3900 110 1.25 5.03 0.478 9.105 2300 80

TKN Coppia nominale - Nominal torque (Nm)

TKmax Coppia massima - Max torque (Nm)
Coppia continua vibratoria a 10 Hz (Nm) - Continuous vibratory torque at 10 Hz
TKW (10Hz) Per frequenze fx differenti vale la TKW √(10/fx) - For different fx frequencies TKW √(10/fx) is valid
CT Fattore statico di rigidità - Static stifness factor (Nm/rad)10³
CTdyn Fattore dinamico di rigidità - Dynamic stifness factor (Nm/rad)10³
ψ Smorzamento relativo - Relative damping
VR Fattore di risonanza - Resonance factor
J1 Inerzia parte motrice del giunto elastico - Elastic coupling driving part inertia
Inerzia parte condotta del giunto elastico + lato entrata del KPT
JL Elastic coupling driven part inertia + KPT input side

tf6042 date: 02-00

DOCUMENT #: 1803659 Page 81 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 ARCUSAFLEX TF 6114
DATI TECNICI / TECHNICAL DATA Rev. 1
trasmissioni industriali
Coppia continua Velocità
Durezza Coppia Nominale Coppia max di vibrazione Elasticità dinamica Flangia tipo
ARCUSAFLEX max
Shore Nominal Torque Max Torque Continuous Dynamic Stiffness Flange Size
Tipo / Size Max Speed
hardness TkN (Nm) Tk max (Nm) Vibration Torque CTdyn. (Nm/rad) SAE J 620
* TkW (10 Hz) (Nm) (rpm)
WN 200 500 100 1100
NN 250 750 125 1700 6.5
AC 2 4200
8
SN 330 1000 165 3300
WN 330 750 165 1100
6.5
AC 2,3 NN 360 900 180 1700 4200
8
SN 400 1000 200 2500
WN 500 1250 250 2100 8 4200
AC 2,6 NN 600 1800 300 3100 10 3600
SN 700 2100 350 4500 11.5 3500
WN 800 2000 400 3600
10 3600
AC 3 NN 900 2700 450 5000
11.5 3500
SN 1000 3000 500 7500
WN 1200 3000 600 8000
11.5 3500
AC 4 NN 1350 3600 650 10000
14 3000
SN 1550 4200 750 13500
WN 1800 4500 900 8500
AC 5 NN 2000 5400 1000 13000 14 3000
SN 2500 7500 1250 22000
WN 3100 7700 1500 16000
14 3000
AC 6 NN 3450 10000 1700 30000
18 2300
SN 4200 12600 2100 45000
WN 4600 10000 2300 35000
14 2600
AC 7 NN 5200 15600 2600 56000
18 2300
SN 6300 18900 3100 100000
WN 6200 14000 3100 38000
18 2300
AC 8 NN 7000 21000 3500 75000
21 2000
SN 7800 23400 3900 110000
WN 12400 28000 6200 76000
18 2300
AC 8 D NN 14000 42000 7000 150000
21 2000
SN 15600 46800 7800 220000
WN 8000 18000 4200 55000
18 2300
AC 9 NN 9000 27000 4800 100000
21 2000
SN 10000 30000 5500 190000
WN 16000 36000 8400 110000
AC 9 D NN 18000 54000 9600 200000 21 2000
SN 20000 60000 11000 380000

Durezza / Shore hardness: WN = 50-55° Shore A

NN = 60-65° Shore A
SN = 70-75° Shore A

10
*= Coppia continua di vibrazione ± TkW: a ƒ = 10 Hz , per altre frequenze ƒx è valida TkW fx

10
Continuous Vibration Torque ± TkW: at ƒ = 10 Hz, for other frequency ƒx is valid TkW fx

Fattore di risonanza VR e relativo Damping Ψ

Resonance factor VR and relative Damping Ψ

Durezza
VR Ψ
Shore hardness
WN 7.85 0.8
NN 5.46 1.15
SN 5.0 1.25

DOCUMENT #: 1803659 Page 82 of 170 LAST UPDATE: 9/20/18

tf6114-rev.1 02/2002
DATE PRINTED: 9/20/18
 OLIO CONSIGLIATO TF 6115
RECOMMENDED OIL
trasmissioni industriali (ISO HM 32) REV. 0

AGIP OSO 32
ARAL VITAM GF 32
BP ENERGOL HLP 32
CASTROL HYSPIN AWS 32
CHEVRON RPM EP HYDRAULIC 32
ESSO NUTO H 32
MOBIL DTE 24
SHELL TELLUS 32
TEXACO RANDO HD 32
TOTAL AZOLLA ZS 32

DOCUMENT #: 1803659 Page 83 of 170 LAST UPDATE: 9/20/18

tf6115 17/03/97
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 84 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 85 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 TF 5938...
FILTRO / FILTER REV. 2
trasmissioni industriali

RIFERIM. / REF. DIMENS. CARTUCCIA / CARTRIDGE

TF 5938-O 1” ¼ 25 µm
X TF 5938-E ¾” 25 µm
TF 5938-K ¾” 10 µm

1
TESTATA
FILTER HEAD

2
BY-PASS

3
TENUTA VITON
VITON SEAL

4
CARTUCCIA
CARTRIDGE

DOCUMENT
TF5938-EK / 14/09/01 #: 1803659 Page 86 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 ELETTROVALVOLA / ELECTRIC VALVE TF 6051
DFE 20 / 3A - 18ES - W201 - 24 Vdc - BSP
REV. 2
trasmissioni industriali

(REF. TF5937-E)

1
5
4
7
8

9
2

POS. CODICE - CODE Q. DESCRIZIONE - DESCRIPTION

1 3CO2261320 1 Corpo Housing DFE/20/3-BSP
2 4SPI512040 3 Spina Pin UNI6874 12x40
3 3CAS120341 1 Cassetto Spool DFE20/3A
4 4GUA123526 2 Gommino O Ring 23.47x2.62
5 3MOL117310 1 Molla Spring DF20 V.18ES
6 3TAP332200 1 Tappo Plug DFE20
7 4GUA130018 1 Gommino O Ring 29.87x1.78
8 4SOL519024 1 Bobina Solenoid 24VDC D19-46.79
9 4SOL519000 1 Cannotto Pusher D19x4O

tf6051 rev.2/07/05/02

DOCUMENT #: 1803659 Page 87 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 88 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 89 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 90 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 KPTO-KPTU
TB 1072-B
parts list
Rev. 11
trasmissioni industriali (TB1066-C & TB1070-B & TB1071-A)

1 inner impeller 61 lock washer 122 lock washer

2 outer impeller 62 screw 123 chain drive
3 cover 63 lock washer 124 cover
4 outer impeller shaft 64 splined hub 125 screw
5 roll bearing 65 flange (RBD) 126 lock washer
6 snap ring 66 rubber block (RBD) 127 shim(s)
7 screw 67 driving ring (RBD) 128 O-ring
8 lock washer 68 screw (RBD) 129 tab washer
9 ring 69 nut (RBD) 130 tab washer
10 orifice plug 70 lock washer (RBD) 131 seal
11 splined hub 71 key 132 flange
12 snap ring 72 feed pump 133 screw
13 coupling bearing carrier 73 screw 134 lock washer
14 ball bearing 74 lock washer 135 screw
15 snap ring 75 hub 136 gasket
16 snap ring 76 key 137 gasket
17 screw 77 lock washer 138 elastic coupling (AC)
18 ring 78 screw 139 driving ring (AC)
19 short end stud / screw (for 27kpto) 79 gear 140 screw (AC)
20 nut 80 screw 142 lock washer (AC)
21 lock washer 85 straight end fitting 143 washer
22 O-ring 86 breather 148 reducing fitting
23 lock washer 87 solenoid valve 149 adapter
24 screw 88 nut 151 snap ring
31 housing 89 lock washer 152 nut (AC)
32 baffle 90 adapter 153 snap ring
33 screw 92 reducing fitting 154 QD-bushing
34 lock washer 93 copper packing 155 hub for QD-bushing
35 screw 94 “T” adapter 156 screw
36 lock washer 95 lubrication pipe 157 key
37 oil level indicator 96 straight end fitting 232 reducing fitting
40 magnetic plug 97 oil filter 263 shim(s)
41 O-ring 98 adapter 265 lock washer
42 cover 99 copper packing 266 lock washer
43 screw 100 adapter
44 lock washer 101 copper packing
45 bearing carrier 102 feed tube
46 seal 103 adapter
47 double roll bearing (KPTO) 104 copper packing
47a ball bearing (KPTU) 105 drain tube
48 snap ring 106 plug
49 inner impeller shaft 107 copper packing
50 shim 108 panel
51 snap ring 109 pressure switch gauge
52 O-ring 110 temperature switch gauge
53 screw 111 pressure gauge pipe
54 lock washer 114 lubrication pipe
55 SAE flange 115 spacer
56 roll bearing 116 short end studs
57 bearing carrier 118 suction flange
58 seal 119 straight union fitting
59 O-ring 120 suction pipe
60 screw 121 straight end fitting

TB1072-B GB.doc #: 1803659

DOCUMENT Page 91 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 KPTO (U) TF 6119/1
TROUBLE SHOOTING REV. 4
trasmissioni industriali

UNIT FAILS TO OPERATE

1 - Check KPT output shaft turns freely with engine shutdown.

2 - Check solenoid valve (item 87 - TB1071-…) is operating.

3 - Check oil level. It must be at blue line on level indicator (item 37 - TB1070-…).

4 - Check oil pressure (item 109 - TB1071-…) (see test certificate).

5 - Remove cover plate (item 42 - TB1070-…) and check:

a) four orifice plugs (item 10 - TB1066-…) be tight
b) nuts (item 20 - TB1066-…) be tight.

6 - Check oil flow by inserting flow meter in feed line from pump to KPTO.

7 - Check (on KPTO with integral pump) condition of pump driving chain.

8 - Check temperature alarm switch (item 110 - TB1071-…) is set at correct level (see test
certificate).

UNIT OPERATES AT REDUCED OUTPUT SPEED

1 - Carry out checks from 1) to 7) as above.

2 - Check engine high idle speed with KPTO dis-engaged.

3 - Check driven machine condition.

OIL LOSS

1 - Check all pipe connections.

3 - Check seals (item 46 and 58 - TB1070-…).

3 - Check engine flywheel housing.

4 - Check engine coolant is not contaminated.

If vapor comes out from the breather, wait until oil temperature reaches more than 55-
60° C. If oil comes out from the breather, check orientation of oil keeper under cover
(item 42 - TB1070-B).

TOO MUCH OIL PRESSURE

1 - Check filter cartridge and replace if necessary (item 97 - TB1071-…).

2 - Check pressure gauge (item 109 - TB1071-…) be not defective.

3 - Check not obstruction inside oil tubes.

