Related Manuals for Duratech GRINDMASTER 512
Summary of Contents for Duratech GRINDMASTER 512
- Page 1 GRINDMASTER 512 Industrial Grinder Manual 1: Operating Instructions P. O . B 1 9 4 0 , J , N D 5 8 4 0 2 - 1 9 4 0 A M E S T O W N 2001...
- Page 2 Clearing the Way for a Better Tomorrow...
- Page 3 GRINDMASTER 512™ 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 F O R E W O R D Foreword Appropriate use of the unit This Industrial Grinder is designed to grind industrial waste and other materials, including wood waste, construction and demolition debris, asphalt, bricks, concrete blocks, tree branches and trunks, compostables and mulch. It is NOT designed to grind steel.
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Page 6: Table Of Contents
1.9 Fire safety ...................... 11 1.10 Important safety reminders ................11 1.11 Towing ......................11 Section 2: Introduction ............12 2.1 Description of the DuraTech GRINDMASTER 512 ........12 2.2 Carrier and Chassis ..................12 2.3 Rotor ......................12 2.4 Engine ......................13 2.5 Hydraulics ...................... - Page 7 T A B L E O F C O N T E N T S Section 3: Operation ............... 20 3.1 Pre-operation inspection ................20 3.2 Starting the GRINDMASTER 512 ............... 21 3.3 Automatic engine shutdown system .............. 22 3.4 Normal Shutdown Procedure ................ 22 3.5 Emergency Shutdown Procedure ..............
- Page 8 T A B L E O F C O N T E N T S Clearing the Way for a Better Tomorrow 5 1 2 G R I N D M A S T 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 9: Manual 1: Operating Instructions
GRINDMASTER 512 Manual 1: Operating Instructions G R I N D M A S T E R 5 1 2 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 and routine adjustments for the most efficient operation of your GRINDMASTER 512. 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: Section 1: Safety
Before operating this unit, you should familiarize yourself with these manuals as well. Safety is an ongoing job experience, and DuraTech has made every effort to make sure that the GRINDMASTER 512 provides operator comfort and security. DuraTech encourages you to bring to our attention as quickly as possible any suggestions you may have concerning the safety of the equipment. -
Page 12: 1.1 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. G R I N D M A S T E R 5 1 2... - Page 13 DuraTech uses industry accepted ANSI standards in labeling its products for safety and operational characteristics. Safety-Aler ety-Aler ety-Aler ety-Aler ety-Alert Symbol t Symbol t Symbol t Symbol t Symbol Read and recognize safety information. Be alert to the potential for personal injury when you see this safety-alert symbol.
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Page 14: 1.2 Operator - Personal Equipment
Do not operate a GRINDMASTER 512 when you are fatigued. Be alert - If you get tired while operating your GRINDMASTER 512, take a break. Fatigue may result in loss of control. Working with any industrial equipment can be strenuous. -
Page 15: Machine Safety Labels
Machine safety labels 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 16 WARNING: HIGH-PRESSURE FLUID HAZARD To prevent serious injury or death: • Relieve pressure on system before repairing or adjusting or disconnecting. • Wear proper hand and eye protection when searching for leaks. Use wood or cardboard instead of hands. • Keep all components in good repair.
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Page 17: Shielding
WARNING: Before attempting to operate your GRINDMASTER 512, carefully read and follow instructions given below and contained elsewhere in this manual. Each and every aspect of the DuraTech Grindmaster should be reviewed by each operator on a frequent basis. Safety systems are in place that result in direct operator security. -
Page 18: Thrown Objects And Operator Safety
When replacing any part on your GRINDMASTER 512, be sure to use only DuraTech authorized parts. Personal protection equipment Operators and authorized observers of the GRINDMASTER 512 are required to wear head, eye, and ear protection. No loose clothing is allowed. -
Page 19: Fire Safety
THIS GRINDER IS NOT TO BE USED FOR ANY PURPOSE OTHER THAN DEFINED IN THE OPERATOR’S MANUAL, ADVERTISING MATERIALS AND OTHER PERTINENT WRITTEN MATERIAL PREPARED BY DURATECH INDUSTRIES INTERNATIONAL, INC. G R I N D M A S T E R 5 1 2... -
Page 20: Section 2: Introduction
Section 2: Introduction Description of the DuraTech GRINDMASTER 512 The GRINDMASTER 512 is a designed to grind drive belt operator cab compartment construction and demolition debris, asphalt, bricks, and concrete blocks. It will also grind wood waste, green waste, tree branches and trunks, compostables and mulch. -
Page 21: Engine
A fixed displacement hydraulic pump is driven from an accessory drive port on the engine to supply fluid energy to the conveyor drive motor and conveyor fold cylinders. The GRINDMASTER 512 utilizes the following hydraulic motors: A hydraulic motor is utilized to transfer fluid energy to the right belt drive pulley. -
Page 22: 2.6 Screens
A shuttle valve is located to the right rear of the rotor. Pushing the valve down provides power to run the conveyor motor. Raising the valve up provides power to the conveyor fold mechanism. For more information on folding and unfolding the conveyor see section 3.9. -
