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Summary of Contents for Blue Diamond G1S
- Page 1 ROCK & CONCRETE GRINDER Operation and Maintenance Manual 159010 - G1S 159015 - G1 159020 - G2 159025 - G3 159030 - G3XL 159035 - G4 Register your WARRANTY within 30 days of purchase 888-376-7027 | BlueDiamondAttachments.com Blue Diamond Attachments®...
- Page 2 Operator’s Manual and thoroughly understand safe and correct operating, installation and maintenance procedures. Model Number: Blue Diamond is continually working to improve its products. Blue Diamond reserves the right to make Serial Number: any improvements or changes as deemed practical...
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Page 3: Table Of Contents
5.4.6 General Inspection ..........Blue Diamond Attachments®... -
Page 4: General Information
WARRANTY ..............Blue Diamond Attachments®... -
Page 5: Safety
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. NOTE: Special point of information or machine adjustment instructions. Blue Diamond Attachments®... -
Page 6: General Safety Instructions
Wood • Soil remediation • Numerous other specialty applications exist. Contact Blue Diamond for additional information. NOTE: Always refer to hydraulic excavator operating manual when operating or working on the grinder. NOTE: Check compressive strength of rock when cutting with the grinder. - Page 7 Do not open covers on grinder during operation. • Wear close fitting clothes with minimal tear strength when working in hazardous area. Severe vibration can cause injury, chronic health conditions, or damage to equipment. • Operate machine with a constant load to minimize vibrations. • Avoid sudden starting or stopping of cutting heads. Blue Diamond Attachments®...
- Page 8 Inoperative safety devices can cause death, serious injury and damage to property and equipment. • Check all safety devices are operating properly before starting work. • Never turn off or disable safety devices. • Make sure all safety devices are readily accessible. • Refer to hydraulic excavator manual for safety device operating instructions. Blue Diamond Attachments®...
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Page 9: Operator Responsibilities
Required Personal Protection Equipment (PPE) is available and personnel are instructed to use them. Hazardous areas in direct vicinity of machine are secured against access before operating machine. Attach a sign to hydraulic excavator boom instructing personnel to wear Blue Diamond Attachments®... -
Page 10: Personal Protective Equipment
Do not wear rings, chains or other jewelry. Hearing Protection Protects against hearing damage. Light Respiratory Protection Protection from hazardous dusts. Protective Goggles Protects eyes from flying debris, dust and fluids. Protective Gloves Protects hands from friction, abrasion, puncture wounds, burns or more serious injuries. Blue Diamond Attachments®... -
Page 11: Rock And Concrete Cutter Decals
Before operating your excavator fitted with the Blue Diamond Grinder you MUST read the Operators Manual that came with the attachment. It is especially important that: 1. BEFORE switching on hydraulic power supply make sure no one is within 50 feet (15 meters) of the Blue Diamond Grinder. Blue Diamond Attachments®... -
Page 12: Technical Data
3. TECHNICAL DATA 3.1 WEIGHT MODEL WEIGHT (lbs) WEIGHT (Kg) 159010 - GS1 159015 - G1 159020 - G2 1,035 159025 - G3 2,045 159030 - G3XL 2,290 1.040 159035 - G4 4,125 1.875 Blue Diamond Attachments®... -
Page 13: Excavator Weight Ratio
-13 to +122° F (-25 to +50° C) 24 Hours Continuous 3.4 HYDRAULIC OPERATING PARAMETERS MODEL GS1-1 5 - 8 19 - 30 GS1-2 6 - 12 22 - 45 G1-2 10 - 18.5 40 - 70 G1-3 13 - 21 50 - 80 Blue Diamond Attachments®... - Page 14 18 - 26 70 – 100 G3-1 32 - 45 120 – 170 G3-2 130 – 170 34 - 45 32-48 G3XL-1 120-180 G3XL-2 40-53 150-200 45-58 G3XL-3 170-220 53-85 G4-1 200-320 G4-2 64-85 240-320 66-85 G4-3 250-320 Blue Diamond Attachments®...
