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Duratech 2009 Operating Instructions Manual

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Manual I: Operating Instructions
2009
Tub Grinder
Includes: Stationary Electric Supplement
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  • Page 1 Manual I: Operating Instructions 2009 Tub Grinder Includes: Stationary Electric Supplement roduct nformatIon nDusTrIes nTernaTIonal Po B 1940, J , nD 58402-1940 amesTown : (701) 252-4601• F : (701) 252-0502 • 0500119 • S 2017 DuraTechInDusTrIes hayBusTer eptember...
  • Page 2 Clearing the Way for a Better Tomorrow...
  • Page 3 2009™ Tub Grinders as of the date of publication. DuraTech reserves the right to make updates to the machine from time to time. Even in the event of such updates, you should still find this manual to be appropriate for the safe operation and maintenance of your unit.
  • Page 4 Clearing the Way for a Better Tomorrow...
  • Page 5 DuraTech Industries International Inc. (DuraTech Industries) has made every effort to assure that this manual completely and accurately describes the operation and maintenance of this Industrial Grinder as of the date of publication. DuraTech Industries reserves the right to make updates to the machine from time to time.

  • Page 6: Table Of Contents

    1.10 Fire Extinguishers ..................17 1.11 Important safety reminders ................18 1.12 Towing ......................18 Section 2: Introduction ............. 19 2.1 Description of the 2009 DuraTech Tub Grinder ..........19 2.2 Electronic governor ..................19 2.3 Dry Clutch ....................... 21 2.4 Rotor ........................ 22 2.5 Screens ......................
  • Page 7 3.19 Loading the tub ....................37 3.20 If lodging occurs while grinding ..............38 3.21 Grinding wet material ..................38 3.22 Preparing the 2009 DURATECH TUB GRINDER for transport ....38 3.23 Preparing the 2009 DURATECH TUB GRINDER for operation after transport ....................40 3.24 Preparing the 2009 DURATECH TUB GRINDER for storage ....
  • Page 8 5.14 Fixed hammer maintenance and replacement ..........74 5.15 Swinging hammer replacement and maintenance ......... 75 Section 6: Troubleshooting the 2009 DURATECH TUB GRINDER 80 6.1 Troubleshooting the electronic governor system ..........80 6.2 Electro-hydraulic valve calibration (for S.N. Up to 20-4-DJ0019) ....86 6.2a Electro-hydraulic valve calibration (for S.N.

  • Page 9: 2009 Tub Grinder Manual 1: Operators Instructions

    2009 Tub Grinder Includes: Stationary Electric Supplement Manual 1: Operating Instructions 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 10: Introduction

    The purpose of this owner’s manual is to explain maintenance requirements, safety, and routine adjustments for the most efficient operation of your 2009 DuraTech Tub Grinder . There is also a trouble shooting section that may help in case of problems in the field. Any information not covered in this manual may be obtained from your dealer.
  • Page 11 User Training Verification Form found in the 2009 DURATECH TUB GRINDER documentation packet. NOTE: This form requires both the dealer’s signature and the customer’s signature. The dealer is responsible for returning the signed form to DuraTech Industries.

  • Page 12: Section 1: Safety

    Before operating this unit, you should familiarize yourself with these manuals as well. Safety is an ongoing job requirement, and DuraTech Industries has made every effort to make sure that the 2009 DuraTech Tub Grinder provides operator security and comfort. DuraTech Industries encourages you to bring to our attention as quickly as possible any suggestions you may have concerning the safety of the equipment.

  • Page 13: Safety-Alert Symbols

    When replacing a machine component to which a decal is attached, be sure to also replace the decal. • Replacement decals can be purchased from your DuraTech dealer. DuraTech Industries uses industry accepted ISO/ANSI standards in labeling its products for safety and operational characteristics. Safety-Alert Symbol Read and recognize safety information.
  • Page 14 This manual uses the symbols to the right to denote important safety instructions and information. DANGER The DANGER, WARNING and CAUTION symbols are used to denote conditions as stated in the text above. WARNING Furthermore, the text dealing with these situations is surrounded by a box with a white background, will begin with DANGER, WARNING, or CAUTION.

  • Page 15: Operator - Personal Equipment

    Do not operate a 2009 DURATECH TUB GRINDER when you are fatigued. Be alert ‑ If you get tired while operating your 2009 DURATECH TUB GRINDER, take a break. Fatigue may result in loss of control. Working with any industrial equipment can be strenuous.

