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Blue Diamond 159010, Operation And Maintenance Manual

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Blue Diamond 159010 Operation And Maintenance Manual Download Page 54

ROCK GRINDER MO

TOR A

SSEMBL

Y

ITEM

PAR

T NUMBER

DESCRIPTION

QT

Y

1

259457

ROCK GRINDER MODEL G4 HYDRA

UIC MO

TOR CO

VER

1

2

259458

ROCK GRINDER MODEL G4 DIS

TRIBUT

OR BL

OCK

1

3

259460

ROCK GRINDER MODEL G4 C

AMRING

1

4

259461

ROCK GRINDER MODEL G4 PIS

TON BL

OCK

1

5

259462

ROCK GRINDER MODEL G4 O-RING

1

6

259437

ROCK GRINDER MODEL G4 O-RING

1

7

259464

ROCK GRINDER MODEL G4 HEX HEAD BOL

T

8

8

259465

ROCK GRINDER MODEL G4 C

YL. BOL

T

16

Summary of Contents for 159010

Page 1: ...ntenance Manual ROCK CONCRETE GRINDER Register your WARRANTY within 30 days of purchase 888 376 7027 BlueDiamondAttachments com 159010 G1S 159015 G1 159020 G2 159025 G3 159030 G3XL 159035 G4 Blue Diam...

Page 2: ...Diamond makes no warranty or guarantee of any kind written or expressed implied or otherwise with regard to the information contained within this manual Blue Diamond assumes no responsibility for any...

Page 3: ...4 2 Mounting 4 2 1 Quick Coupler 4 3 Hydraulic Installation 4 3 1 Case Drain Line 4 4 Initial Startup 4 4 1 Checks during initial operation 4 5 Remove Ginder 5 OPERATION 5 1 Lifting Eye 5 2 Emergency...

Page 4: ...nap Type 6 6 Replace Cutter Heads 6 6 1 Remove Cutter Heads 6 6 2 Install Cutter Heads 6 7 Pedestal If Equipped 6 7 1 Disassemble Pedestal 6 7 2 Assemble Pedestal 6 8 Replace Hydraulic Hoses 6 9 Remov...

Page 5: ...UTION are used to call attention to safety information that if not followed will or could result in death or injury NOTICE and NOTE are used to call your attention to important information The definit...

Page 6: ...wires tree limbs etc when operating equipment Be aware of clearances during turns and when moving equipment 6 Reinstall all covers removed for maintenance activities Covers are required during operati...

Page 7: ...g strikes during thunder storms can cause death or serious injury Do not operate machine during thunderstorms Do not work on machine or stay in hydraulic excavator during thunder storms Do not remain...

Page 8: ...ing operation Do not open covers on rock and concrete cutter during operation Wear close fitting clothes with minimal tear strength when working in hazardous area Cutter heads become very hot during o...

Page 9: ...taining to industrial safety 2 In addition to the safety instructions contained in this manual follow all required safety accident prevention and environmental regulations 3 Know applicable industrial...

Page 10: ...E EQUIPMENT Personal Protective Equipment PPE protects personnel against dangers which may affect their health or safety during work Follow instructions PPE posted in the work area Protective Work Clo...

Page 11: ...e dirty or illegible from wear or other causes Keep all safety maintenance and operating instructions highly legible at all times Replace damaged labels and signs immediately Location of grinder decal...

Page 12: ...s Manual 5 CHECK HYDRAULIC HOSES to and from the excavator and grinder for any damage before startup of the grinder 6 AT ALL TIMES when cutting or trenching make certain no cutting material can enter...

Page 13: ...ton 1 3 2 8 5 15 12 20 AMBIENT TEMPERATURE RANGE MAXIMUM TIME OF OPERATION 13 to 122 F 25 to 50 C 24 Hours Continuous MODEL GPM L m GS1 1 GS1 2 G1 2 G1 3 5 8 6 12 10 18 5 13 21 19 30 22 45 40 70 50 80...

Page 14: ...m G1 4 G2 2 G2 3 G2 4 G3 1 G3 2 16 24 13 24 16 26 18 26 32 45 34 45 60 90 50 90 60 100 70 100 120 170 130 170 G3XL 1 G3XL 2 G3XL 3 45 58 40 53 32 48 170 220 150 200 120 180 G4 1 G4 2 G4 3 66 85 64 85...