Page 23: Drive Belts
Drive Belts One set of drive belts are located in each drive compartment. These belts are coupled to the pulley mounted on the end of the rotor shaft. The drive belt tension is maintained by adjusting bolts located in each drive compartment. Adjust belts so there is 1/4”... -
Page 24: Wheels And Tires
Wheels and Tires The trailer chassis uses tubeless tires. The tires are constructed with either a radial or bias-ply casing and a stabilizing belt of multiple layers. 2.10 Fuel System One 175-gallon fuel tank supplies all of the fuel requirements of the grinder. Fuel filters are provided to prevent passage of foreign material through the fuel lines into the engine. -
Page 25: Starting System
2.13 Starting System The GRINDMASTER 512 engine uses a 24-volt start system, and a 24-volt lighting and accessory system. An alternator and rectifier supplies current to maintain the starting batteries while the engine is running. The electrical system utilizes two batteries connected in series. - Page 26 figure 2.5 512 rotor control panel change filter pressure gauge rotor drive pressure guage emergency horn stop button rotor control dash lights conveyor exterior lights water shear spray figure 2.6 push box cylinder controls push box cylinder control throttle G R I N D M A S T E R 5 1 2 O P E R A T I N G I N S T R U C T I O N S...
- Page 27 figure 2.7 conveyor fold lever and conveyor shuttle valve to conveyor fold conveyor shuttle valve conveyor fold lever to conveyor motor figure 2.8 fuel pressure gauge and mechanical switch gauges used by automatic fuel pressure gauge shutdown sytem mechanical switch gauges used by automatic shutdown system figure 2.13...
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Page 28: 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 GRINDMASTER 512, perform an inspection that includes the following items. As each task is performed, check or initial the adjacent box. -
Page 29: Starting The Grindmaster 512
Starting the GRINDMASTER 512 WARNING: Before starting the engine, ALWAYS make sure that the conveyor shuttle valve is in the conveyor fold position, and that the conveyor toggle switch is in the off position. If the conveyor shuttle valve is in the conveyor run position, and the conveyor toggle switch is in the on position, the conveyor will begin to turn when the motor is started which could result in damage to the machine. -
Page 30: 3.3 Automatic Engine Shutdown System
Attempt to restart engine following the normal starting procedure. If the engine will not continue running, contact a qualified mechanic. Normal Shutdown Procedure Use the following procedure to shut down the GRINDMASTER 512 under normal operation: Retract “push box.” Allow conveyor belt to run until empty. -
Page 31: Emergency Shutdown Procedure
Emergency Shutdown Procedure Push in the engine kill button or the engine shutdown button located on the control panel and remove key. NOTE: Reset engine kill button before starting. Both switches should be periodically tested to ensure proper operation. Test the switch only after the engine has been running at a low idle for 3 to 5 minutes and the hydraulic controls are in their normal or off positions. -
Page 32: Grinding Materials
Grinding Materials CAUTION: Never operate the grinder while personnel are located outside of the operator’s compartment. Before grinding materials, be certain the front window guard is latched in place. Debris may be cast from the hopper during the grinding process. Ensure that there are no materials jammed in the rotor area before engaging the rotor. - Page 33 NOTE: Always observe operation of the grinder and its components. Note and report any trouble before or during the operation, while paying special attention to the following: Drifting hydraulic cylinders. Excessive oil pressure, oil leaks, and excessive oil consumption. Unusual noise or vibration in the hydraulic pumps. Unusual noise or vibration in the engine.
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Page 34: Clearing Jams
During normal operations, materials may occasionally become jammed near the shear bar and rotor. This situation occurs because of the wide variety of materials and size of materials capable of being processed by the GRINDMASTER 512. To clear a jam situation, follow the instructions outlined below: Put rotor in neutral position. -
Page 35: Belt Tracking
Belt Tracking Mechanics must train the belts by eliminating structural and mechanical defects so the belt will run square to a centerline. Aim at providing the best possible conditions for the belt to move the load efficiently, reliably and without damage. One or more of the following can influence belt tracking: Idlers - troughing and return. - Page 36 Once the preliminary checks have taken place, it is now time for belt start-up. From this point on, whether you’re dealing with a new installation or replacing a belt on an existing system, the procedures for correcting any tracking or training problems will be the same.
- Page 37 Another condition that might be encountered as the belt is observed would be one section of the belt runs odd at all points. Two factors can cause this problem: The belt may be improperly spliced (out of square). Check splicing directions and squaring techniques.