  • Page 16: Machine Safety Labels

    Machine safety labels ( REV. 10-13 ) The safety decals located on your machine contain important information that will help you operate your equipment. Become familiar with the decals and their locations. DANGER: OBJECTS THROWN BY MACHINE DO NOT OPERATE WITHOUT WEARING SAFETY GLASSES AND A HARD HAT.
  • Page 17 WARNING: FOR YOUR PROTECTION AND SAFETY OF OTHERS, FOLLOW THESE SAFETY RULES READ AND UNDERSTAND OPERATORS MANUAL BEFORE OPERATING MACHINE. PLACE ALL CONTROLS IN NEUTRAL, STOP 6500208 ENGINE, REMOVE IGNITION KEY, LOCK OUT POWER SOURCE, AND WAIT FOR ALL MOVEMENT TO STOP BEFORE SERVICING, ADJUSTING, REPAIRING, OR UNPLUGGING.
  • Page 18 WARNING: THROWN OBJECT HAZARD, TO PREVENT SERIOUS INJURY OR DEATH DO NOT RAISE TUB WHEN ROTOR IS TURNING. DISENGAGE ROTOR AND ALLOW TO COME TO A 6500209 COMPLETE STOP. BE CERTAIN THAT ALL PERSONNEL ARE CLEAR OF MACHINERY AREA. RAISE TUB TO FULL VERTICAL POSITION. STOP ENGINE AND REMOVE KEY BEFORE APPROACHING TUB AND ROTOR AREA.
  • Page 19 OR SMOLDERING EXISTS, AND THE BATTERY IS SWITCHED OFF. REMOVE ALL FLAMMABLE DEBRIS FROM ENGINE, SHIELDING, CONTROL PANEL, UNDER MACHINE AND ANYWHERE MATERIAL IS COLLECTED. DURATECH INDUSTRIES IS NOT RESPONSIBLE FOR FIRES CAUSED BY HAZARDS LEFT TO SMOLDER OR 6500425 BURN, OR IMPROPER SHUTDOWN PROCEDURES.

  • Page 20: Shielding

    Each and every aspect of the DuraTech Industries 2009 DuraTech Tub Grinder should be reviewed by each operator on a frequent basis. Safety systems are in place that result in direct operator security.

  • Page 21: Thrown Objects And Operator Safety

    • Ensure rotor is at a complete stop, engine is shut down, and the ignition key is removed before any performing any maintenance. • Never grab rope, cable, twine or similar material hanging out of tub while the tub grinder is running.

  • Page 22: Service And Maintenance

    Keeping the tub covered with DuraTech Industries Tub Covers will also reduce the risk of potential injury or property damage. Use of a Tub Cover will not reduce the area over which thrown objects may fall, but it does reduce the percentage of objects thrown from the tub.

  • Page 23: Personal Protection Equipment

    DO NOT PERFORM MAINTENANCE ON THE INTERIOR OF THE TUB DURING WET WEATHER CONDITIONS When replacing any part on your Tub Grinder, be sure to use only DuraTech Industries authorized parts. Personal protection equipment ( REV. 08-04 ) Operators and authorized observers of the Tub Grinder are recommended to wear head, eye, and ear protection. No loose clothing is allowed.
  • Page 24 PROPER OPERATION OF THE TUB GRINDER: • Do not grind materials any finer than necessary. Finely ground materials will produce more dust and increase the risk of fire. If finely ground materials are required, it is better to grind the materials coarse first with large opening screens installed in the grinder and then regrind them to the desired consistency by installing smaller opening screens in the grinder.

  • Page 25: Fire Extinguishers

    ( REV. 08-04 ) Fire extinguishers are provided on these DuraTech grinders in the unlikely event that a fire does start on the grinder. An extinguisher is located near the front of the grinder. The extinguishers are ABC dry chemical extinguishers that are appropriate for use with all materials normally encountered on a tub grinder.

  • Page 26: Important Safety Reminders

    1.11 Important safety reminders ( REV. 08-04 ) Always follow basic safety precautions when using this unit to reduce the risk of injury. IMPORTANT: NEVER perform maintenance in the tub, under the machine, on the conveyor, or other moving part of the machine without first shutting off the engine and removing the key. Unauthorized personnel should stay out of the grinding area.

  • Page 27: Section 2: Introduction

    Section 2: Introduction 2.1 Description of the 2009 DuraTech Tub Grinder ( REV. 08-04 ) The Tub Grinder is designed to grind wood waste, green waste, construction and demolition debris, tree branches and trunks, compostables and mulch. The unit incorporates a number of basic features including the engine, electronic engine controls, rotating tub, the electronic governor, the rotor and hammer assemblies, the tub chain and drive assemblies, as well as the belly and discharge conveyors assemblies.
  • Page 28 figures 2.2 & 2.3 major system components discharge conveyor in the operating position folding tub flare tub roller access engine compartment panel and shield access panel engine work compartment light access panel radiator access panel tub drive access panel and shield hydraulic oil reservoir control panel...

  • Page 29: Dry Clutch

    2.3 Dry Clutch ( REV. 9-17 ) The HPTO™ Hydraulic Power Take-off is a hydraulically actuated, enclosed dry clutch that requires no adjustment throughout its wear life. During a torque spike, the clutch will act as a torque limiter by slipping to absorb the shockload.