Page 15: ...ROCK NOTE Contact Blue Diamond before cutting reinforced concrete MODEL MODEL HP PSI Kw MPa G1S G1 G2 G3 G1S G1 G2 G3 24 40 60 90 5 076 5 800 7 300 9 400 20 30 45 65 35 40 50 65 G3XL 120 90 G3XL 11 6...

Page 16: ...16 3 7 OVERVIEW 4 INSTALLATION AND STARTUP Grinder Main Components Blue Diamond Attachments 16...

Page 17: ...flying debris 6 Excavator must provide adequate view of work area 7 Minimum 14 Lumens sq ft 150 Lux protected lighting 8 E Stop functional at operating and driving positions highly recommended 9 Audi...

Page 18: ...ve mandrels 10 Install remaining bolts 11 Tighten all bolts in an alternate horizontal pattern Note Refer to Torque Tables in back of this manual 4 3 HYDRAULIC INSTALLATION Incorrect installation of h...

Page 19: ...e excavator arm 6 Remove end cap from ball valve of excavator arm Removing check valve from return line of hydraulic hammer systems will cause catastrophic grinder hydraulic motor failure Never remove...

Page 20: ...ic flow and pressure settings on the excavator are the responsibility of the operator 1 Check all fastenings hoses and couplings 2 Check the hydraulic oil level and shut off valves 3 Check all hydraul...

Page 21: ...Do not overload cutter bits Machine can be damaged Cutting conditions are best if cutting heads move toward the carrier vehicle If unit moves sideways to achieve a larger cutting area ensure pressure...

Page 22: ...int completely intact Deformation at load bearing components such as base body Mechanical damage like strong notches especially in areas where tensile stress occurs Reduction of cross section due to w...

Page 23: ...devices are installed and functional 5 3 BEFORE USE Always perform the following before using the grinder to prolong service life and maintain productivity 5 3 1 BITS Unevenly worn bits can cause exce...

Page 24: ...ctivate grinder when loading excavator When working with grinder never fully extend or retract the jib lifting cylinder Only switch on grinder in a raised position without contacting cutting material...

Page 25: ...tting material When cutting proceed as follows 1 Raise grinder 2 Switch on grinder and start up 3 Slowly lower the rotating cutting heads onto the cutting material 4 Slowly apply cutting heads and ens...

Page 26: ...ace damaged or worn parts immediately Tighten all loose connections Eliminate oil leaks immediately Replace worn or damaged hydraulic hoses 5 4 5 Cleaning Improper cleaning procedures can cause seriou...

Page 27: ...ng with the grinder it may be necessary to mount it at an angle on the hydraulic excavator 1 Ensure grinder head is connected to hydraulic excavator in accordance with speciff ications 2 Position grin...

Page 28: ...safety of the rock and concrete cutter Routine maintenance will prevent unplanned down time and help serve to aid safe work with the grinder NOTE If regular checks reveal a rapid wear rate increase fr...

Page 29: ...nergol GR XP 68 Spirax 80 EP Omala Oil 100 GPD 80 Spartan EP 100 Meropa 68 Universal Gear Lubricant EP 80 EP 90 Degol BG 68 Mobil Gear GX 90 Mobilube GX 90 EP SAE 90 Energol GR XP 220 Spirax 90 EP Oma...

Page 30: ...and equipment Always check clearances before lifting or moving grinder Removing oil fill or drain plug without relieving gear case pressure can cause severe injuries Depressurize entire hydraulic sys...

Page 31: ...specifications 13 Clean oil filler opening and fill plug 14 Reinstall oil fill plug 15 Clean grinder 16 Dispose of used oil in accordance with the applicable environmental regulations 6 5 Replace Bit...

Page 32: ...ct brochures for more detailed safety information Follow approved safety procedures Wear all approved personal protective equipment To avoid personal injury or damage to tools tines and blades please...

Page 33: ...aterials according to local state and or federal regulations 6 5 5 Standard Retaining Clip Type 1 Place tool against open side of retaining clip 2 Strike the flat end of the tool firmly to dislodge cl...

Page 34: ...ps and ensure both are fully seated in groove 6 5 7 Quick Snap Ring Type 1 Place curved tip of draw hook in quick snap ring hole 2 Grip draw arrow firmly and pull upwards 3 Remove bit from block 4 Cle...

Page 35: ...1 Lay grinder with disassembled cutter heads on side using an appropriately weight rated lifting device 2 Lift cutter head using suitable weight rated lifting equipment 3 Carefully set cutter head on...