DOCUMENT #: 1803659 Page 92 of 170 LAST UPDATE: 9/20/18

tf6119-1-gb/4 05/03/01
DATE PRINTED: 9/20/18
DOCUMENT #: 1803659 Page 93 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
GARANZIA BASE, TERMINI E CONDIZIONI
TF 6401-I - rev. 0
1) Premessa
TRANSFLUID garantisce che i propri prodotti, al momento della
spedizione, sono conformi alle specifiche pubblicate nei propri
cataloghi o documenti tecnici validi al momento della spedizione
stessa e che sono esenti da difetti nei materiali e nella
fabbricazione. Questi termini di garanzia sostituiscono tutte le
altre garanzie, anche legali, espresse o implicite, comprese, a
titolo esemplificativo e non esaustivo, le garanzie di
commerciabilità e di idoneità ad un uso particolare (e qualsiasi
garanzia implicita che sorga nel corso delle prestazioni, nel
corso delle trattative o dell’uso commerciale). Fatti salvi i casi di
dolo e colpa grave, in nessun caso TRANSFLUID sarà
responsabile per danni diretti, indiretti, consequenziali, fortuiti od
extracontrattuali basati su una richiesta d’indennizzo da parte
del Compratore per violazione di garanzia, violazione di
contratto, responsabilità oggettiva. In nessun caso il risarcimento
da parte di TRANSFLUID potrà superare l’importo che il
Compratore ha pagato per il prodotto fornito da TRANSFLUID.
2) Durata e limiti della garanzia
a) La durata della garanzia è pari a diciotto (18) mesi dalla
messa in servizio del prodotto fornito da TRANSFLUID e
comunque non oltre ventiquattro (24) mesi dalla data di
spedizione del prodotto originale dallo stabilimento
TRANSFLUID.
b) I prodotti, se inutilizzati e stoccati a lungo termine, devono
essere immagazzinati e trattati in accordo alle linee guida
redatte da TRANSFLUID per tipologia di prodotto che sono
rese disponibili su richiesta.
c) La garanzia per le parti la cui usura o deterioramento è
fortemente legata alle condizioni di impiego (tensionamento
delle cinghie, condizioni ambientali, urti e sovraccarichi non
previsti), alla sensibilità dell’operatore (utilizzo entro i limiti
approvati), ad eventi esterni (inceppamenti della macchina
condotta), non opera se tali parti sono state utilizzate (non
sono nuove), o se non viene chiaramente dimostrato dal
Compratore un eventuale difetto di fabbricazione riconducibile
a TRANSFLUID.
Tipiche parti soggette ad usura o deteriorabili sono:
- filtri, tenute e guarnizioni
- molle, viti, tappi
- interruttori e fusibili
- materiali e superfici di attrito
- cinghie e catene
- lubrificanti in genere
d) L’installazione e la manutenzione dei prodotti TRANSFLUID
deve essere eseguita in conformità a quanto indicato nel
manuale di installazione, uso e manutenzione che viene
sempre fornito a corredo di ogni prodotto.
e) In caso di fornitura di componenti sfusi/disassemblati, la
garanzia copre solo ed esclusivamente eventuali difetti dei
componenti stessi, relativamente al materiale o alle
lavorazioni meccaniche effettuate da TRANSFLUID.
f) La garanzia decade nei casi in cui:
- il prodotto venga utilizzato oltre i limiti indicati nei cataloghi
o manuali di installazione o in applicazioni non approvate da
TRANSFLUID;
- la rottura derivi da abuso, negligenza, omessa o inadeguata
manutenzione, mancato collegamento o controllo dei
dispositivi di protezione o a seguito di incidenti;
- il prodotto venga modificato o disassemblato senza
approvazione scritta di TRANSFLUID.
3) Prestazioni incluse/escluse nella garanzia
a) Eventuali prodotti o componenti i cui difetti, ad insindacabile
giudizio di TRANSFLUID, sono coperti da garanzia, saranno
riparati o sostituiti senza alcun addebito, salvo quanto
stabilito ai punti successivi. Le parti sostituite saranno
coperte dal residuo periodo della garanzia originale che resta
in vigore sul prodotto inizialmente fornito (non decorrerà
quindiDOCUMENT
un nuovo termine di garanzia).
#: 1803659 Page 94 of 170
BASIC GUARANTEE, TERMS AND CONDITIONS
TF 6401-GB - rev. 0
1) Preamble
TRANSFLUID guarantees that at the time of dispatch, its
products comply with the specifications published in its
catalogues or technical documents, which were valid at the time
of dispatch, and that the products are free from defects in
material and workmanship. These terms of guarantee substitute
all other guarantees, including legal, expressed or implicit
guarantees, including but not limited to, guarantees of saleability
and suitability for a particular use (and any other implicit
guarantee arising during the course of the services, negotiations
or commercial use). Except in the event of serious negligence
and fraud, under no circumstances will TRANSFLUID be held
liable for direct, indirect, consequential, fortuitous or extra
contractual damage based upon claims for compensation by the
Buyer for violation of the guarantee, contract or objective
responsibility. Under no circumstances can the compensation by
TRANSFLUID exceed the amount paid by the Buyer for the
product supplied by TRANSFLUID.
2) Duration and limits of the guarantee
a) The duration of the guarantee is equal to eighteen (18)
months from the time the product supplied by TRANSFLUID
is commissioned, and nonetheless, no more than twenty-four
(24) months from the date of dispatch of the original product
from TRANSFLUID’s plant.
b) Product that are not used and stored for a long period must
be kept and handled in keeping with the guidelines, which are
available upon request, drawn up by TRANSFLUID according
to product type.
c) The wear or tear of parts, which is particularly due to
conditions of use (tension of the belts, environmental
conditions, unforeseen knocks and overloading), or to the
sensitivity of the operator (use within the approved limits) or to
external circumstances (jamming of the machine), is not
covered by the guarantee if these parts have been used (are
not new), unless the Buyer can clearly prove the
manufacturing defect, which is ascribable to TRANSFLUID.
Typical parts subject to wear or tear include:
- filters, seals and gaskets
- springs, screws, plugs
- switches and fuses
- material and friction surfaces
- belts and chains
- lubricants in general
d) Installation and maintenance of TRANSFLUID products must
be carried out following the installation, use and maintenance
manual, which is always supplied with each product.
e) With regard to the supply of loose/disassembled parts, the
guarantee solely and exclusively covers faults of the
components themselves, related to the material or
mechanical workmanship carried out by TRANSFLUID.
f) The guarantee is no longer valid when:
- the product is used exceeding the limits stated in the
catalogues or installation manuals, or in applications that are
not approved by TRANSFLUID;
- breakage results from abuse, negligence, omission or
inadequate maintenance, failed connection or control of the
protection devices or as a result of accidents;
- the product is modified or disassembled without
TRANSFLUID’S written approval.
3) Services included/excluded in the guarantee
a) In TRANSFLUID’S final decision, products or components,
whose faults are covered by the guarantee, will be repaired or
replaced at no extra cost, with the exception of the
subsequent points. The replaced parts will be covered from
the remaining period of the original guarantee, which stays in
force for the product initially supplied (a new guarantee period
will therefore not come into effect).
LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 TF 6401-I - rev. 0
b) Sono esclusi dalla garanzia, e pertanto restano a carico del
Compratore, costi derivanti da:
- rimozione del prodotto TRANSFLUID dal macchinario in cui
è inserito e relativa rimessa in servizio;
- adeguato imballaggio ed oneri derivanti da trasporti di
andata e ritorno del materiale;
- ripristino di lubrificanti in genere, tubazioni, cofanature
insonorizzanti, carter, ecc;
- qualsiasi altro costo non espressamente approvato per
iscritto da TRANSFLUID.
c) Per le operazioni di smontaggio/reinstallazione/messa in
servizio del prodotto, il Compratore potrà richiedere il
supporto di un tecnico specializzato inviando un regolare
ordine di acquisto. L’intervento sarà fatturato da TRANSFLUID
applicando le correnti tariffe ASSIOT (Associazione Italiana
costruttori organi di trasmissione, affiliata EUROTRANS).
d) TRANSFLUID non potrà essere ritenuta responsabile per
mancati o minori profitti, costi per macchinari sostitutivi, fermi
macchina, danni ad apparecchiature o proprietà causati da un
eventuale malfunzionamento dei propri prodotti.
4) Modalità di richiesta di prestazioni in garanzia
a) Il Compratore, qualora intenda avvalersi della garanzia, dovrà
informare TRANSFLUID per iscritto, entro 7 (sette) giorni dal
momento in cui si è evidenziato un difetto, comunicando:
- descrizione del prodotto;
- numero di serie (ove previsto), numero di specifica o codice
articolo;
- riferimento alla data ed al documento di acquisto o
consegna;
- ragionevole prova che il difetto rientri nelle condizioni di
garanzia completata da una descrizione dettagliata
dell’anomalia o malfunzionamento ed eventualmente
supportata da fotografie.
In caso di malfunzionamento occorso dopo la messa in
servizio del prodotto, dovranno essere comunicati inoltre:
- tipo di applicazione;
- potenza e giri del motore (in caso di motore endotermico
anche marca e modello);
- diametro, tipo, numero gole e posizione puleggia (se
l’applicazione lo prevede);
- ore di funzionamento.
b) In base al prodotto coinvolto, al malfunzionamento segnalato,
all’urgenza di intervento, TRANSFLUID indicherà se il
prodotto stesso dovrà essere consegnato o spedito in porto
franco ad un centro autorizzato o direttamente presso la
propria sede.
c) Una volta ricevuto il prodotto, TRANSFLUID o il distributore
autorizzato provvederanno ad una approfondita analisi;
se il prodotto sarà ritenuto coperto da garanzia:
- TRANSFLUID riparerà o sostituirà gratuitamente le parti
necessarie al ripristino della piena e sicura funzionalità;
se il prodotto NON sarà ritenuto coperto da garanzia,
TRANSFLUID:
- invierà un rapporto tecnico motivando la decisione;
- stilerà un preventivo di riparazione;
- solo dopo aver ottenuto l’ordine dal Compratore, procederà
con la riparazione.
d) I prodotti riparati saranno restituiti al Compratore in porto
assegnato, utilizzando lo stesso mezzo di trasporto con cui
sono pervenuti (a meno che non sia diversamente
specificato).
e) Qualora il Compratore decida di non accettare il preventivo di
riparazione, dovrà comunicare per iscritto la propria decisione
chiedendo esplicitamente la rottamazione o la restituzione
delle parti che saranno spedite nello stato in cui si trovano.
DOCUMENT
TRANSFLUID s.r.l. ■ #: 1803659
Via V. Monti, ■ ■ Page 95 of 170 Fax +39-02.33910699 e-mail: LAST
19 20016 Pero (Milano) Italy Tel. +39-02.339315.1 ■
TF 6401-GB - rev. 0
b) Excluded from the guarantee and remaining at the Buyer’s
expense are the costs resulting from:
- removal of the TRANSFLUID product from the machinery
onto which it is fitted, and recommissioning;
- suitable packing and charges resulting from the return
transport of the material;
- restoration of lubricants in general, piping, sound proof
canopies, guards, etc.;
- all other costs not expressly approved in writing by
TRANSFLUID.
c) The Buyer can request the support of a specialised technician
to disassemble/re-install/recommission the product by
sending a standard purchase order. TRANSFLUID will invoice
the work, applying the current ASSIOT rates (Italian
Association of Gears and Transmission Elements
Manufacturers, a member of EUROTRANS).
d) TRANSFLUID cannot be held liable for lost or reduced profit,
costs for replaced machinery, still machinery, damage to
equipment or property caused by failure of its products.
4) Conditions for requesting services under guarantee
a) If the Buyer intends to take advantage of the guarantee, he
must inform TRANSFLUID in writing within 7 (seven) days of
discovering a fault, stating:
- product description;
- series number (where foreseen), specification number or
article code;
- reference to the date and document of purchase or delivery;
- reasonable proof that the fault falls within the conditions of
guarantee, together with a detailed description of the
irregularity or failure and where possible, supported by
photographs.
In the event of failure after commissioning the product, the
following must also be communicated:
- type of application;
- power and engine rpm (stating also the make and model for
endothermic engines);
- diameter, type, number of races and position of pulley (if
foreseen by the application);
- hours of operation.
b) TRANSFLUID will indicate whether the product must be
delivered or sent free port to an authorised centre or directly
to its own plant depending on the product concerned, the
failure indicated and the urgency of the intervention.
c) On receiving the product, TRANSFLUID or the authorised
distributor will carry out a thorough analysis; if the product is
deemed to be covered by the guarantee:
- TRANSFLUID will repair or replace the parts needed to
restore full and safe working at no cost;
If the product is NOT deemed to be covered by the guarantee,
TRANSFLUID:
- will send a technical report explaining its decision;
- will draw up an estimate for the repair;
- will carry out the repair upon receipt of the order from the
Buyer.
d) The repaired products will be returned to the Buyer freight
collect, by the same means of transport that was used for the
arrival (unless stated otherwise).
e) Should the Buyer decide not to accept the estimate for the
repair, he must communicate his decision in writing, explicitly
asking for the parts to be scrapped or returned; the parts will
be sent in their current state.
■ UPDATE: 9/20/18
info@transfluid.it www.transfluid.it
■
DATE PRINTED: 9/20/18
 Paint Care