  • Page 30: Rotor

    1/2 to completely full. The 2009 DURATECH TUB GRINDER’s tub can be tilted 90 degrees for access to the rotor, screens, and drive line. The tub has an electronic safety switch that will not allow the tub to be raised with the rotor turning. The switch provides feedback to the operator through two indicator lights which are located on the control panel.

  • Page 31: Hydraulic Cooler

    2.8 The conveyor system ( REV. 08-04 ) The conveyor system on the 2009 DURATECH TUB GRINDER consists of a belly conveyor and a discharge conveyor. The belly conveyor transfers the ground material from the rotor to the discharge conveyor. The discharge conveyor then moves the material away from the unit.
  • Page 32 figure 2.6 top control panel for machines with a Cat engine Fuel gauge Dry clutch display Panel lights 5700939 5700941 Oil pressure Water temperature Diagnostic lamp Warning lamp 5700940 Voltmeter 5700938 Fuel pressure 5700907 Engine tachometer Circuit breaker 5700497 Key switch 5700831 Throttle control Maintenance lamp Engine kill switch...
  • Page 33 figure 2.7 Remote rotation bottom control panel Radio radio/ Conveyor Forward/ Conveyor for machines with Local remote On/Off Reverse Up/Down either a John Deere or switch control Cat engine (S.N. UP TO 0034) Electronic governor Optional jack control switches Lights On/Off Up/Down Left/Right Optional tub cover...

  • Page 34: Other Controls

    2.11 Other controls ( REV. 09-17 ) Radio remote control unit (optional) The optional radio remote control unit allows the operator to remotely start and stop the tub, change the tub’s direction of rotation to forward or reverse, perform an emergency stop, and raise and lower the conveyor. NOTE: See also section 3.17, “Operating the grinder using the remote radio option.”...

  • Page 35: Section 3: Operation

    Also make sure that anyone who will assist you in the operation or maintenance of this machine understands how the machine operates. Before operating the 2009 DuraTech Tub Grinder, perform an inspection that includes the following items. As each task is performed, check or initial the adjacent box.

  • Page 36: Starting The Tub Grinder

    3.2 Starting the Tub Grinder ( REV. 08-04 ) NOTE: The engine will start easier at cool temperatures by use of a starting aid. A block heater or other means can be used to warm the engine. NOTE: Do not crank the engine for more than 30 seconds. Allow the starter motor to cool for two minutes before cranking again.

  • Page 37: Automatic Engine Shutdown System

    Throttle operation for machines with Cat engines To increase throttle speed, push and hold throttle control switch up. To decrease throttle speed, push and hold throttle control switch down. 3.5 Automatic engine shutdown system ( REV. 08-04 ) The engine will automatically shut down if it overheats or if engine oil pressure is inadequate. If this happens, perform the following steps: Check the engine oil level.

  • Page 38: Emergency Shutdown Procedure

    3.7 Emergency shutdown procedure ( REV. 08-04 ) IMPORTANT: Emergency shutoff controls are for EMERGENCY use Only. DO NOT use the emergency shutoff controls for normal stopping procedure. NOTE: The emergency stop button will have to be reset before restarting the engine. Push in emergency stop button located on the control panel (large red button), and remove key.

  • Page 39: Operation Of The Electronic Governor

    ENGINE LOAD KNOB This knob is used only in engine (auto) mode. It controls the load placed on the engine. Turning the knob clockwise decreases engine load, and turning the knob counterclockwise increases the engine load. RANGE SWITCH This switch is a coarse adjustment for the engine load knob and can be switched to a H‑ high, M‑medium or L‑low setting.

  • Page 40: Calibration Of The Electronic Governor

    ( REV. 08-04 ) To calibrate the electronic governor, perform the following steps: Begin calibration procedure with 2009 DURATECH TUB GRINDER Tub Grinder completely shutdown. Place the MODE switch in the OFF position and the RANGE switch in the H‑High position. Rotate the TUB SPEED KNOB fully clockwise toward the rabbit position.
  • Page 41 To raise the tub, perform the following steps: Verify that the tub grinder is parked on level surface. Disengage the clutch, and wait for the rotor to stop turning. If your machine is equipped with a tub cover place tub cover in fully closed position As material in the tub may roll some distance, make sure the area on the right hand side of machine is clear of personnel and equipment.

  • Page 42: Lowering The Tub

    3.13 Lowering the tub ( REV. 08-04 ) To lower the tub, perform the following steps: Remove the safety stop on the hydraulic cylinder, and place safety stop in storage location on the inside of frame rail. Clear the area of equipment and personnel. Engine speed should be 1000 RPM.

  • Page 43: Operating The Grinder Using The Remote Radio Option

    OMNEX ORIGA T110 TRANSMITTER Mode of operation The Omnex Origa system has several modes of operation. The mode preset for DuraTech Industries is: The Power ON (green) button powers up the transmitter. Output 9 on the receiver is energized when the Power ON button is pressed.
  • Page 44 Output 10 on the reciever is energized when any of functions 3‑8 are pressed. Functions 1 & 2 are interlocked latched functions and are used for tub rotation. Pressing one function will start that function. It will not stop until either button is pressed. There is a two second delay when changing tub direction.

