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Operation and Maintenance 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 Diamond Attachments®

Содержание 159010

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 47: ...ROCK GRINDER FULL ASSEMBLY...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...ROCK GRINDER BASE PLATE...

Страница 52: ...ROCK GRINDER...

Страница 53: ...ROCK GRINDER MOTOR ASSEMBLY...

Страница 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...

Страница 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...

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

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