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Page 15: Hydraulic Performance
3.5 HYDRAULIC PERFORMANCE MODEL G3XL 3.6 MAXIMUM COMPRESSION STRENGTH (ROCK) NOTE: Contact Blue Diamond before cutting reinforced concrete. MODEL 5,076 5,800 7,300 9,400 G3XL 11,600 14,500 Blue Diamond Attachments®... -
Page 16: Overview
3.7 OVERVIEW Grinder Main Components 4. INSTALLATION AND STARTUP Blue Diamond Attachments®... -
Page 17: Hydraulic Excavator Minimum Requirements
Old parts can fail and cause death, serious injury and/or damage to property and equipment. Never reuse old parts. Use only original equipment parts. 4.2 MOUNTING The grinder is supplied with a pedestal for mounting to a quick-coupler or adapter plate. Mating areas of connector plates must be flat and smooth (Roughness Ra 12.5 max – surface deviation 0.5 mm). Blue Diamond Attachments®... -
Page 18: Quick Coupler
Make sure work area is clear and environment is clean. • Wear close fitting clothes with minimum tear strength and all proper Personal Protective Equipment. • Always install hydraulic hoses with protection against mechanical or thermal damage. The grinder is supplied with three pre-installed hydraulic hoses: Return, Case Drain and Pressure. Blue Diamond Attachments®... - Page 19 Attach return hose to ball valve on the opposite side to supply hose. Tighten nut. Position oil receiver tank beneath case drain line of grinder Fill hydraulic oil using a funnel until it overflows into case drain line. Connect and screw case drain hose from grinder on separate drain line on hydraulic excavator. Blue Diamond Attachments®...
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Page 20: Case Drain Line
Hydraulic system contamination can damage equipment. Never leave hydraulic ports open. Always plug hydraulic ports and hoses when not in use. Position grinder on stand. Loosen quick coupling device from excavator arm. Switch off hydraulic excavator and safeguard against it being switched on again. Depressurize entire hydraulic circuit. Blue Diamond Attachments®... -
Page 21: Operation
Do not cut while tracking excavator. This may damage unit. • Do not place cutting unit against working surface before starting. This may damage unit. Unit should be running and fed into working surface at a rate that does not allow stalling. Blue Diamond Attachments®... -
Page 22: Lifting Eye
Avoid damage from sharp edges on lifting devices. Note: Some grinder lifting eyes may not have wear indicators. Check for obvious wear and thickness reduction of lifting eye. Wear Indicator Worn to Indicator Wear Indicator Worn to Indicator Acceptable Wear Replace Lifting Eye Blue Diamond Attachments®... -
Page 23: Emergency Shutdown
Check for movement of bits in the bit blocks. If any bit has a play of more than 0.3 times bit shaft diameter, replace bit block or wear sleeve immediately. Note: Wear sleeve and bit block replacement should only be done by Blue Diamond. Blue Diamond Attachments®... -
Page 24: Pedestal (If Equipped)
Hydraulic oil temperature must not exceed 144° F (80° C). Check hydraulic oil temperature regularly when grinder is operating for long periods of time. 5.4.1 SWITCHING ON Switch on hydraulic excavator. Raise grinder. Start hydraulic motor for grinder. Blue Diamond Attachments®... -
Page 25: Working With Rock And Concrete Cutter
Make cutting movements in a horizontal or vertical direction. When making lateral cuts with the hydraulic excavator jib, do not exert excessive force to the hydraulic excavator. Trenching - Move Toward Excavator Vertical Cutting - Move Down Face Side-to-Side Cutting Pattern Blue Diamond Attachments®... -
Page 26: Switching Off
Make sure no residual contaminates such as concrete are left between bit and bit blocks. Contaminates could harden set bits in bit boxes. Clean grinder cutting head daily after use and check all parts for damage. Areas to which safety stickers are adhered should be wiped clean using a cloth. Blue Diamond Attachments®... -
Page 27: General Inspection
Note: Refer to Torque Tables in the back of this manual. 6. Maintenance Old parts can fail which can cause death, serious injury and/or damage to property and equipment. Never reuse old parts. Use only original equipment parts. Blue Diamond Attachments®... -
Page 28: Maintenance Safety
Bearing surfaces of bit blocks are worn Replace Bit blocks worn in snap ring area Bit blocks broken Charging spiral cannot be repaired Gear Housing Plate thickness less than 3 mm. Replace Wear Plates Weld seams cracked, deformed, or damaged. Blue Diamond Attachments®... -
Page 29: Lubrication
Mobil Gear GX 90 Mobilube GX 80 Mobilube GX 90 SHELL Spirax 80 EP Spirax 90 EP Omala Oil 100 Omala Oil 220 TEXACO Meropa 68 Meropa 220 Universal Gear Lubricant EP 80 Universal Gear Lubricant EP 90 Blue Diamond Attachments®... -
Page 30: Oil Capacity
Depressurize entire hydraulic system and lockout against restart before performing maintenance on grinder. • Slowly loosen oil fill and drain plugs and wait for pressure to drop before completely removing plugs. Position grinder horizontally on assembly stand. Lock out and tag power to grinder. Place waste oil container under oil drain plug (1). Loosen oil fill plug (2) and bleed off any pressure. NOTE: Remove oil fill plug first to allow oil to drain more quickly and efficiently. Oil drain plug is on opposite side. Blue Diamond Attachments®... -