  • Page 45: Grinding

    3.17 Grinding ( REV. 08-04 ) Before you begin grinding, start the machine and check the direction of the tub’s rotation. Also check the electronic governor for proper operation. Watch for unusual or excessive vibration. If any occurs, immediately shut off the power. Determine the cause and correct it before starting the grinder again.

  • Page 46: If Lodging Occurs While Grinding

    3.22 Preparing the 2009 DURATECH TUB GRINDER for transport ( REV. 09-17 ) To prepare the 2009 DURATECH TUB GRINDER for transport over public roads, perform the following steps: Be sure all loose parts such as screens, hammer rods, or extra hammers are properly stowed.
  • Page 47 Raise the trailer landing gear and lock the handle in its storage position. 10. Check the lights and the brakes for proper function. 11. Check local ordinances regarding restrictions for machine travel on local roads. Read Section 1.12 “Towing” in the “Safety” section in this manual. figure 3.2 conveyor in the transport position...

  • Page 48: Preparing The 2009 Duratech Tub Grinder For Operation

    ( REV. 08-04 ) To prepare the 2009 DuraTech Tub Grinder for operation after transport, perform the following steps: Check the location. • Are there power lines, branches, roof trusses, etc. that will obstruct the unfolding operation of the conveyor and the loading operation of the tub? •...

  • Page 49: Removing The 2009 Duratech Tub Grinder From Storage

    3.25 Removing the 2009 DURATECH TUB GRINDER from storage ( REV. 08-04 ) To remove the 2009 DURATECH TUB GRINDER from storage, perform the following steps: Perform a thorough pre‑operation inspection as specified in Section 3.1 (page 23) of this manual.

  • Page 50: Adjusting The Conveyor Belt Tension

    3.27 Adjusting the conveyor belt tension ( REV. 08-04 ) IMPORTANT: Do not overtighten conveyor belts. Use only enough tension to eliminate belt slippage. Both rollers on the belly conveyor and the discharge conveyor are adjustable to allow for belt stretch and tracking. If the conveyor belt slows down or stops during operation, slippage may be the cause.

  • Page 51: Adjusting The Conveyor Belt Tracking

    3.28 Adjusting the conveyor belt tracking ( REV. 08-04 ) A. When a new belt is installed, use only genuine DuraTech Industries parts. Begin by adjusting the drive roller so that the mounting bearings are the same distance from the end of the conveyor frame.

  • Page 52: Adjusting Belly Belt Seals

    3.29 Adjusting belly belt seals ( REV. 08-04 ) Belt seal Always make sure the belt seals (pn# 1700166) and endless belt are in contact with each other. When adjusting the belt seal as it wears down, loosen the bolts and push belt seal down so that it cones in contact with the endless belt again.

  • Page 53: Adjusting Tub Chain Tension

    3.31 Adjusting tub chain tension ( REV. 08-04 ) To adjust the tub chain tension, perform the following steps: Loosen (4) bolts holding motor mounting lock bolts plate. Turn (2) adjusting bolts to set chain tension. Tighten the (4) bolts holding motor mounting plate.

  • Page 54: 2009 Track Option

    2009 Track machine W/ long conveyor option RUNNING THE 2009 TRACK USING MANUAL CONTROLS Manual lever controls 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 55 The manual controls are located on the front of the 2009 Track radiator platform. To move the 2009 Track using these controls, simply push the levers forward to go forward, pull the levers back to go backwards, and for turning, operate one lever opposite the other.
  • Page 56 CONTROL PANEL FOR THE 2009 TRACK The control panel is located on the left hand side of the engine. Controls on the control panel include; engine start, emergency kill switch, throttle, tub controls, conveyor on/off, conveyor positioning, rotor engage, rotor disengage button, tub governor, tub tilt, and the job hours reset button.
  • Page 57 Top control panel (up to S.N. 0034) Fuel Gauge Dry clutch display Panel Lights Top control panel (S.N. 0035 and up) Fuel Gauge Dry clutch display 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 58 Top control panel 5700941 5700939 CAT Panel - All S.N. Water temperature Oil pressure Warning lamp Diagnostic lamp 5700940 Voltmeter 5700938 Fuel pressure 5700907 Engine tachometer Circuit breaker 5700497 Key switch 5700831 Throttle control Engine kill switch Maintenance lamp Service tool connector Maintenance clear switch Bottom control panel Remote...
  • Page 59 Bottom control panel Conveyor up/down (S.N. 0035 and up) Tub rotation forward/reverse Radio start Electronic Governor Conveyor on/off Lights On/Off Tub cover in/out, up/down Rotor status lights Track speed Remote radio/Local switch High/Low Job hours Conveyor fold/unfold Job hours reset button Screen On/Off Grinding hours Up/Down...
  • Page 60 BATTERY DISCONNECT SWITCH The battery disconnect switch is used to connect and disconnect the main battery cable to the machine. When the machine is not in use, it should be disconnected. Battery disconnect switch 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 61: Section 4: Engine Maintenance

    Section 4: Engine Maintenance Engine oil level, engine coolant level, air filters, and fan belt tension should be checked daily. All debris, and combustible or ignitable material should be cleared from the engine compartment daily or more often as conditions warrant.
  • Page 62 Stop the engine. Turn the battery disconnect switch to the OFF position. Disconnect the negative battery cable from the battery. Disconnect the connectors from the computerized equipment listed on the previous page. Move each har- ness to a position that will not allow the harness to accidentally move back and make contact with any of the connector pins.

