Duratech HD-9 User manual

P. O . B OX 1940, JAMESTOWN, ND 58402-1940
NOVEMBER 2002 0500095
TM
HD-9
Industrial Tub Grinder
Serial Number JJ0101 and Up
Manual 1:
Operating Instructions

Clearing the Way for a Better Tomorrow

DuraTech Industries International Inc. (DuraTech Industries) has made every effort to assure that
this manual completely and accurately describes the operation and maintenance of the HD-9™
Industrial Tub Grinder as of the date of publication. DuraTech Industries 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.
This manual, as well as materials provided by component suppliers to DuraTech Industries are all
considered to be part of the information package. Every operator is required to read and understand
these manuals, and they should be located within easy access for periodic review.
is a registered trademark of Duratech Industries International, Inc.
HD-9 is a trademark of Duratech Industries International, Inc.
TM
HD-9
Industrial Tub Grinder
Serial Number JJ0101 and Up
Manual 1:
Operating Instructions

Clearing the Way for a Better Tomorrow

iHD-9 OPERATING INSTRUCTIONS
FOREWORD
Foreword
All personnel must read and understand before operating unit
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.
Even in the event of such updates, you should still find this manual to be appropriate
for the safe operation and maintenance of your machine.
This manual, as well as materials provided by component suppliers to DuraTech
Industries are all considered to be part of the information package. Every operator
is required to read and understand these manuals All manuals should be located
within easy access for troubleshooting and periodic review.
Appropriate use of the unit
This Industrial Grinder is designed to grind wood waste and other materials,
including grass clippings, leaves, construction and demolition debris, tree branches
and tree trunks It is NOT designed to grind rocks, steel, concrete, or the like.
Operator protection
As with all machinery, care needs to be taken by the operator in order to insure the
safety of the operator and those in the surrounding area.
WARNING: Operators and those observing the operation of the Industrial
Grinder are required to wear head, eye, and ear protection. No loose clothing is
allowed.

ii HD-9 OPERATING INSTRUCTIONS
TABLE OF CONTENTS
HD-9 Manual 1: Operators Instructions ............................ 1
Purpose ....................................................................................... 2
Section 1: Safety ....................................................................... 2
1.1 Safety-alert symbols .......................................................................................... 3
1.2 Operator - personal equipment.......................................................................... 5
1.3 Machine safety labels ....................................................................................... 6
1.4 Shielding ........................................................................................................... 8
1.5 Industrial Grinder safety review ........................................................................ 8
1.6 Thrown objects and operator safety ................................................................. 9
1.7 Service and maintenance ................................................................................ 11
1.8 Important safety reminders ............................................................................. 11
1.9 Towing ............................................................................................................. 12
1.10 Fire Prevention .............................................................................................. 12
1.11 Fire Extinguishers .......................................................................................... 13
Section 2: Introduction ........................................................... 15
2.1 Description of the DuraTech Industrial Tub Grinder....................................... 15
2.2 Electronic governor ......................................................................................... 16
2.3 Rotor clutch ..................................................................................................... 16
2.4 Torque limiter .................................................................................................. 16
2.5 Rotor ............................................................................................................... 17
2.6 Screens............................................................................................................ 17
2.7 Tub .................................................................................................................. 17
2.8 Tub cover (optional) ........................................................................................ 18
2.9 The conveyor system ...................................................................................... 18
2.10 Magnetic roller (optional) .............................................................................. 18
2.11 Mill grate (optional) ....................................................................................... 18
2.12 Hydraulic cooler ............................................................................................ 18
2.13 Overview of the HD-9 operator controls ...................................................... 19
2.13.1 Control Panel .............................................................................................. 19
2.13.2 Other operator controls .............................................................................. 20