Page 31: Replace Bits
Place striking iron with semi-circular opening on clamping ring opening. Strike clamping ring with a forceful impact. Pull round shank chisel out of chisel bracket. Clean dirt from bit block. Insert new bit. Place new clamping ring in striking iron. Blue Diamond Attachments®... -
Page 32: Clamping Sleeve Type
Inspect tools before each application. If they are dull, cracked, or burred do not use them. Operate all machines with hand lowered. To avoid injury by flying debris, stay clear of machines when hoods are raised. Grinding of product produces potentially hazardous dust/mist that can irritate skin, eyes, nose, throat and cause temporary or permanent respiratory disease. Blue Diamond Attachments®... -
Page 33: Standard Retaining Clip Type
Clean dirt from bit block. Slide new bit into block. Set clip into tool and position the clip on retaining groove. Firmly strike tool, snapping clip into place. 6.5.6 Snap Ring Type Using provided tool expand first snap ring and remove over shank. Blue Diamond Attachments®... -
Page 34: Quick Snap Type
Place curved tip of draw hook in quick snap ring hole. Grip draw arrow firmly and pull upwards. Remove bit from block. Clean dirt from bit block. Slide new bit in bit block. Position new quick snap ring with opening facing down on shaft of the round attack bit and apply firm pressure until clip snaps in place. Blue Diamond Attachments®... -
Page 35: Replace Cutter Heads
Note: Refer to Torque Tables in the back of this manual. Install bits. 6.7 Pedestal (If Equipped) 6.7.1 Disassemble Pedestal Loosen screw connection from bolt adapter or quick coupler. Lift bolt adapter or quick coupler off rock and concrete cutting head with suitable lifting equipment. Attach lifting equipment to pedestal and put slight strain on line. Blue Diamond Attachments®... -
Page 36: Assemble Pedestal
Ensure all tools, materials and other equipment are removed from working area. Clean working area and remove spilled substances such as liquids, processing materials and similar items. Ensure all safety devices on machine are fully functional. Ensure hydraulic excavator startup checks are complete. Blue Diamond Attachments®... -
Page 37: Troubleshooting
Ensure all covers and safety devices are installed and functioning. Note: Refer to hydraulic excavator operating instructions when faults occur and during troubleshooting procedures. If actions listed in troubleshooting tables do not eliminate faults, contact Blue Diamond immediately. Blue Diamond Attachments®... - Page 38 Hydraulic pump delivery Increase delivery volume. slowly. volume too low. Replace hydraulic motor with a motor recommended by Blue Diamond with lower displacement volume. Poor hydraulic pump Replace hydraulic pump efficiency to hydraulic motor. or motor. Oil leaks between hydraulic Replace damaged hydraulic pump and hydraulic motor.
- Page 39 Corrosion or debris between Disassemble bits. bit shaft and block. Clean bit shafts after opera- tion and treat with corrosion inhibitor. Contact Blue Diamond. Loud gear noise. Damage to internal parts. Replace Gears. Loud hydraulic Air in hydraulic circuit or Bleed system.
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Page 40: Storage And Transport
8.3.1 Crane or Hoist The grinder is equipped with a lifting lug for lifting by crane under the following conditions: • Crane and lifting gear must be must be designed to hoist weight of grinder. • Operator must be certified to operate crane. Blue Diamond Attachments®... -
Page 41: Forklift
12 Months 24 Months Temperature Tropical Coastal A. No special maintenance measures necessary. Install plugs and closures. B. Fill hydraulic motor and hydraulic oil. C. Rinse hydraulic motor with preservation agent. D. Fill hydraulic motor with preservation agent. Blue Diamond Attachments®... -
Page 42: Cutter Heads
8.4.2 Bits If grinder is stored for an extended period of time, remove bits. These can corrode with the cutting material and bond with bit blocks. Preserve bits with oil and store protected against contamination and mechanical damage. Blue Diamond Attachments®... -
Page 43: Hydraulic Schematic
Blue Diamond Attachments®... -
Page 44: Torque Tables
Blue Diamond Attachments®... - Page 45 Blue Diamond Attachments®...
- Page 46 Blue Diamond Attachments®...
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Page 55: Warranty
BLUE DIAMOND ATTACHMENTS liability for any defect with respect to accepted goods shall be limited to repairing the goods at a BLUE DIAMOND ATTACHMENTS designated location or at an authorized dealer location, or replacing them, as BLUE DIAMOND ATTACHMENTS shall elect. The above shall be in accordance with BLUE DIAMOND ATTACHMENTS warranty adjustment policies. - Page 56 QUALITY | DEPENDABILITY | INTEGRITY Blue Diamond® Attachments 4512 Anderson Road, Knoxville, TN 37918 88-376-7027 Blue Diamond Attachments®...
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