  • Page 63: Batteries

    A heavy‑duty, general‑purpose, lithium‑based grease is recommended for lubricating the 2009 DuraTech Tub Grinder. 2 0 0 9 D U R A T E C H T U B G R I N D E R...
  • Page 64 LUBRICATION CHART 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 65 figure 5.1 tub chain idler lubrication points tub chain idler pivots (Ref # 3) figure 5.2 drive line lubrication points lubrication zerk (Ref # 6) lubrication zerk (Ref # 6) figure 5.3 belly conveyor roller lubrication points belly conveyor roller (Ref # 11) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 66 figure 5.4 discharge conveyor roller, and discharge conveyor lift pivot lubrication points discharge conveyor lift pivot (Ref # 10) discharge conveyor roller (Ref # 8) figure 5.5 conveyor fold pivot lubrication point discharge conveyor fold pivot (Ref # 9a) figure 5.6 discharge conveyor roller lubrication point discharge conveyor roller...
  • Page 67 figure 5.6 tub pivot lubrication points tub pivots (Ref # 12) figure 5.7 radiator pivot lubrication points radiator pivots (Ref # 18) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 68: Pressure Roller Lubrication

    figure 5.8 optional tub cover lubrication points (Ref #19) tub cover tub cover (Ref # 19) (Ref # 19) 5.4 Pressure roller lubrication ( REV. 08-04 ) The grinder has a pressure roller with tapered roller bearings. These bearings should be checked for lubrication Tub Pressure Roller lubrication point every 1000 hours of operation or annually‑...

  • Page 69: Rotor Bearing Lubrication (For S. N. Up To 064)

    5.5 Rotor bearing lubrication (For S. N. up to 064) ( REV. 08-04 ) As a general rule, rotor bearing oil should be replaced every 500 hours of operation. However, if the oil becomes discolored or milky in appearance, the oil should be replaced immediately. The static oil level should bring oil to the centerline of the bottom roller.

  • Page 70: Hydraulic System

    DuraTech Industries recommends using Cenex Qwiklift HTB if your machine has a Qwiklift decal on the hydraulic tank. Other acceptable fluids include Mobil 423, Farmland Super HTB, Conoco Hydroclear Power Tran Fluid or other similar fluids. If the hydraulic tank does not have this decal, then all of the above fluids are acceptable.

  • Page 71: Clutch System

    5.7 Clutch system ( REV. 08-04 ) Check all HPTO bolted connections and hydraulic connections every 500 hours. Clutch is to be serviced and inspected after 5000 hours of operation ‑ contact your dealer for details. 5.8 Axle, wheels and tires ( REV.

  • Page 72: Brake Component Lubrication

    Brake component lubrication ( REV. 08-04 ) CAUTION: Care must be exercised when lubricating the camshaft bushings and anchor pins. Over lubrication could cause a safety problem as brake linings become saturated with lubricants. NOTE: When reline shoe linings become saturated with grease, replace with new shoe and lining assemblies.
  • Page 73 FREQUENCY OF SERVICE Camshaft roller journals, anchor pins, slack adjusters every 25,000 to 30,000 miles or every six months depending on severity of operating conditions. (For off highway use: service every 4 months depending on severity of operating conditions SUGGESTED PREVENTATIVE MAINTENANCE •...

  • Page 74: Rotor Bearing Installation (For S.n. Up To 064)

    5.10 Rotor bearing installation (For S.N. up to 064) ( REV. 09-17 ) WARNING: To ensure the rotor is not unexpectedly started, turn off and lock out or tag the power sources before proceeding. Failure to observe these precautions could result in bodily injury. NOTE: Bearing housing caps and bases are not interchangeable and must be matched with mating half.
  • Page 75 A. V-ring Seal Slide one of the V‑ring seals onto the shaft, making sure the lip is toward the bearing. Set aside until step 11. NOTE: Do not install the V‑ring seal on the seal until the housing cap has been set in place and tightened.

  • Page 76: Rotor Bearing Maintenance

    Apply lubricant to the bearings and the seal rings. The lubricant should be smeared between the rolling elements. Use Mobil SHC‑626 or similar oil for bearing lubricant. Do not use detergent motor oil! Place the shaft with the bearing into lower half of the housing while carefully guiding the seal rings into the housing grooves.