iiiHD-9 OPERATING INSTRUCTIONS
TABLE OF CONTENTS
Section 3: Operation ............................................................... 21
3.1 Pre-operation inspection .................................................................................. 21
3.2 Starting the Industrial Tub Grinder .................................................................. 22
3.3 If the engine fails to start ................................................................................ 23
3.4 Throttle operation ............................................................................................ 23
3.5 Automatic engine shutdown system ................................................................ 23
3.6 Normal shutdown procedure ........................................................................... 24
3.7 Emergency shutdown procedure ..................................................................... 25
3.8 Murphy System Operation for serial numbers JJ0101-JJ0142, JJ0145, JJO148,
& JJO150 ............................................................................................................... 26
3.9 Parts of the electronic governor ...................................................................... 27
3.10 Operation of the electronic governor ............................................................ 28
3.11 Calibration of the electronic governor ........................................................... 29
3.12 Tub rotation controls ...................................................................................... 29
3.13 Raising the tub ............................................................................................... 30
3.14 Lowering the tub ........................................................................................... 31
3.15 Starting and stopping the belly and discharge conveyors .............................. 31
3.16 Raising the discharge conveyor ..................................................................... 31
3.17 Operating the grinder using the remote radio option ..................................... 32
3.18 Grinding ......................................................................................................... 34
3.19 Loading the tub .............................................................................................. 34
3.19A Grinding with tub cover .............................................................................. 35
3.20 If lodging occurs while grinding ..................................................................... 35
3.21 Grinding wet material .................................................................................... 35
3.22 Preparing the HD-9 for transport .................................................................. 35
3.23 Preparing the HD-9 for operation after transport ......................................... 36
3.24 Preparing the HD-9 for storage .................................................................... 37
3.25 Removing the HD-9 from storage ................................................................ 37
3.26 Installing a screen .......................................................................................... 38
3.27 Adjusting the conveyor belt tension ............................................................... 39
3.28 Adjusting the conveyor belt tracking ............................................................. 40
3.29 Sizing the tub drive chain ............................................................................... 41
3.30 Adjusting tub chain tension ............................................................................ 41
3.31 Checking for wear on the friction disc torque limiter .................................... 42
3.32 Engaging and adjusting the rotor clutch ......................................................... 43

iv HD-9 OPERATING INSTRUCTIONS
TABLE OF CONTENTS
3.33 Electro-hydraulic valve coil test .................................................................... 44
3.34 Electro-hydraulic valve calibration ................................................................ 45
Section 4: Engine Maintenance ............................................... 45
Section 5: General Maintenance ............................................. 46
5.1 Welding Procedure .......................................................................................... 46
5.2 Batteries .......................................................................................................... 48
5.3 Lubrication ...................................................................................................... 48
5.4 Pressure roller lubrication ............................................................................... 54
5.5 Brake component lubrication ........................................................................... 55
5.6 Hydraulic system............................................................................................. 57
5.7 Axle, wheels and tires ..................................................................................... 57
5.8 Hammermill maintenance ............................................................................... 58
5.9 Fixed hammer maintenance and replacement ................................................. 59
5.10 Swinging hammer replacement and maintenance ......................................... 60
Section 6: Troubleshooting the HD-9 ..................................... 63
6.1 Troubleshooting the electronic governor system ............................................. 63
6.2 General Troubleshooting .................................................................................. 67
6.3 Troubleshooting Microtronics wireless remote controls .................................. 68
6.4 Troubleshooting Omnex Wireless Remote Controls ........................................ 72
Appendix A: Warranty .............................................................. 75
Appendix B: SPECIFICATIONS ................................................ 76
Appendix C: Operator Training Form ...................................... 78
HD-9 Documentation Comment Form ..................................... 79

1HD-9 OPERATING INSTRUCTIONS 1
TM
HD-9
Industrial Tub Grinder
Serial Number JJ0101 and Up
Manual 1:
Operating Instructions