Page 36: ...nce when not in use 1 Clean area around hydraulic hose connections 2 Loosen threaded connections on hydraulic hose fittings 3 Loosen hose fitting on hydraulic excavator 4 Remove hydraulic hose and ins...

Page 37: ...ntain order and cleanliness at work site Poorly stacked or scattered parts and tools can cause accidents Before restart Make sure all removed parts are correctly reinstalled and fasteners are torqued...

Page 38: ...achine down Relieve hydraulic pressure and lock out controls Remove trapped material Run cutter briefly in reverse Disassemble cutter heads Check operating pressure and adjust to recommended value Inc...

Page 39: ...shutoff valve closed Coupling not properly seated Corrosion or debris between bit shaft and block Air in hydraulic circuit or motor Low return line pressure Internal parts worn from foreign material L...

Page 40: ...re installation Dispose of packaging materials in accordance with legal requirements and local regulations 8 3 Transport Falling or swinging equipment can cause death serious injury and or damage to p...

Page 41: ...opposite side 3 Ensure assembly stand cannot tip with an eccentric center of gravity 4 Lift assembly stand with grinder attached and start transport 8 4 Storage Always store the grinder on the assembl...

Page 42: ...reserve cutter heads with oil 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...

Page 43: ...EF DWG NO 3rd ANGLE PROJECTION REV SHEET SIZE Chris Spade 7 9 2019 1 9 N A HYDRAULIC INSTALLATION 1 HYDRAULIC EQUIPMENT LP LINE W CHECK VALVE DIRECT TO TANK HYDRAULIC INSTALLATION 1 1 of 1 A0 MATERIAL...

Page 44: ...ANISM PART NAME DRAWING NUMBER REF DWG NO 3rd ANGLE PROJECTION REV SHEET SIZE Chris Spade 7 9 2019 1 9 N A HYDRAULIC INSTALLATION 2 HYDRAULIC EQUIPMENT LP LINE THROUGH VALVE BLOCK INTO THE TANK REFERE...

Page 45: ...45 Torque Table 1 of 2 Blue Diamond Attachments 45...

Page 46: ...Torque Table 2 of 2 Blue Diamond Attachments 46...

Page 47: ...ROCK GRINDER FULL ASSEMBLY...

Page 48: ...GRINDER MODEL G4 SLIDING RING SEAL 2 8 259407 ROCK GRINDER MODEL G4 SEALING LID 2 9 259408 ROCK GRINDER MODEL G4 O RING 2 10 259409 ROCK GRINDER MODEL G4 USIT RING 24 11 259410 ROCK GRINDER MODEL G4...

Page 49: ...DEL G4 ROLLER BEARING 1 26 259425 ROCK GRINDER MODEL G4 MOTOR FLANGE 1 27 259426 ROCK GRINDER MODEL G4 TURCON ROTO GLYD 1 28 259427 ROCK GRINDER MODEL G4 O RING 1 29 259428 ROCK GRINDER MODEL G4 SOCKE...

Page 50: ...1 46 259444 ROCK GRINDER MODEL G4 ADAPTER PLATE 1 47 259445 ROCK GRINDER MODEL G4 FASTENING PLATE 1 48 259446 ROCK GRINDER MODEL G4 SOCKET HEAD CAP SCREW 4 49 259447 ROCK GRINDER MODEL G4 HEX HEAD CAP...

Page 51: ...ROCK GRINDER BASE PLATE...

Page 52: ...ROCK GRINDER...

Page 53: ...ROCK GRINDER MOTOR ASSEMBLY...

Page 54: ...R 1 2 259458 ROCK GRINDER MODEL G4 DISTRIBUTOR BLOCK 1 3 259460 ROCK GRINDER MODEL G4 CAMRING 1 4 259461 ROCK GRINDER MODEL G4 PISTON BLOCK 1 5 259462 ROCK GRINDER MODEL G4 O RING 1 6 259437 ROCK GRIN...

Page 55: ...ated capacity WARRANTY CLAIM To submit a warranty claim a return authorization from BLUE DIAMOND ATTACHMENTS must be obtained The failed part may then be returned Tampering with the failed part may vo...

Page 56: ...QUALITY DEPENDABILITY INTEGRITY Blue Diamond Attachments 4512 Anderson Road Knoxville TN 37918 88 376 7027 Blue Diamond Attachments 56...

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