  • Page 77: Dodge Rotor Bearing Installation (Sn 065 & Up)

    5.12 Dodge Rotor bearing installation (SN 065 & up) ( REV. 09-17 ) WARNING: To ensure the rotor is not unexpectedly started, turn off and lock out or tag the power sources before proceeding. Failure to observe these precautions could result in bodily injury. NOTE: Bearing housing caps and bases are not interchangeable and must be matched with mating half.
  • Page 78 MOUNTING Install the non expansion unit first. Apply a coating of light oil or other rust inhibitor to the adapter area of the shaft. Before mounting bearing to shaft, remove lockplate from bearing and turn locknut counterclockwise one to two turns to allow adapter Picture 1 to expand fully.
  • Page 79 Once “ZERO reference point” is reached, scribe a line through both locknut face and adapter face (Picture 2). Then continue to tighten the locknut (Picture 3) by turning it clockwise using hammer and drift or spanner by the appropriate rotation angle shown on Table 1.
  • Page 80 ISAF: For 2 Bolt and 4 Bolt Pillow Blocks: 1) Remove bearing cap 2) Remove stabilizing ring; 3) Reassemble cap on base, 4) Torque cap bolts to recommended torque values. (Table 2) DISMOUNTING Remove weight off bearing via a sling or jacks. Remove mounting bolts from bearing.

  • Page 81: Hammermill Maintenance

    5.13 Hammermill maintenance ( REV. 08-04 ) Visually examine the mill to see if any of the internal parts show excessive wear. These parts should include liners, rotor discs and the holes in the discs that support the rods. Enlarged holes can cause rods to break or bend. Also check rods, rod locking or retaining devices, hammers, screens, screen tracks and hold downs, main shaft, platform locking devices, hinges or anything else that could wear and perhaps fail and causing damage to the hammermill and/or personnel if not properly maintained.

  • Page 82: Fixed Hammer Maintenance And Replacement

    5.14 Fixed hammer maintenance and replacement ( REV. 09-17 ) CAUTION: Disengage the driveline clutch. Shut off the engine. Remove the key before working on the rotor. IMPORTANT: The bolts on the hammer tips should be checked periodically for proper torque. Torque ratings for two bolt tips are listed below.

  • Page 83: Swinging Hammer Replacement And Maintenance

    5.15 Swinging hammer replacement and maintenance ( REV. 10-13 ) CAUTION: Disengage the clutch, shut off the engine and remove the key before working on the rotor. When installing or changing hammers, be sure to follow the hammer diagram carefully. Misplacement of the hammers could cause excessive vibration.
  • Page 84 FIXED HAMMERS SPACING CHART figure 5.11 fixed hammer pattern (18 hammers) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 85 FIXED HAMMERS SPACING CHART figure 5.12 fixed hammer pattern (32 hammers) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 86 SWINGING HAMMERS SPACING CHARTS ( FOR S.N. UP TO 0034) figure 5.13 full set swing (58 hammers) figure 5.13 1/2 Set Swing (32 hammers) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 87 figure 5.14 SWINGING HAMMERS SPACING CHART swing hammer pattern (36 hammers) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 88: Section 6: Troubleshooting The 2009 Duratech Tub Grinder

    Section 6: Troubleshooting the 2009 DURATECH TUB GRINDER 6.1 Troubleshooting the electronic governor system ( REV. 08-04 ) When power is reaching the electronic governor the fuse light should be on. If this light fails to go on, check the fuse, the battery connections, the wiring harness, and the indicator lamp.
  • Page 89 Checking the ENGINE MODE operation of the electronic governor. If the tub mode controls function correctly after following the tub mode trouble shooting check list, then follow the calibration instructions on page 32 of this manual. If the tub will not rotate, proceed to trouble shooting table 6.2. Table 6.2 troubleshooting the electronic governor’s...
  • Page 90 ELECTRONIC GOVERNOR HARDWARE TEST (For S.N. Up to 20-4-DJ0019) NOTE: The 2009 DURATECH TUB GRINDER contain a 12 volt system. Power source: 12 volts DC Red wire + positive pin A wiring harness Black wire ‑ Negative Pin B wiring harness Test output voltage to valve DC Red wire + positive pin D wiring harness.
  • Page 91 ELECTROHYDRAULIC VALVE COIL TEST (For S.N. Up to 20-4-DJ0019) See the figure 6.2 for the location of the electro‑hydraulic valve coil. This test requires an accurate ohm meter. Disconnect the wiring harness leads at the valve coil. Set the meter to read ohms.
  • Page 92 ELECTRONIC GOVERNOR HARDWARE TEST (For S.N. 20-2-GJ0020 & Up) NOTE: 2009 DURATECH TUB GRINDERs contain 24 volt systems. Power source: 24 volts DC Red wire + positive pin A wiring harness Black wire ‑ Negative Pin B wiring harness Test output voltage to valve DC Red wire + positive pin D wiring harness.
  • Page 93 ELECTROHYDRAULIC VALVE COIL TEST (For S.N. 20-2-GJ0020 & Up) See the figure 6.4 for the location of the electro‑hydraulic valve coil. This test requires an accurate ohm meter. Disconnect the wiring harness leads at the valve coil. Set the meter to read ohms.