Care of Finish Guide

How to Maintain and Care for Your Imron® Finish

Axalta’s Imron® polyurethane enamels provide superior protection against

elements your vehicle will face throughout its long life. To make sure you
maximize the benefits of Imron®, use the following guide to take care of your
finish.
 Wash your vehicle often, especially when exposed to dusty, acidic or alkaline environments.
 When washing your vehicle, use non-abrasive, neutral pH (non acidic or alkaline) detergent.
Do not use solvent-based solutions for washing large areas.
 During the first 30 days when the finish is still fresh, clean the vehicle with water rinse only.
The use of pressure washers when paint is still fresh could affect the finish. Avoid high
pressure too close to areas that have chips or cracks visible or with fresh paint.
 Do not wash the vehicle using extremely hot water or while the surface is hot.
 Avoid washing with stiff bristles. Soft cloth and felt brushes are recommended.
 Do not allow spilled gasoline, oil, anti-freeze, hydraulic fluid, or windshield washer fluid to
stand on the paint – remove immediately by rinsing with water. With some oils and hydraulic
fluids, allowable exposure time before staining occurs is significantly shortened if fluid or
paint surface is hot.
 Do not wax for the first 60 days.
 Have any paint nicks or scratches repaired as soon as they occur to protect against future
degradation.
 Should your vehicle's finish become damaged, have it repaired as soon as possible. Contact
a reputable repair shop near you and specify the Axalta Imron® quality used for the original
finish. This will assure you the best possible color match and the same durability and
appearance as when your vehicle was new or newly refinished.
 For the name of the nearest Axalta Coating Systems Repair Facility call us at 1 855 6
AXALTA or visit axalta.us.

DOCUMENT #: 1803659 Page 96 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 7
Section

Controls
Overview

DOCUMENT #: 1803659 Page 97 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Center Control Box
1

2
3
4
5
A C E G
B D F H

6 7

8
10

11
9

12 14

15

16
13

DOCUMENT #: 1803659 Page 98 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Center Control Box
ITEM # DESCRIPTION NOTE
1 MAIN ENGINE SCREEN
2 MAIN ENGINE CONTROL PAD
2A THROTTLE UP
2B THROTTLE DOWN
2C REGEN
2D REGEN INHIBIT DO NOT PRESS THIS BUTTON
2E MENU
2F ENTER
2G SCROLL UP
2H SCROLL DOWN
3 IGNITION SWITCH
4 LEFT LOAD CELL PRESSURE
GAUGE
5 RIGHT LOAD CELL PRESSURE
GAUGE
6 AIR PRESSURE GAUGE

7 WATER PRESSURE GAUGE

8 TRACTION FRAME
9 LIGHTS ON/OFF

10 OPERATOR SELECT SWITCHES OPERATOR CONTROL

TO EITHER SIDE OF THE MACHINE
11 BEACONS ON/OFF
12 WATER PUMP ON/OFF

13 SLURRY PUMP ON/OFF

14 BLOWER ON/OFF
15 CLUTCH ON/OFF
16 TANK SLIDE

DOCUMENT #: 1803659 Page 99 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 CAT C18 Tier4 Control Box
(See Cat Manual for more information)

DOCUMENT #: 1803659 Page 100 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Message Display
DEF Level (14) - This gauge is located on the left side of each menu screen, and indicates the level of
DEF remaining in the DEF tank.

Indicator Bar (15) - This area is located on the right side of each menu screen. An indicator will
illuminate when the monitoring system senses any of the following statuses:

DOCUMENT #: 1803659 Page 101 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Display Home
The following options are displayed in the "Default" menu:

"Speed (RPM)" - This gauge indicates engine speed (rpm). When the throttle control lever is moved
to the full throttle position without load, the engine is running at high idle. The engine is running at
the full load rpm when the throttle control lever is at the full throttle position with maximum rated
load.

"Percent Load" - This gauge indicates the percentage of full load rpm at which the engine is
operating.
"Time to Regen" - When you scroll to this option, the display will show the time remaining until the
next regen is required to run. A forced DPF regeneration will not be allowed until this timer is less
than 8 hours.

Note: Some applications will configure this option to display the time remaining only when regens
are disabled. In that case, the display will read "AUTO" as long as automatic regens are enabled.
When regens are disabled, the time until the next regen is required will be displayed.

"Coolant Temp" - This gauge indicates the current temperature of the engine coolant.

"Oil Pressure" - This gauge indicates the current engine oil pressure.

"Fuel Pressure" - This gauge indicates fuel pressure to the fuel injection pump from the fuel filter. A
decrease in fuel pressure usually indicates a dirty fuel filter or a plugged fuel filter. As the fuel filter
becomes plugged, there will be a noticeable reduction in the performance of the engine.

"Battery Voltage" - This gauge indicates the voltage of the electrical system.
DOCUMENT #: 1803659 Page 102 of 170 LAST UPDATE: 9/20/18
DATE PRINTED: 9/20/18
 Performance Display
The following options are displayed in the "PERFORMANCE" menu:

"Engine Requested Speed" - The display will show the requested speed of the engine.

"Engine Desired Speed" - The display will show the desired speed of the engine.

"Speed" - This gauge indicates engine speed (rpm). When the throttle control lever is moved to the
full throttle position without load, the engine is running at high idle. The engine is running at the full
load rpm when the throttle control lever is at the full throttle position with maximum rated load.

"Percent Load" - This gauge indicates the percentage of full load rpm at which the engine is
operating.

"Coolant Temp" - This gauge indicates the current temperature of the engine coolant.

"Intake Manifold Temp" - The display will show the temperature at the manifold.

"Turbo Boost Pressure" - The display will show the pressure at the intake manifold.

"Oil Pressure" - The display will show the engine oil pressure for engine.

"Fuel Pressure" - The display will show the fuel pressure for the engine.

"Fuel Rate" - This gauge shows average fuel consumption in G/hr.

"Battery Voltage" - This gauge indicates the voltage of the electrical system.

DOCUMENT #: 1803659 Page 103 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Totals & Configuration Display
The following options are displayed in the "Totals" menu:

"Total Fuel Used" - The display shows the total amount of fuel that has been consumed by the
machine.

"Total ARD Fuel Used" - The display will show the amount (in gallons) of fuel burned through the
regeneration system over the life of the engine.

"Total DEF Used" - The display shows the total amount of diesel exhaust fluid that has been
consumed by the system.

"Engine Hours" - The display will show the total number of hours the engine has been operating.

"Idle Speed" - The display will show the low idle speed setting on the engine.

"High Idle Speed" - The display will show the high idle speed setting on the engine.

DOCUMENT #: 1803659 Page 104 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Settings Display
The following options are available in the "Settings" menu:

"Day Backlight Brightness" - Select this option in order to adjust the brightness of the following
items: Message digital display area, switch lights and instrument panel lights. This will improve the
visibility of the information.

"TSC1 Enabled" - This will allow an external throttle over the "J1939" data link to control engine
speed. When the "TSC1" is in the NO position, only the control panel throttle will be allowed to
change engine speed.

DOCUMENT #: 1803659 Page 105 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Diagnostics Display

"Diagnostics" menu to view any fault codes that may be present.

DOCUMENT #: 1803659 Page 106 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 DEF Level -C18

DOCUMENT #: 1803659 Page 107 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Cat C4.4 Tier 4 Instrument Panel

DOCUMENT #: 1803659 Page 108 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 CAT C4.4 Tier 4 Menu Screens

DOCUMENT #: 1803659 Page 109 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 CAT C4.4 Tier 4 Screen Symbol Guide

DOCUMENT #: 1803659 Page 110 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 DEF Level – C4.4 ACERT
Initial Indication Level 1 Level 2 Level 3
Reduced Time:
Mild: reduced time >3.5% DEF Level
<8.0% Reading
Inducement Time <20% <14% DEF Level Reading Reduced
1st Occurrence DEF Level Reading DEF Level Reading Severe: Reduced Performance:
performance 0% Usable DEF
>3.5% Level Reading

5 Minute Cooldown
Mild: None With 100% Torque
Derate
Severe:
Inducement Time
None None Reduced Then
Repeat Occurrence
Performance
Shutdown
75% Torque Derate Or
Idle Only

+ + +
OEM Gauge +
Low DEF Lamp
Notification
Emissions System
Failure Lamp

Engine Shutdown
Lamp

DOCUMENT #: 1803659 Page 111 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 EPA Tier 4 Final / EU Stage IV 9.3 L - 18 L Engines Quick Reference Card
Lamps Event Operator Action Lamps Event Operator Action
Emissions Malfunction Indicator Lamp • Check Diesel Exhaust Fluid (DEF) level.
(EMIL) indicates level 1 emissions • Top off DEF tank. Indicates engine or aftertreatment fault. • Contact local Cat dealer.
system fault. Lamp will illuminate. • Refer to the Operation & Maintenance Manual.