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Page 38: Conveyor
Conveyor figure 3.2 conveyor fold lever and conveyor shuttle valve to conveyor fold conveyor shuttle valve conveyor fold lever to conveyor motor A shuttle valve is located to the right rear of the rotor. Pushing the valve down provides power to run the conveyor motor. -
Page 39: Preparing The 512 For Transport
Fold the discharge conveyor into the transport position which is described on the previous page. NOTE: Before transporting the Grindmater 512, verify that the conveyor tiedown strap is firmly cinched. CAUTION: DO NOT MOVE THE GRINDMASTER 512 without first securing the conveyor in transport position. Shut down the engine using the normal shutdown procedure. -
Page 40: Preparing The 512 For Operation After Transport
3.11 Preparing the 512 for operation after transport To prepare the 512 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? Lower the trailer landing gear. -
Page 41: Section 4: Engine Maintenance
Section 4: Engine Maintenance Engine oil level, engine coolant level, air filters, and fan belt tension should be checked daily. Follow the engine manufacturer’s recommendations for the replacement of parts and fluids, and follow the manufacturer’s recommended maintenance schedule . Engine specifications should be found in the Operation and Maintenance manual for the engine. -
Page 42: Lubrication
The Lubrication Chart is a general guide for “relubrication”. Certain conditions may require a change of lubrication periods as dictated by experience. A heavy-duty, general-purpose, lithium-based grease is recommended for lubricating the GRINDMASTER 512. LUBRICATION CHART LUBRICATION POINTS... - Page 43 GENERAL MAINTENANCE CHART ITEM/FUNCTION ACTION INTERVAL ENGINE Engine oil level. Add new oil as required (see specs). Check Daily Engine for rough operation or unusual noise. Check Daily Engine compartment for oil, water, or other fluid leaks. Inspect Daily Condition and tension of all drive belts. Inspect Daily Exhaust pipes, clamps and hardware for security.
- Page 44 figure 5.1 lubrication points shear bar conveyor conveyor G R I N D M A S T E R 5 1 2 O P E R A T I N G I N S T R U C T I O N S...
- Page 45 figure 5.2 lubrication points quill coupling quill bearings motor G R I N D M A S T E R 5 1 2 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 46: Hydraulic System
Hydraulic system CAUTION: Lack of proper hydraulic oil level in the reservoir tank will cause system to heat under continuous running. Check the hydraulic oil level daily and replace as necessary. Both hydraulic oil filters should be changed after the first 10 hours of operation. -
Page 47: Axle, Wheels And Tires
Axle, wheels and tires TIRE PRESSURE Set the tire pressure according to the manufacturer’s specifications. The appropriate tire pressure can be found on the sidewall of the tire. WHEEL BEARINGS The wheels have tapered roller bearings in an oil bath. Each hub is equipped with a transparent oil cap which has an oil level indicator mark that allows for easy checking of the oil level. -
Page 48: 5.5 Brake Component Lubrication
5.5 Brake component lubrication A schedule for the periodic lubrication of brake components should be established by the operator on the basis of past experience and the severity of operating conditions. GUIDELINES • For camshaft roller journals: Lubricate with high temperature anti-seize grease. •... -
Page 49: Rotor Bearing Installation
Rotor bearing installation 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 50 Install the bearing parts in the following sequence. NOTE: There is only one way to correctly install the bearing. Refer to Figure 5.5 for illustration. 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 51 Remove any paint, dirt or burrs from the mating surfaces of the housing halves. Thoroughly clean the seal groves on both sides. Set the lower half of housing on the base with all four cap bolts in place, and apply oil to the bearing seats. Apply grease to the seal grooves in the lower housing. Be sure the housing is positioned as shown in Figure 5.5 view relative to adapter nut.
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Page 52: Rotor Bearing Maintenance
Rotor bearing maintenance WARNING: To insure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failure to observe these precautions could result in bodily injury. Remove the housing cap in order to inspect the bearing and lubricant. Before reassembly, it is important that the V-ring seals be removed. -
Page 53: Appendix A: Warranty
DuraTech Industries International Inc., reserves the right to make changes in material and/or designs of this product at any time without notice. This warranty is void if DuraTech Industries International Inc. does not receive a valid warranty registration card at its office in Jamestown, North Dakota, USA, within 10 days from date of original purchase. -
Page 54: Appendix B: Specifications
Appendix B: SPECIFICATIONS Gener Gener General al al al al Gener Gener Weight ...................... 52,000 lbs. Transport Length ..................46’ (552”) Transport Height ..................13’ (156”) Axle .................... (2)-22,500 lb. axles Tires ................(8)-225/70R R22.5 16 Ply Brakes ....................... Air brakes Fuel Capacity .................. -
Page 55: Grindmaster 512 Documentation Comment Form
GRINDMASTER 512 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? • Is the information clearly presented? •...
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