  • Page 94: Electro-Hydraulic Valve Calibration (For S.n. Up To 20-4-Dj0019)

    Electro-hydraulic valve calibration (for S.N. Up to 20-4-DJ0019) ( REV. 02-11 ) IMPORTANT: Stay clear of all moving parts while calibrating the electro‑hydraulic valve. The tub will be rotating during this adjustment. location of adjusting nut and jam nut found under rubber cap end electro-hydraulic valve To calibrate the electro‑hydraulic valve coil after following the three steps above, perform the following steps: Remove the rubber end cap from the end of the electro‑hydraulic valve.

  • Page 95: Electro-Hydraulic Valve Calibration (For S.n. 20-2-Gj0020 And Up)

    6.2a Electro-hydraulic valve calibration (for S.N. 20-2-GJ0020 and up) ( REV. 02-11 ) location of acorn nut and jam nut electro-hydraulic valve To calibrate the electro‑hydraulic valve coil after following the three steps above, perform the following steps: Shut down the machine using the normal shutdown procedure in this manual Disconnect the wiring harness from the electro‑hydraulic valve coil.

  • Page 96: General Troubleshooting

    6.3 General Troubleshooting ( REV. 08-04 ) general troubleshooting 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 97: Troubleshooting Omnex Wireless Remote Controls

    6.4 Troubleshooting Omnex Wireless Remote Controls ( REV. 08-04 ) The OMNEX ORIGA is a portable, long range, programmable, 8‑channel radio remote control unit for 10 to 32 VDC operated fixed and mobile equipment. TROUBLESHOOTING THE OMNEX ORIGA THE REMOTE RADIO CONTROLLER (T100)/TRANSMITTER THE REMOTE RADIO RECEIVER (R100e) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 98 LED to the left of the GREEN Power button will begin flashing rapidly. Enter the programming values. The programming values for DuraTech are 2266888888. If throttle is included, use 2266228888. Press and hold the SETUP button on the R100E Receiver (approx. 5 sec.). The Yellow Setup LED will start flashing slowly while the R100E Receiver enters into programming mode.
  • Page 99 REPLACING BATTERIES Install batteries by removing the battery cover using a slotted screwdriver and inserting 4 “AA” Alkaline batteries. Orientation for batteries is embossed inside the battery housing. WIRING SCHEMATIC FOR THE R100e RECEIVER 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 100: Troubleshooting Omnex Wireless 10 Button Remote Control

    Troubleshooting Omnex Wireless 10 Button Remote Control ( REV. 10-13 ) 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
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  • Page 110: Troubleshooting The Caterpillar C9 And C15 Tier Iii Engine And The Caterpillar C27 Tier Ii Engine

    One connector is used to connect the DuraTech wiring harness to the Caterpillar wiring. If the Caterpillar engine requires troubleshooting, the DuraTech connection can be removed during the diagnosis. To remove the DuraTech wiring for Caterpillar engine diagnoses disconnect connection A.

  • Page 111: Appendix A: Warranty

    This warranty is limited to the replacement of any defective part or parts if DuraTech Industries is notified within thirty (30) days of failure.

  • Page 112: Appendix B: Specifications

    Appendix B: SPECIFICATIONS MODEL 2009 DURATECH TUB GRINDER General Weight ..................... 38,000 lbs. Transport Width ....................8’ 6” Transport Height ....................11’ Transport Length With Fifth Wheel ..............42’ 9” Axles ....................(1) 22,500 lbs. Tires ...................... 255/70R22.5 Fuel Capacity ........105 gallons (200 gallons with pintle hitch.) Hydraulic Oil Capacity ................50 gallons...
  • Page 113 2009 Tub Grinder Stationary Electric Supplement Operating Instructions 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 114 Clearing the Way for a Better Tomorrow 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 115: 2009El Electric Tub Grinder Operators Manual Supplement

    2009EL Electric Tub Grinder Operators Manual Supplement This is a supplement to the 2009 Tub Grinder Operators Manual. The main part of this book applies to this Tub Grinder except where described in this attached supplement. Before Starting the 2009EL Electric Tub Grinder review all: •...
  • Page 116 Then press the start button for the main electrical motor (labeled ‘ROTOR’). The start button can be found in two different places, on the control panel marked rotor or on the large soft start panel. Start button ROTOR Large soft start panel start button Then press the start button for the electrical motor that runs the hydraulic pump.

  • Page 117: Supplement Section 1: Start Up (For Sn 065 And Up)

    Supplement Section 1: Start up (For SN 065 and up) ( REV. 09-17 ) At start up it is recommended that the rotor motor (labeled ‘ROTOR’) be started first and then the hydraulics motor (labeled ‘HYDRAULICS’). This will keep the amount of electricity used at initial startup down. Before starting the 2009EL Electric Tub Grinder make sure that “SS bypass”...
  • Page 118 Then press the start button for the main electrical motor (labeled ‘ROTOR’). The start button can be found in one place, on the control panel marked rotor. Start button ROTOR Then press the start button for the electrical motor that runs the hydraulic pump. This can be found on the control panel marked hydraulics.