Indicates level 2 emissions system • Check DEF level.

fault. Lamp will illuminate with • Top off DEF tank. Active Regeneration in process. • No action required.
flashing action lamp. • Refer to the Operation & Maintenance Manual.

Indicates level 3 emissions system • Check DEF level

fault. Lamp will illuminate with • Top off DEF tank Active Regeneration needed. • Verify Automatic Regeneration is enabled
• Refer to the Operation & Maintenance Manual. (see below).
flashing action lamp and audible alarm.
Engine idle/Shutdown will occur.

The DEF level indicator will
illuminate when the DEF level is low.
The DEF level indicator and EMIL will
illuminate when the DEF level is
critically low.
The DEF level indicator and EMIL will
illuminate with a flashing action
lamp when the DEF level is critically
low. Power loss will occur.
Warning: Active Regeneration required. • Stop machine.
• Add DEF to DEF tank. • Put transmission in neutral.
• Apply Parking Brake / Hydraulic Lockout.
• Press and hold top position of Regeneration
Warning: Active Regeneration required.
Switch for at least 2 seconds.
• Add DEF to DEF tank. within 10 minutes
To enable system:
Automatic Regeneration is disabled. • Cycle engine start switch key OR
• Add DEF to DEF tank. • Press and hold top position of Regeneration
Switch for at least 2 seconds.

The DEF level indicator and EMIL will

illuminate with a flashing action
lamp with an audible alarm when
the DEF level is empty. Engine
idle/shutdown will occur.
Normal Operation: During the first start of the day, the machine will likely elevate
• Add DEF to DEF tank. engine speed to approximately 1,000 rpm and perform a “start up” regeneration.
• Refer to the Operation & Maintenance Manual.
This regeneration is to warm up the aftertreatment system for prompt and proper
operation and can be interrupted without penalty.

ULTRA LOW SULPHER FUEL ONLY
Battery Disconnect: This decal is located near the battery disconnect Switch. Do not
This machine requires Ultra Low sulfur Diesel fuel (≤15ppm or mg/kg), turn the battery disconnect switch to the OFF position until the Wait to Disconnect
Diesel Exhaust Fluid that meets all the requirements defined by ISO 22241-1, lamp is no longer illuminated. If the switch is turned to the OFF position when the
and low-ash oil (Cat ECF-3 spec – API CJ-4 and ACEA E9) lamp is illuminated, a fault code will be logged and aftertreatment damage may occur.
423-1796 1
SAFETY.CAT.COM

Diesel Exhaust Fluid Cleanliness: Contaminants can degrade the life of DEF Delayed Engine Shutdown: The engine may continue to run after the key is turned to
and system components. Filtering is recommended when filling the DEF tank. the off position to prevent aftertreatment system component failure. In the event of an
Prior to filling the DEF tank, clean the blue colored DEF tank filler cap and emergency, turn the key fully to the left to shut down the engine. With an emergency
surrounding area. Do not fill the DEF tank from a contaminated container or shutdown, a fault code will be logged and aftertreatment damage may occur.
funnel. Do not overfill the tank. Care should be taken when dispensing DEF.
Spills should be cleaned immediately and machine or engine surfaces should
be wiped clean and rinsed with water.

To FORCE a regeneration: To DISABLE a regeneration:

293-9659 1
1. S
 top machine 2. P
 ut transmission in neutral*
SAFETY.CAT.COM

3. Apply
 parking brake/ 4. P
 ress and hold top position of the Press and hold bottom position of the
QUESTIONS?
hydraulic lockout* Regeneration Switch for a minimum of Regeneration Switch for a minimum of Contact your local Cat ® Dealer.
2 seconds. 2 seconds.
*If applicable

EPA Tier 4 Final / EU Stage IV 9.3 L - 18 L Engines Quick Reference Card

Lamps Event Operator Action Lamps Event Operator Action
Emissions Malfunction Indicator Lamp • Check Diesel Exhaust Fluid (DEF) level.
(EMIL) indicates level 1 emissions • Top off DEF tank. Indicates engine or aftertreatment fault. • Contact local Cat dealer.
system fault. Lamp will illuminate. • Refer to the Operation & Maintenance Manual.

DOCUMENT #: 1803659
Indicates level 2 emissions system • Check DEF level.
fault. Lamp will illuminate with • Top off DEF tank. Active Regeneration in process. • No action required.
flashing action lamp. • Refer to the Operation & Maintenance Manual.

Indicates level 3 emissions system • Check DEF level

fault. Lamp will illuminate with • Top off DEF tank Active Regeneration needed. • Verify Automatic Regeneration is enabled
• Refer to the Operation & Maintenance Manual. (see below).
flashing action lamp and audible alarm.
Engine idle/Shutdown will occur.

The DEF level indicator will
illuminate when the DEF level is low.
The DEF level indicator and EMIL will
illuminate when the DEF level is
critically low.
The DEF level indicator and EMIL will
illuminate with a flashing action
lamp when the DEF level is critically
low. Power loss will occur.
Warning: Active Regeneration required. • Stop machine.
• Add DEF to DEF tank. • Put transmission in neutral.
• Apply Parking Brake / Hydraulic Lockout.
• Press and hold top position of Regeneration
Warning: Active Regeneration required.
Switch for at least 2 seconds.
• Add DEF to DEF tank. within 10 minutes
To enable system:
Automatic Regeneration is disabled. • Cycle engine start switch key OR
• Add DEF to DEF tank. • Press and hold top position of Regeneration
Switch for at least 2 seconds.

The DEF level indicator and EMIL will

Normal Operation: During the first start of the day, the machine will likely elevate
illuminate with a flashing action • Add DEF to DEF tank. engine speed to approximately 1,000 rpm and perform a “start up” regeneration.
lamp with an audible alarm when • Refer to the Operation & Maintenance Manual. This regeneration is to warm up the aftertreatment system for prompt and proper
Page 112 of 170

the DEF level is empty. Engine

idle/shutdown will occur. operation and can be interrupted without penalty.

ULTRA LOW SULPHER FUEL ONLY
Battery Disconnect: This decal is located near the battery disconnect Switch. Do not
This machine requires Ultra Low sulfur Diesel fuel (≤15ppm or mg/kg), turn the battery disconnect switch to the OFF position until the Wait to Disconnect
Diesel Exhaust Fluid that meets all the requirements defined by ISO 22241-1, lamp is no longer illuminated. If the switch is turned to the OFF position when the
and low-ash oil (Cat ECF-3 spec – API CJ-4 and ACEA E9) lamp is illuminated, a fault code will be logged and aftertreatment damage may occur.
423-1796 1
SAFETY.CAT.COM

Diesel Exhaust Fluid Cleanliness: Contaminants can degrade the life of DEF Delayed Engine Shutdown: The engine may continue to run after the key is turned to
and system components. Filtering is recommended when filling the DEF tank. the off position to prevent aftertreatment system component failure. In the event of an
Prior to filling the DEF tank, clean the blue colored DEF tank filler cap and emergency, turn the key fully to the left to shut down the engine. With an emergency
surrounding area. Do not fill the DEF tank from a contaminated container or shutdown, a fault code will be logged and aftertreatment damage may occur.
funnel. Do not overfill the tank. Care should be taken when dispensing DEF.
Spills should be cleaned immediately and machine or engine surfaces should
be wiped clean and rinsed with water.

To FORCE a regeneration: To DISABLE a regeneration:

293-9659 1
1. S
 top machine 2. P
 ut transmission in neutral*
SAFETY.CAT.COM

3. Apply
 parking brake/
hydraulic lockout*
DATE PRINTED: 9/20/18
LAST UPDATE: 9/20/18
4. P
 ress and hold top position of the
Regeneration Switch for a minimum of
2 seconds.
Press and hold bottom position of the
QUESTIONS?
Regeneration Switch for a minimum of Contact your local Cat ® Dealer.
2 seconds.

*If applicable
 LEFT AND RIGHT OPERATOR BOXES
1
3

ITEM # DESCRIPTION NOTE

1 E-STOP

2 2 SPEED HIGH/LOW HIGH SPEED FOR TRAVEL AND

LOW SPEED FOR GRINDING

3 BRAKE ON/OFF BRAKE MUST BE ON TO START

ENGINE
4 LEFT DEPTH CONTROL LIFT/LOWER RAISE/LOWER LEFT DEPTH
CONTROL WHEELS

5 RIGHT DEPTH CONTROL RAISE/LOWER RIGHT DEPTH

LIFT/LOWER CONTROL WHEELS
6 MAIN FRAME LIFT/LOWER RAISE LOWER MAIN FRAME

DOCUMENT #: 1803659 Page 113 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 HYDRAULIC CONTROLS

1 5 2 6 3 7 4

8 9 10

ITEM # DESCRIPTION
1 SYSTEM PRESSURE GAUGE
2 DRIVE PRESSURE GAUGE
3 CHARGE PRESSURE GAUGE
4 LUBE PRESSURE GAUGE
5 MAIN FRAME LEFT PRESSURE GAUGE
6 MTRACTION FRAMTE PRESSURE
7 MAIN FRAME RIGHT PRESSURE GAUGE
8 LEFT MAIN FRAME ADJUSTMENT
9 TRACTION FRAME ADJUSTMENT
10 RIGHT MAIN FRAME ADJUSTMENT

DOCUMENT #: 1803659 Page 114 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 OPERATOR SEAT CONTROLS

DETAIL A
SCALE 1 : 3

ITEM # DESCRIPTION
FORWARD / NEUTRAL LOCKED / REVERSE
1 JOYSTICK

DOCUMENT #: 1803659 Page 115 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PLUS ONE CONTROL BOX

1 2 3

MANUAL OVERRIDE SWITCHES

ITEM # DESCRIPTION NOTE
1 PLUS ONE ON/OFF
2 FORWARD/REVERSE BYPASS
3 ESTOP BYPASS

DOCUMENT #: 1803659 Page 116 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PLUS ONE Cruise Control Screen ICONS 
1. System fault indicator – flashes if there is a system fault 
2. Left Down Pressure adjust with potentiometer 
a. LC=Load Cell 
b. MF=Main Frame 
3. Right Down Pressure adjust with potentiometer 
a. LC=Load Cell 
b. MF=Main Frame 
4. Feet per Minute Indicator 
5. Trip Footage – measures footage per shift, reset to “0” before starting grind 
6. Total Footage‐Lifetime odometer displays in feet 
7. Percent of Speed‐When in manual mode (see item 8) ground drive speed is controlled by 
joystick only. When in Auto speed is controlled by cruise control, Up/Down arrows increase or 
decrease speed in Auto Only 
8. Auto/Manual‐shows what mode the Plus One is in 
9. Droop Set Point‐arrows raise ↑ or lower ↓ droop (engine RPM) set point. Set point to be 
determined based on cutting situations 
10. Water In/Out Temperature‐water out temperature indicates whether grinding head is working 
well 
11. Bar Graph‐shows graph when engine RPM is above droop point setting (arrow) goes red when 
past droop point 

DOCUMENT #: 1803659 Page 117 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PLUS ONE Cruise Control Screen 
1. Push to show fault screen, ESC to return to operator screen 
2. Push to reset daily footage, follow directions on screen to reset 
3. Push to increase % of joystick ↑ 
4. Push to decrease % of Joystick ↓ 
5. Not used 
6. Push for manual or auto operation 
7. Droop setting increase ↑ 
8. Droop setting decrease ↓ 
9. Press for system pressures and temperature readings 

   

DOCUMENT #: 1803659 Page 118 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PLUS ONE System Temperature and Pressure Screen 

PLUS ONE Fault Screen 
Red dot next to system listed indicates a fault in that system 

DOCUMENT #: 1803659 Page 119 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Profile Wheel Assembly

Clam Shell:
Remove to slide assembly in or
out for profile and matching cut

DOCUMENT #: 1803659 Page 120 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 8
Section

Basic Operation
Instruction

DOCUMENT #: 1803659 Page 121 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
Grinding Operation, PC1500 Series, PC4500 Series, and PC6000 Series 
 
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 Series 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 pavement. Raise lower switch is now in “NEUTRAL” position. 
7. Check water spray bar: Raise equipment fully, set brake 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, engine SHUT OFF and head not rotating prior to cleaning 
spray bar and nozzles. 
8. Remove SAFETY PINS and return to seat. Lower equipment, STOP when vacuum 
skirting touches pavement.  

DOCUMENT #: 1803659 Page 122 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 9. Whether BUMP grinding or CONTINOUS grinding the process usually starts at the 
shoulder of the pavement. If grinding with a PC1500 Series (THE PC1500 Series 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, persons 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 2000, 
turn water valve ON. Observe water flow/pressure. Adjust water pressure to 5 PSI. 
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 enter 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 

DOCUMENT #: 1803659 Page 123 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 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.    
 
  
   

DOCUMENT #: 1803659 Page 124 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 9
Section

Blade Shaft Speeds

DOCUMENT #: 1803659 Page 125 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6000 Series and PC4500 Series Blade Shaft Speeds
Belt  14M 2660 x125
Gear Box Ratio 1.33

Low Range Sheave Setup
Engine RPM Drive Sheave Driven Sheave Blade Shaft RPM
1400 50 60 877
1500 50 60 940
1600 50 60 1003
1700 50 60 1065
1800 50 60 1128
1900 50 60 1190
2000 50 60 1253
2100 50 60 1316

High Range Sheave Setup
Engine RPM Drive Sheave Driven Sheave Blade Shaft RPM
1400 60 50 1263
1500 60 50 1353
1600 60 50 1444
1700 60 50 1534
1800 60 50 1624
1900 60 50 1714
2000 60 50 1805
2100 60 50 1895

*Note: Engine cannot be run below 1600 RPM for sustained periods

DOCUMENT #: 1803659 Page 126 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 10
Section

Blade Shaft Removal &

Installation

DOCUMENT #: 1803659 Page 127 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
Blade Shaft and Blade Removal and installation
This process is typical for PC4500, PC4504, and PC6000. The PC6000
blade shaft is shown in pictures.
 
The Blade Shaft assembly weighs approximately 4000 lbs. and is approximately 7’ 6” in length. It must be
lifted to the vertical position to change blades. Failure to follow these instructions and/or failure to use
the proper tools and fixtures can lead to serious injury or death.
 
Always heed the following WARNINGS when performing this procedure.
 
Two people familiar with normal and safe rigging practices and familiar with this process should be
used for this procedure. one person should not attempt this alone
 
Never attempt to stand the Blade Shaft vertically on anything except a hard, flat, level concrete
surface capable of supporting the weight of the Blade Shaft.
 
Never stand the Blade Shaft in anything except the 7600102 stand provided. (Figure 1).
 
 Never attempt to lift the Blade Shaft with anything except the proof tested 2502246 hoist ring
provided. (Figure 2).
 
Always inspect these two items for damage and inspect all other rigging used prior to lifting the
assembly.
 
 
 

Figure 1 - 7600102 Stand Figure 2 - 2502246 Hoist Ring

DOCUMENT #: 1803659 Page 128 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
To Remove the Blade Shaft Assembly from the
Machine
 
 
1. Position the machine on a flat concrete or asphalt surface, and set the brakes.

2. Shut off the Main Engine and disengage the clutch.

 
3. Adjust the Depth Control Wheels so that the head is just touching the pavement with the Main Frame
down.
4. Remove the belt guard and belt.

5. Remove the cap screws that secure the head bearings to the Main Frame.

6. Slowly raise the Main Frame. The head will remain on the ground. (Figure3).

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 3 - Blade Head and Shaft on the ground after Main Frame raised
 
7. Pin the Main Frame in the raised position and roll the head forward until it can be turned 90 degrees and
rolled out from under the machine. Note: Field experience has shown that it is often helpful to roll the
assembly up onto two used spacers which can then be used as a “turn-table”. Two people must be used
for this step.
 
8. Block the Blade Shaft front and rear of the blades so it cannot roll. (Wooden 2 x 4’s are good for
this.) Now remove the driven sheaves and keys on each end of the shaft.

DOCUMENT #: 1803659 Page 129 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
9. The Blade Shaft is made with one fixed flange on one end and one flange that is a threaded nut with 12
5/8” cap screws in the outer face. Remove the bearing from the end with this nut. The bearing on the
fixed flange end need not be removed.
 
10. Using a 15/16” socket and ratchet, alternately loosen, but do not remove, all 12 5/8” cap screws.

11. Using the special spanner provided, loosen just slightly the threaded nut.
 
 
Note:
 
If there are any exposed threads on the 8” diameter Blade Shaft protruding beyond the nut, be sure to
clean and lubricate them thoroughly before loosening the nut.

12. The push plate, blades, and spacers can now all be removed one at a time.+

1 3 . Install the 2502246 hoist ring into the threaded hole provided on the nut end of the Blade Shaft and
tighten. (Figure 4).
 

 
Figure 4 - 2502246 Hoist Ring installed on nut end of the Blade Shaft

DOCUMENT #: 1803659 Page 130 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
 
Note:
 
Be sure that the bolt enters fully and the shoulder rests squarely on the end of the Blade Shaft. It may be
necessary to clean or tap the threads in the end of the Blade Shaft.
 
 
 
Caution:
 
Never attempt to lift the Blade Shaft without the hoist ring fully seated.
 
 
14. Attach a suitable lifting device to the hoist ring and slowly lift the Blade Shaft assembly to the
vertical position. (Figure 5)
 

 
Figure 5 - Slowly lift Blade Shaft assembly to the vertical position

DOCUMENT #: 1803659 Page 131 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
15. Position the Blade Shaft over the 7600102 stand and slowly lower the Blade Shaft into the stand until it is
fully seated against the step shoulder in the shaft. (Approximately 6”) (Figure 6)
 
 
 

Figure 6 - Lower Blade Shaft into 7600102 stand until fully seated against the step shoulder
 
 
 
 
16. Slacken the hoist, and before removing the rigging, attempt to rock the Blade Shaft. It should be stable.
If it is not stable, find out why before proceeding, your life may depend on it.
 
17. With the Blade Shaft standing solidly in the vertical position, and working from the ground or an approved
safe work platform, remove the rigging, the joist ring, and the threaded end nut.

18. The push plate, blades, and spacers can now all be removed one at a time.

DOCUMENT #: 1803659 Page 132 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
Assembly and Installation of the Blade Shaft
This process is typical for PC4500, PC4504, and PC6000. PC6000 shaft is
shown in photos.
 
Cleanliness is all important. There must be no foreign material on the Blade Shaft, threaded nut, pusher plate,
or in between the blades and spaces. If there is blade wobble and short blade life will result.
 
1. With a clean Blade Shaft standing in the 7600102 stand as described above, alternately stack blades and spacers
onto the shaft followed by a .375 push plate. The number of blades and spacers may vary due to manufacturing
tolerances. The total width of the stack including the push plate should be
50.750” Add spacers as necessary behind the push plate to achieve this dimension. (Figure 7)
 
 

Figure 7 - After thorough cleaning stack blades and spacers on Blade Shaft

DOCUMENT #: 1803659 Page 133 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
2. Coat the shaft threads with "Never-Seize" and snug them against the push plate with all 12 5/8" bolts backed
out below the face of the nut. Tighten these only by hand at this time. (Figure 8).
 

 
Figure 8- Coat shaft threads with "Never-Seize" and hand tighten 5/ff'bolts at this stage

DOCUMENT #: 1803659 Page 134 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
3. Install the hoist ring and attach to a suitable lifting device as described above. (Figure 9).
4. Using spanner wrench tighten loose flange (fig 10). Make sure pusher spacer does not turn when
tightening loose flange. When you cannot tighten loose flange further by hand with Spanner STOP.
 

 
Figure 9 - Install 2502246 Hoist Ring and hold and stabilize shaft

DOCUMENT #: 1803659 Page 135 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
 

 
Figure 10 – Tighten the threaded nut
 
5. Tighten the 12 5.8” cap screws alternately and evenly at 180 degree intervals (much like you would
tighten a cylinder head). Torque to 85-100 ft/lbs. This will adequately compress the stack. (Figure 10 and
Figure 11)
 

 
Figure 11 - Tighten 5/8" cap screws alternately and evenly at 180 degree intervals to 85-100 ft/lbs

DOCUMENT #: 1803659 Page 136 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
6. Place a bead of silicone around the gap between the nut and the push plate. This will prevent concrete
slurry from damaging the threads of the
5/8” cap screws
 

 
Figure 12 - Placing silicone around gap between nut and push plate as well as thread at outside of Blade Shaft
 
7. Put a bead of silicone around the thread at the outside of the Blade Shaft to protect it. (Figure 12)
Note: Allow adequate cure time for silicon. Wrap with duct tape if adequate cure time can’t be met..
 
 

DOCUMENT #: 1803659 Page 137 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
8. Using a suitable lifting device as discussed above, lift the Blade Shaft out of the stand and lower it into the
horizontal position. (Figure 13).
 