  • Page 119: Supplement Section 2: Shut-Down Procedure (For S.n. Up To 064)

    Supplement Section 2: Shut-Down Procedure (For S.N. up to 064) ( REV. 02-11 ) Run 2009EL Electric Tub Grinder until discharge conveyor is empty, and grind as much of the material in the tub as possible. Push stop button. For the rotor motor the button is located on the control panel marked ‘ROTOR’, and on the large soft start panel.

  • Page 120: Supplement Section 2: Shut-Down Procedure (For Sn 065 And Up)

    Supplement Section 2: Shut-Down Procedure (For SN 065 and up) ( REV. 09-17 ) Run the 2009EL Electric Tub Grinder until discharge conveyor is empty, and grind as much of the material in the tub as possible. Push the stop button for the rotor motor. The button is located on the control panel marked ‘ROTOR’. Stop button ROTOR Then press the stop button for the electrical motor that runs the hydraulic pump.

  • Page 121: Supplement Section 3: Lubrication

    Supplement Section 3: Lubrication ( REV. 04-11 ) The Teco-Whitewestinghouse Motor that powers the rotor requires the use of Esso Polyrex Em or equivalent grease. The (2) grease zerks on this motor must be re‑lubricated every 1000 hours. 270 grams of grease is to be placed in the drive end zerk.

  • Page 122: Supplement Section 4: Raising/Lowering The Tub Platform, Raising/Lowering The Discharge Conveyor, And Folding/Unfolding The Discharge Conveyor

    The Teco-Whitewestinghouse Motor that powers the hydraulic pump requires the use of Esso Polyrex Em or equivalent grease. The (2) grease zerks on this motor must be re‑lubricated every 2000 hours. 130 grams of grease is to be placed in the drive end zerk. 65 grams required for end opposite the drive. DO NOT OVER GREASE! Locations of the grease zerks are shown below: Front location (top of motor) Drive end location (top of motor)

  • Page 123: Supplement Section 5: Hydraulic Cooler

    The 75Hp electric motor has its own soft start panel with start and stop buttons on the front of it. At startup of the grinder, it is recommended that the main electrical motor be started first and then the 75 Hp electric motor. This will keep the amount of electricity used at initial startup down.

  • Page 124: Supplement Section 6: Control Panel

    Supplement Section 6: Control Panel ( REV. 02-11 ) The control panel for the 2009EL electric tub grinder is located on the right hand side of the machine. Controls on the panel include; engine start, engine stop, emergency kill switch, throttle, tub controls, conveyor on/off, conveyor positioning, rotor engage button, rotor disengage button, tub governor, tub tilt, grinding hours and job hours reset button.

  • Page 125: Supplement Section 7: Belt Deflection

    Supplement Section 7: Belt Deflection ( REV10-13) Belt deflection needs to be checked regularly on a new installation. 380v 50 Hz application The customer has (2) 4 strand belts, 5V profile, 85” (2160mm), belt type is Gates Predator. Belt deflection should be 0.30” (7.6mm). Force used for a new belt is 24‑25 lb. (11to 11.5kg), for an older belt, deflection force is 21‑22 lb.

  • Page 126: Model 2009El Electric Specifications

    MODEL 2009EL ELECTRIC SPECIFICATIONS General (Mobile Unit) Weight w/460 Volt Motor ..................30,520 lbs. w/380 Volt Motor ..................31,620 lbs. Transport Width ....................8’ 4” Transport Height ..................... 10’ 10” Transport Length ..................30’ 5” Axles ................Tandem Axles, 22,500 lbs. Tires .................(4) 445/50R 22.5 Super Singles Hydraulic Oil Capacity ................50 gallons Lights ..............
  • Page 127 Electric Skid Unit Electric Mobile Unit 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 128 Clearing the Way for a Better Tomorrow 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 129: Appendix C: Operator Training Form

    Appendix C: Operator Training Form The following personnel, by their signature, certify that they have read this manual in its entirety and comprehend its instructions. Only personnel so qualified are allowed to operate this unit. Printed Name Review Date Signature 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...
  • Page 130 Clearing the Way for a Better Tomorrow 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

  • Page 131: 2009 Duratech Tub Grinder Documentation Comment Form

    2009 DURATECH TUB GRINDER Documentation Comment Form DuraTech Industries welcomes your comments and suggestions regarding the quality and usefulness of this manual. Your comments help us improve the documentation to better meet your needs. • Did you find any errors? •...
  • Page 132 Clearing the Way for a Better Tomorrow 2 0 0 9 D U R A T E C H T U B G R I N D E R O P E R A T I N G I N S T R U C T I O N S...

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