 
Figure 13 - Lowering Blade Shaft into horizontal position
 
9. Re-install the bearing and drive sheaves, and position the shaft back under the machine.
 
10. Lower the machine slowly until the bearing mounts are just above the bearing housings, and then install the
bolts. Be sure that the Blade Shaft assembly is mounted squarely under the machine and tighten the bolts.
Install and tighten the belts and re-install the belt guards.

DOCUMENT #: 1803659 Page 138 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  

 
Removal of Blade Shaft Bearings
1. Remove the sealant from the three (3) Allen head bolts that secure the outer seal retainer to the
bearing housing and remove the Allen bolts and the retainer from the bearing housing.
 
2. After removing the sealant from the two (2) Allen bolts that clamp the centrifugal labyrinth seal to the
Blade Shaft, remove the bolts and the seal.
 
3. After removing the sealant from the Allen bolts that retain the inner seal retainer to the bearing housing
remove the bolts and the retainer.

4. After placing a suitable block under the bearing housing remove the four (4) nuts that hold the bearing
housing together.
 
5. Separate the bearing housing halves exposing the bearing, taking note of the position of the stabilizing
ring, the rubber labyrinth seals and the V- ring contact seals.

6. Remove the outer rubber labyrinth and the V-ring contact seal.
 
7. Using a suitable tool, mark the location of the taper adapter sleeve on the shaft.
 
8. With a suitable tool, lift the locking tab of the locking ring from the bearing retaining nut.
 
9. Using the hammer driven wrench supplied with the PC4500, PC4504, or PC6000, remove the
retaining nut.

10. Remove the locking ring.

11. Thread the retaining nut back on the adapter sleeve leaving 1/8” (3mm) clearance between the
retaining nut and the bearing.
 
12. Place the “U” shaped fixture of the bearing puller tool supplied with the PC4500 behind the bearing
being careful to place the “U” shaped fixture the adapter sleeve, NOT THE SHAFT.
 
13. Using the threaded rods supplied, attach the circular fixture of the bearing puller to the “U” shaped
fixture, making certain that the circular fixture is resting on the shaft and the side of the circular fixture is
against the end of the adapter sleeve.

DOCUMENT #: 1803659 Page 139 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
14. Tighten the nuts on the threaded rods, alternately, so that an even pressure is exerted on the circular
fixture. Continue tightening the nuts until the bearing is released from the sleeve.

15. Remove the bearing puller assembly.

16. Remove the bearing and adapter from the shaft.

 
 

 
Installation of Blade Shaft Bearings
Install the Blade Shaft bearings in reverse order of removal, as outlined above. Always pack the bearing

with fresh grease. Use Lubriplate EMB. (Figure 14).

 
Figure 14 - Using Lubriplate EMB to pack bearings with fresh grease

DOCUMENT #: 1803659 Page 140 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
  
Use caution when installing the “V” ring seal. This seals should be rolled onto the
labyrinth seal #2703312 after the bearing housing is bolted together. The lip face of the seal must have full
face contact on the bearing housing. (Figure 15).
 

 
Figure 15 - "V" ring seal
 
 

DOCUMENT #: 1803659 Page 141 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 11
Section

Hydraulic and
Electrical Schematics

DOCUMENT #: 1803659 Page 142 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 DOCUMENT #: 1803659
Page 143 of 170
24V
24V
GND

SENSOR POWER 6,7,8 LEFT SENSOR GROUND

4,5,6 PLUSONE SIGNAL SIGNAL
BOX SENSOR GROUND JOYSTICK SENSOR POWER

PLUG

6, 7, AND 8 GO TO PLUS ONE 6, 7, AND 8 GO TO PLUS ONE

4 PIN FORWARD REVERSE PLUS ONE

PLUG

J1939
6 PIN
6
5
4
3
3, 4, 5, AND 6 GO TO PLUS ONE
1 AND 2 GO TO CUMMINS 15L
CONTROL BOX

HEAVY & SPECIALTY EQUIPMENT OPERATIONS, NAMPA, IDAHO

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
 8 7 6 5 4 3 2 1

"THIS DRAWING IS THE PROPERTY OF DIAMOND PRODUCTS- GGEM. IT IS TRANSMITTED

AS A CONFIDENTIAL DISCLOSURE, AND IS RETURNABLE UPON REQUEST.
IT CONTAINS PROPRIETARY INFORMATION IN GENERAL AND IN DETAIL, AND
IT MAY NOT BE COPIED, OR ITS CONTENTS REVEALED TO OTHERS, WITHOUT
THE WRITTEN CONSENT OF DIAMOND PRODUCT-GGEM. ANY PATENTS OBTAINED
COVERING DESIGN AND CONSTRUCTION SHOWN HEREON BELONG SOLELY TO
DIAMOND PRODUCTS-GGEM. THIS LEGEND SHALL APPEAR ON ANY REPRODUCTION OF
THIS DRAWING IN WHOLE OR IN PART."

F
F NOTES: (UNLESS OTHERWISE SPECIFIED)

1. DRAWING TO BE INTERPRETED PER:

ASME Y14.100-2000 DIMENSIONS AND TOLERANCING,
ASME Y1.1-1989 ABBREVATIONS.

DOCUMENT #: 1803659
CENTER BOX
7100372
E
E

FUSEBOX
7100625 6 PIN ROUND POWER/GROUND 7100777
4 PIN E-STOP 7100775

4 PIN JOYSTICK FWD/REV 7100776

PLUSONE
8 PIN FWD/REV 7100773 7100624
D
D
6 PIN 7100774

23 PIN 7100772

REVERSE ALARM

Page 144 of 170

MAIN FRAME DOWN SIGNAL

C C

DRIVE PUMP
2600669 DP610
7100778

J1939
15L CUMMINS
CONTROL BOX
7100614
B B
ENCODER
7100557

RIGHT/LEFT
JOYSTICKS
7100804
UNLESS OTHERWISE SPECIFIED
DRAWING IS IN INCHES AND DIAMOND PRODUCTS
TOLERANCES ARE BELOW
HEAVY & SPECIALY EQUIPMENT OPERATIONS, NAMPA, IDAHO
DESC:
A .X ±.1 ANGULAR PLUS ONE SCHEMATIC PC6004
±.03 ± 1° A

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
.XX
.XXX ±.005 MATERIAL:
.XXXX ±.0002 FINISH
FINISH
FINISH:

DRAWN BY: DATE: SIZE: REVISION:

PART NO:
KP 7/24/17
SHEET: SCALE: DWG. NO:
1 OF 1 1:1 1803650
D 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

"THIS DRAWING IS THE PROPERTY OF DIAMOND PRODUCTS- GGEM. IT IS TRANSMITTED

AS A CONFIDENTIAL DISCLOSURE, AND IS RETURNABLE UPON REQUEST.
IT CONTAINS PROPRIETARY INFORMATION IN GENERAL AND IN DETAIL, AND
IT MAY NOT BE COPIED, OR ITS CONTENTS REVEALED TO OTHERS, WITHOUT
THE WRITTEN CONSENT OF DIAMOND PRODUCT-GGEM. ANY PATENTS OBTAINED
COVERING DESIGN AND CONSTRUCTION SHOWN HEREON BELONG SOLELY TO
DIAMOND PRODUCTS-GGEM. THIS LEGEND SHALL APPEAR ON ANY REPRODUCTION OF
THIS DRAWING IN WHOLE OR IN PART."
ENGINE WIRING/DIAMOND PRODUCTS F
F NOTES: (UNLESS OTHERWISE SPECIFIED)

1. DRAWING TO BE INTERPRETED PER:

ASME Y14.100-2000 DIMENSIONS AND TOLERANCING,
WIRING INTERFACE CONNECTION PC6004EC
DIAMOND SYMBOL KEY
ASME Y1.1-1989 ABBREVATIONS. PRODUCTS
DIAMOND REAR E-STOP DIAMOND DIAMOND E-STOP LIGHT
PRODUCTS 7100781 PRODUCTS PRODUCTS
FRONT E-STOP LEFT E-STOP RIGHT E-STOP

DOCUMENT #: 1803659
7100741 GROUND
7100467-02 7100467-01

ORANGE WIRE 12V

E
ORANGE STRIPE WIRE 12V E

REAR E-STOP 6 PIN

LIGHT GREEN WIRE 24V
2 3 5 6 4 1
FRONT E-STOP
6 PIN
2 3 5 6 4 1 BLACK WIRE
S T O J U S T O J U

DIAMOND PRODUCTS DIAMOND PRODUCTS LEFT OPERATOR

FRONT E-STOP HARNESS REAR E-STOP HARNESS BOX 23 PIN RIGHT OPERATOR
BOX 23 PIN
MC5010
D C1-P11
2 3 5 6 4 1 2 3 5 6 4 1 S T O J U S T O J U D
FRONT E-STOP 6 PIN REAR E-STOP 6 PIN
MC5010
C1-P10

30 30
MC5010 CR
6 6 C1-P41 85 86

29 29

Page 145 of 170

27 27

23 23 30 87

C C
31 31

DIAMOND PRODUCTS DIAMOND PRODUCTS

CR
FUSE BOX 7100625 CENTER E-STOP 6 PIN CENTER BOX 7100939 85 86
MC5010
C1-P42
1 2 3 4 5 6
Diamond Products
30 Pin Harness DIAMOND PRODUCTS 6 PIN

30 87
DIAMOND PRODUCTS
4PIN

4
B B
3
1 2 3 4 2

1
DIAMOND PRODUCTS
PLUS 1 BOX 7100624

CAT SUPPLIED CAT SUPPLIED UNLESS OTHERWISE SPECIFIED

FRONT ENGINE MAIN ENGINE DRAWING IS IN INCHES AND DIAMOND PRODUCTS
TOLERANCES ARE BELOW
HEAVY & SPECIALY EQUIPMENT OPERATIONS, NAMPA, IDAHO
CONTROL BOX CONTROL BOX DESC: ENGINE WIRING/ DIAMOND PRODUCTS
A .X ±.1 ANGULAR
12V 24V WIRING INTERFACE CONNECTION A
±.03 ± 1°

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
.XX PC6004EC
.XXX ±.005 MATERIAL:
.XXXX ±.0002 FINISH
FINISH
FINISH:

DRAWN BY: DATE: SIZE: REVISION:

PART NO:
KP 11/1/17
SHEET: SCALE: DWG. NO:
1 OF 1 1:1 1803680
D 1

8 7 6 5 4 3 2 1
 DOCUMENT #: 1803659
Diamond Products Cat Supplied Front Diamond Products Rear
Front E-Stop 7100741 Engine Control Box 12v E-Stop 7100781
Diamond Products Left
E-Stop 7100467-02 Diamond Products Right
Cat Supplied Main Engine E-Stop 7100467-01
Control Box 24V

Diamond Products
Plus 1 Box 7100624
Diamond Products Diamond Products 30 Pin
Fuse Box 7100625 Harness to Center Box

Page 146 of 170

Diamond Products
Center Box 7100939

Diamond Products
23 Pin Harness to
Left Operator Box

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
Diamond Products Rear Diamond Products
Diamond Products Front E-Stop Diamond Products E- Diamond Products
E-Stop Harness from Diamond Products 30 4 Pin Harness from
Harness From Front E-Stop Stop plug 6pin to cat 23 Pin Harness to
Rear E-Stop Pin from Fuse Box Center Box
box and plus one Right Operator Box
 01 02 03 04 05 06 07 08 09 10

1 2
A 3 A

Ground Drive Control Joystick

MB B Drive Wheel 2

DOCUMENT #: 1803659
0 RPM

B B

Ground Drive Motor

C C

1 4
Drive Wheel 1

Page 147 of 170

0 RPM

T1 X3 S MA A
Ground Drive Pump
D D

E E
Ground Drive Motor

HEAVY & SPECIALTY EQUIPMENT OPERATIONS, NAMPA, IDAHO

NAME: PC6004EC GROUND DRIVE HYDRAULIC CIRCUIT
F SCALE: NONE F
1 Charge relief @ 350 p.s.i. DWG. BY: M.C.D.S. APPROVED BY:

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 6/24/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310014.01 SHEET 1 OF 2

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06

Reference Part Number Quantity Catalog Description

1 2600669 1 Ground Drive Pump
2 2706229 1 Charge Filter Element
A 3 2801445 1 Joystick A
4 2600500 2 Ground Drive Motor

DOCUMENT #: 1803659
B B

C C

Page 148 of 170

D D

NAME: PC6000EC GROUND DRIVE HYDRAULIC CIRCUIT

E DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 6/24/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310014!01 SHEET 2 OF 2

01 02 03 04 05 06
 01 02 03 04 05 06 07 08 09 10

A A

06
06

DOCUMENT #: 1803659
07

B B

04
03
A1 B1 A2 B2
01
X 02
1
05
C C
2 2
UNLOADER
VALVE P

Page 149 of 170

T
1
CASE
D DRAIN D
FRONT HAND
VALVE ASSEMBLY

P P

T
TO FUNCTION PUMP
MANIFOLD
E E
08

S 09

NAME: FUNCTION PUMP HYDRAULIC CIRCUIT PC6004

F 1 Pressure Compensator @ 2100 p.s.i. F
2 Load Sense Standby Pressure @ 275 DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
p.s.i.
DWG. DATE: 7/1/2011 PART NO: REV. NO: 2

REV. DATE: 8/8/2011 DWG. NO: 7310017$01 SHEET 1 OF 4

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

17 17
18 10
A 18 A

DOCUMENT #: 1803659
17 11
10 12 14
18
B B

13 20 22 15
15
19 21

TO GROUND DRIVE
MOTORS 'X' PORT B B
A B A B A B A B A B
C C

Page 150 of 170

2

D D

1
P
E E

T
TWO SPEED MAIN FRAME TRACTION FRAME TANK SLIDE WATER PUMP TRASH PUMP LEFT DEPTH RIGHT DEPTH

1 Reduced Pressure Set @ 400 p.s.i.

2 Reduced Pressure Set @ 250 p.s.i.

NAME: FUNCTION PUMP HYDRAULIC CIRCUIT PC6004

16
F SCALE: NONE F
DWG. BY: M.C.D.S. APPROVED BY:

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/1/2011 PART NO: REV. NO: 2

REV. DATE: 8/8/2011 DWG. NO: 7310017$01 SHEET 2 OF 4

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06
Reference Part Number Quantity Catalog Description
01 2600700 1 Function Pump
02 2703808 1 Unloader Valve Cartridge
2706141 1 24VDC Coil
A 03 A
04 2703647 1 Unloader Valve Body
05 2706109 1 Hand Valve
06 2703389 2 Loading Leg Cylinder
07 2703395 1 Wheel Base Adjustment Cylinder
08 2706105 1 Return Filter

DOCUMENT #: 1803659
09 2706106 1 Thermal Transfer Cooler
10 2703389 2 Main Frame Cylinder
B 11 2703390 1 Traction Frame Cylinder B
12 2703394 1 Tank Slide Cylinder
13 2600702 1 Water Pump Motor
14 2600476 1 Trash Pump Motor
15 2600474 2 Depth Motor
16 7100398 1 PC6004 Function Manifold Valve
17 2706235 3 Body
18 2704711 3 Reducing/Relieving Cartridge
C 19 FDCB 1 Flow Control Cartridge C

20 GCI 1 Flow Control Body

Page 151 of 170

22 DCI 1 Flow Control Body

D D

NAME: FUNCTION PUMP HYDRAULIC CIRCUIT PC6004

E DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/1/2011 PART NO: REV. NO: 2

REV. DATE: 8/8/2011 DWG. NO: 7310017:01 SHEET 3 OF 4

01 02 03 04 05 06
 01 02 03 04 05 06 07 08 09 10

A A

DOCUMENT #: 1803659
Double&Acting Cylinder Fully Adjustable Needle with Reverse
Relief Valve Atmospheric Reservoir
Flow Check

B B
Variable Piston Pump with Load Sense

C C

Directional Valve,
Solenoid Operated Pilot to Open Check Valve Hydrostatic Reservoir
3&Way Pressure Regulator 1&Direction Motor
with Drain

Page 152 of 170

D D

Directional Valve, Manually

Operated Ball&Type Load Shuttle
E Two&Stage Pressure Bidirectional Motor E
Reducing Valve

NAME: FUNCTION PUMP HYDRAULIC CIRCUIT PC6004

F SCALE: NONE F
Cooler Filter DWG. BY: M.C.D.S. APPROVED BY:

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/15/2011 PART NO: REV. NO: 2

REV. DATE: 8/8/2011 DWG. NO: 7310017&01 SHEET 4 OF 4

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

2
A A

A B

DOCUMENT #: 1803659
X 2 1

B B

1 2
1 LS

2
C C
3 3
P 1

2 1

Page 153 of 170

1 2 3
D D

1 2

S CASE 1
DRAIN
P T
E E

NAME: BLOWER HYDRAULIC CIRCUIT

F 1 Relief set @ 5000 p.s.i. F
2 Pressure Compensator set @ 4800 p.s.i. DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/6/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310018$01 SHEET 1 OF 3

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06
Reference Part Number Quantity Catalog Description
1 2703401 1 Function Pump
2 2600667 1 Blower Motor
A 3 2705689 1 Blower Manifold A

DOCUMENT #: 1803659
B B

C C

Page 154 of 170

D D

NAME: BLOWER HYDRAULIC CIRCUIT

E DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/6/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310018301 SHEET 2 OF 3

01 02 03 04 05 06
 01 02 03 04 05 06

A A

DOCUMENT #: 1803659
Solenoid Operated, 3 Way, 2 Position,
B Air Bleed Start up Valve Poppet, Pilot to Open, Spring B
Directional Spool Valve, Soft Shift
Biased Closed
Variable Piston Pump with Load Sense

C C

Page 155 of 170

Check Valve Fully Adjustable Needle Valve
Relief Valve, Direct Acting Bidirectional Motor

D D

NAME: BLOWER HYDRAULIC CIRCUIT

Hydrostatic Reservoir Atmospheric Reservoir
E DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 7/6/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310018 01 SHEET 3 OF 3

01 02 03 04 05 06
 01 02 03 04 05 06 07 08 09 10

A A
7
L R

STEERING 8
CYLINDER

DOCUMENT #: 1803659
LEFT
STEERING
VALVE
B B
4
5
6
STEERING
DIVERTER
VALVE P T
C C

2
3 7 L R

Page 156 of 170

1
D D
STEERING RIGHT
RELIEF STEERING
VALVE VALVE

1
E E
STEERING
PUMP P T

NAME: STEERING CIRCUIT PC6004

F SCALE: NONE F
DWG. BY: M.C.D.S. APPROVED BY:

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 8/3/2011 PART NO: REV. NO: 1
1 Relief set @ 2000 p.s.i.
REV. DATE: DWG. NO: 7310020$01 SHEET 1 OF 3
01 02 03 04 05 06 07 08 09 10
 01
Reference Part Number Quantity
1 2600472
2 2704524
A 3 2703313
4 2703870
5 2703777
6 2703779
7 2502220
8 2703379
02 03 04 05 06
Catalog Description
1 Steering Pump, PC6004
1 Relief Cartridge
1 Relief Valve Body A
1 Drectional Valve Cartridge
1 Directional Valve Body
1 24VDC Coil
2 Steering Valve
1 Steering Cylinder

DOCUMENT #: 1803659
B B

C C

Page 157 of 170

D D

NAME: STEERING CIRCUIT PC6004

E DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 8/3/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310020501 SHEET 2 OF 3

01 02 03 04 05 06
 01 02 03 04 05 06

A A

Double"Acting Cylinder

DOCUMENT #: 1803659
Fixed Displacement Pump
B B

Steering Valve

C C

Page 158 of 170

Atmospheric Reservoir Drectional Valve Cartridge
Relief Valve

D D

NAME: STEERING CIRCUIT PC6004

Hydrostatic Reservoir DWG. BY: M.C.D.S. APPROVED BY: SCALE: NONE
E E

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
DWG. DATE: 8/3/2011 PART NO: REV. NO: 1

REV. DATE: DWG. NO: 7310020"01 SHEET 3 OF 3

01 02 03 04 05 06
 12
Section

Reference Material

DOCUMENT #: 1803659 Page 159 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
DOCUMENT # 1803597 DATE PRINTED: 11/28/2017

PC6004 REFRENCE CHART
GROUND DRIVE PUMP: SET PSI 2700 BLADE SHAFT BOLTS TORQUE 85 FT LBS
AUXILIARY PUMP: SET PSI 1800 BLADE SHAFT BOLTS 5/8‐11 x 1 1/4 (15/16 SOCKET)
BLOWER PUMP: SET PSI 2000

GREASE SCHEDULE
HEAD BEARINGS 16 PUMPS EVERY 10HRS
FRONT BOGEY GREASE POINTS 5 PUMPS WEEKLY
ENGINE FRAME PIVIOT POINTS 3 PUMPS WEEKLY
FRONT SLIDE GREASE RAILS MONTHLY
DEPTH CONTROL WHEEL ASSEMBLY 2 PUMPS WEEKLY
BLOWER 2 PUMPS MONTHLY
TRASH PUMP 2 PUMPS DAILY
TRACTION FRAME PIVIOT POINTS 5 PUMPS WEEKLY
TANK SLIDE GREASE POINTS 5 PUMPS MONTHLY

WASH OUT & DAILY MAINTENANCE
TRASH PUMP FLUSH DAILY
DEMISTER FILTER & HOUSING WASH OUT DAILY
LOBSTER POT FILTER & HOUSING WASH OUT DAILY
CLEAN SPRAY BAR NOZZLES DAILY PRIOR TO SHIFT AND INSPECT THROUGH OUT SHIFT
WATER FILTER BASKET CLEAN DAILY & THROUGH OUT SHIFT
VACUUM HEAD BOX INSPECT & CLEAN DAILY
VACUUM SEPERATOR CLEAN & INSPECT DAILY
CHECK FLUIDS DAILY (ENGINGE OIL, HYDRAULIC OIL, COOLANT, TRASH PUMP OIL)

WINTERIZING
DRAIN ALL WATER LINES
DRAIN BOWL AT TRASH PUMP
LEAVE WATER BALL VALVE PARTIALLY OPEN
SPRAY BLOWER LOBES WITH LITE OIL & RUN FOR 30 SECONDS
CHECK ANTI‐FREEZE/CONDITION & CONTACT LOCAL ENGINE DEALER FOR FUTHER QUESTIONS
ENGINE SERVICE HYDRAULIC SERVICE BLOWER RIGHT ANGLE DRIVE
OIL‐15W‐40 OIL‐ISO68 30W‐SYN GEAR OIL‐75W/90SYN
250‐500 HOURS FITERS 500 HOURS 1000 HOURS 1000 HOURS
OIL 1000 HOURS 
TRASH PUMP TORQUE HUBS transfluid clutch
OIL‐30W SYN GEAR OIL‐75W/90 SYN ISO HM  32
500 HOURS 1000 HOURS
SERVICE PARTS
CUMMINS QSX15 CUMMINS QSB4.5
PRIMARY AIR FILTER‐AF472 PRIMARY AIR FILTER‐ P532966
SAFETY AIR FILTER ‐AF417M SAFETY AIR FILTER‐P533781
OIL FILTER‐ LF9000 OIL FILTER‐LF3970
FUEL FITER‐FS1040STD PRIMARY FUEL FILTER‐FS19732
SECONDARY FUEL FILTER‐FF5421
SERVICE PARTS
CAT C18 CAT C4.4
AIR FILTER PRIMARY‐1W‐3637 AIR FILTER PRIMARY‐206‐5234
AIR FILTER SECONDARY‐1W3636 AIR FILTER SECONDARY ‐206‐5235
OIL FILTER‐ 1R‐0716 (REQUIRES 2) OIL FILTER‐289‐0600
FUEL FILTER‐1R‐0749 WATER FILTER‐308‐7298
WATER FILTER‐326‐1643

DP# DESCRIPTION
2706897 GROUND DRIVE PUMP  FILTER
2703304 RETURN FILTER
2703305 HYDRAULIC TANK BREATHER

Page 1 of 2
DOCUMENT #: 1803659 Page 160 of 170 LAST UPDATE: 9/20/18
O:\Engineering Nampa ID\PC6004\Machine Literature\REF SHEETS ‐ PC6004 ‐ 1803661.xlsx
DATE PRINTED: 9/20/18
DOCUMENT # 1803597 DATE PRINTED: 11/28/2017

FUSE BOX
  101A RED 24 V RELAY POWER
101B RED 24 V
101C RED 24V ENCODER POWER
302 ORANGE BECON POWER
303U BLACK/STRIPE LIGHT POWER
302L BLACK/STRIPE LIGHT POWER
102 TAN TRACTION FRAME UP
103 TAN/STRIPE TRACTIONFRAME DOWN
104 WIGHT BRAKE
107 BLUE 2 SPEED HIGH
108 PURPLE WATER PUMP
109 PINK TRASH PUMP
110 GREEN BLOWER COIL
111 LIGHT BLUE TANK SLIDE LEFT
112 LIGHT BLUE/STRIPE TANK SLIDE RIGHT
113 YELLOW LEFT DEPTH UP
114 YELLOW/STRIPE LEFT DEPTH DOWN
115 BLUE RIGHT DEPTH UP
116 BLUE/STRIPE RIGHT DEPTH DOWN
117 BROWN MAIN FRAME UP
118 BROWN/STRIPE MAIN FRAME DOWN
MFD ORANGE/STRIPE DUMP COIL POWER
101A RED PLUS ONE POWER
101A RED PLUS ONE POWER
119 GRAY SMART COIL SIGNAL
120 WIGHT BACKUP ALARM POWER
200R LIGHT GREEN REAR E STOP IN
FRONT E STOP IN ORANGE 201F 201R LIGHT GREEN ESTOP IN
FRONT ESTOP OUT  ORANGE 202F 202R LIGHT GREEN ESTOP OUT
203F ORANGE FRONT ESTOP OUT
205F ORANGE/STRIPE FRONT ESTOP OUT
205F ORANGE/STRIPE LIGHTS ON ESTOP
302A ORANGE/STRIPE BECON POWER
302A ORANGE/STRIPE BECON POWER
302A ORANGE/STRIPE BECON POWER
303U BLACK/STRIPE LIGHT POWER
303U BLACK/STRIPE LIGHT POWER
303U BLACK/STRIPE LIGHT POWER
303U BLACK/STRIPE LIGHT POWER
303U BLACK/STRIPE LIGHT POWER
303U BLACK/STRIPE LIGHT POWER
303L BLACK/STRIPE LIGHT POWER
303L BLACK/STRIPE LIGHT POWER
303L BLACK/STRIPE LIGHT POWER
303L BLACK/STRIPE LIGHT POWER
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK
GROUND BLACK

DO NOT CHANGE, ADD, OR ALTER ELECTRICAL SYSTEM

Page 2 of 2
DOCUMENT #: 1803659 Page 161 of 170 LAST UPDATE: 9/20/18
O:\Engineering Nampa ID\PC6004\Machine Literature\REF SHEETS ‐ PC6004 ‐ 1803661.xlsx
DATE PRINTED: 9/20/18
 How to Recalibrate 
Joysticks PC6000 Series and 
PC4500 Series 
1. PC6000 Series turn on front engine key power. PC4500 series turn on engine Key Power.
2. Unplug  joystick from the bottom of joystick box (figure 1)

Figure 1: Unplug Joystick 

3. Turn key power off
4. Plug Joystick back in at the bottom of the joystick box (figure 1)
5. Turn key power back on, go to DP610 Screen, press button 1 to show faults (figure 2)

DOCUMENT #: 1803659 Page 162 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Figure 2: DP610 Fault Screen 

6. The DP610 screen should show a “Joystick Not Calibrated”  fault
7. Push joystick forward and hold for 10 seconds (figure 3), then center the joystick for 10 seconds
(figure 4), then reverse for 10 seconds (figure 5). Repeat until the red dot on DP610 screen
(figure 2) goes away. (Do this to calibrate for both sides PC6000 series)

Figure 3: Joystick Forward  Figure 4: Joystick Neutral  Figure 5: Joystick Reverse 

DOCUMENT #: 1803659 Page 163 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 How to put PC6000 Series and PC4504 Machines into 
Manual Mode 
1. Turn machine off, set parking brake.  
2. Open Plus One Box (located on left side of machine PC6000 Series, behind the separator 
PC4504) and flip switches (figure 1 and figure 3) 

     
Figure 1: Plus One Box in    Figure 2: Joystick in Plus 
  Plus One Mode  One Mode
3. Remove joystick box and unplug joystick from Plus One Mode (Figure 2). 
4. Plug joystick harness into Manual Mode (Figure 4) 
5. Put joystick box back on and start machine 

     

Figure 3: Plus One Box in 
Figure 4: Joystick in Manual Mode 
Manual Mode 

DOCUMENT #: 1803659 Page 164 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 13
Section

Machine Serial
Numbers

DOCUMENT #: 1803659 Page 165 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6004EC SERIAL NUMBER PLATE

ITEM NO. DISCRIPTION

1 MACHINE MODEL #
2 MACHINE SERIAL NUMBER
3 LARGE ENGINE SERIAL NUMBER
4 SMALL ENGINE SERIAL NUMBER
5 MANUFACTURE DATE (MONTH/YEAR)
6 MANUFACTURE LOCATION
7 TOLL FREE NUMBER FOR PARTS AND SERVICE

DOCUMENT #: 1803659 Page 166 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 PC6004EC SERIAL NUMBER PLATE LOCATION

MACHINE SERIAL
LOCATED INSIDE
NUMBER PLATE
FUSE BOX
LOCATION ON FRAME
MACHINE SERIAL
NUMBER PLATE

DOCUMENT #: 1803659 Page 167 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 BLOWER
BLOWER DRIVE MOTOR
SMALL ENGINE

DOCUMENT #: 1803659
SLURRY PUMP
TORQUE HUB AND DRVE MOTORS LARGE ENGINE STEERING CYLINDER GROUND DRIVE PUMP

TRANSFLUID COOLER FUEL TANK WATER TANK

Page 168 of 170

HYDRAULIC COOLER
AND RIGHT ANGLE
DRIVE COOLER

ENCODER

DATE PRINTED: 9/20/18

LAST UPDATE: 9/20/18
TRANSFLUID CLUTCH RIGHT ANGLE DRIVE DEPTH CONTROL MOTOR
AND LEFT LOAD CELL
PC6004EC COMPONENT SERIAL NUMBER PLATE LOCATIONS:
 PC6004 Serial Numbers: 
Manufacture Date: _________________ 

Serial #:_________________ 

Large Engine Serial #:_________________ 

Large Engine Arrangement #:_________________ 

Small Engine Serial #:_________________ 

Small Engine Arrangement #:_________________ 

Right Torque Hub Serial #: _________________ 

Left Torque Hub Serial #: _________________ 

Right Drive Motor Serial #:_________________  

Left Drive Motor Serial #:_________________  

Blower Serial #:_________________ 

Ground Drive Pump Serial #:_________________ 

Blower Drive Pump Serial #: _________________ 

Blower Drive Motor Serial #: _________________ 

DOCUMENT #: 1803659 Page 169 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18
 Right Angle Drive Serial #: _________________ 

Depth Control Motor Right Serial #: _________________ 

Depth Control Motor Left Serial #: _________________ 

Right Angle Drive Cooler Serial #: _________________ 

Hydraulic Cooler Serial #: _________________ 

Transfluid Cooler Serial #: _________________ 

Trash Pump Type: _________________ 

Trash Pump Serial #: _________________ 

Water/Fuel Tank Serial # (on front along the legs):  _________________ 

Left Load Cell Cylinder Serial #: _________________ 

Right Load Cell Cylinder Serial #: _________________ 

Encoder Serial #: _________________ 

DOCUMENT #: 1803659 Page 170 of 170 LAST UPDATE: 9/20/18

DATE PRINTED: 9/20/18