2HD-9 OPERATING INSTRUCTIONS
Introduction
This Industrial Grinder is designed to grind wood waste and other materials, including grass clippings, leaves,
construction and demolition debris, tree branches and tree trunks It is NOT designed to grind rocks, steel, concrete, or
the like.
Purpose
The purpose of this owner’s manual is to explain maintenance requirements and routine adjustments for the most
efficient operation of your HD-9. 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.
SPECIAL NOTE: When reference is made as to front, rear, left hand, or right hand of this
machine, the reference is always made from standing at the rear end of the machine and
looking toward the hitch. Always use serial number and model number when referring to
parts or problems. Please obtain your serial number and write it below for your future
reference.
MODEL: HD-9 SERIAL NO. ________________________
Section 1: Safety
Thank you for taking the time to read the operation and maintenance manual for the DuraTech Industries HD-9.
Because your safety and that of others is of the utmost importance, you should familiarize yourself with this entire
manual before operating this unit. The safety of the operator is of great importance to DuraTech Industries. We have
provided decals, shield and other safety features to aid you in using your machine safely. In addition, we ask you to be
a careful operator who will properly use and service your DuraTech Industries equipment.
The HD-9 incorporates a number of third party products. For example, the engine, and hydraulic pumps are third party
products. More information about the operation and care of these products can be found in each product’s respective
manual(s). Before operating this unit, you should familiarize yourself with these manuals as well.
Safety is an ongoing job experience, and DuraTech Industries has made every effort to make sure that the HD-
9provides operator comfort and security. DuraTech Industries encourages you to bring to our attention as quickly as
possible any suggestions you may have concerning the safety of the equipment. DuraTech Industries is dedicated to
enhancing the safety of the HD-9.

3
HD-9 OPERATING INSTRUCTIONS
WARNING: FAILURE TO COMPLY WITH SAFETY INSTRUCTIONS THAT FOLLOW
WITHIN THIS MANUAL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
BEFORE ATTEMPTING TO OPERATE THIS MACHINE, CAREFULLY READ ALL
INSTRUCTIONS CONTAINED WITHIN THIS MANUAL.
THIS MACHINE IS NOT TO BE USED FOR ANY PURPOSE OTHER THAN THOSE
EXPLAINED IN THE OPERATOR’S MANUAL, ADVERTISING LITERATURE OR OTHER
DURATECH WRITTEN MATERIAL PERTAINING TO THE HD-9.
1.1 Safety-alert symbols
Decals are illustrated in Part 2: Parts Reference.
The safety decals located on your machine contain important and useful information that will help you operate your
equipment safely.
To assure that all decals remain in place and in good condition, follow the instructions below:
• Keep decals clean. Use soap and water - not mineral spirits, adhesive cleaners and other similar cleaners
that will damage the decal.
• Replace all damaged or missing decals. When attaching decals, surface temperature of the machine must
be at least 40° F (5° C). The surface must be also be clean and dry.
• 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 Industries dealer.
This unit is supplied with an operation and maintenance manual and this manual should be kept with the unit for
periodic review by operational personnel.
Operators of the HD-9 are required to wear head, eye, and ear protection as well as clothing appropriate for the
application. Individuals with loose clothing, unrestrained long hair, jewelry, or other accessories which may hang
loosely away from the body should not be allowed on or near the machine.

4HD-9 OPERATING INSTRUCTIONS
DuraTech uses industry accepted ANSI standards in labeling its products for safety and operational characteristics.
DANGER: Indicates an imminently
hazardous situation that, if not avoided, will
result in death or serious injury. This signal
word is to be limited to the most extreme
situations, typically for machine components
that, for functional purposes, cannot be
guarded.
WARNING: Indicates a potentially
hazardous situation that, if not avoided, could
result in death or serious injury, and includes
hazards that are exposed when guards are
removed. It may also be used to alert against
unsafe practices.
CAUTION: Indicates a potentially hazardous
situation that, if not avoided, may result in
minor or moderate injury. It may also be used
to alert against unsafe practices.
SafSaf
SafSaf
Safety-Alerety-Aler
ety-Alerety-Aler
ety-Alert Symbolt Symbol
t Symbolt Symbol
t Symbol
Read and recognize safety information. Be alert to
the potential for personal injury when you see this
safety-alert symbol.
DANGER
INFORMATION
CAUTION
WARNING
This manual uses the symbols to the right to denote
important safety instructions and information.
The DANGER, WARNING and CAUTION symbols are
used to denote conditions as stated in the text above.
Furthermore, the text dealing with these situations is
surrounded by a box with a white background, will begin
with DANGER, WARNING, or CAUTION.
The INFORMATION symbol is used to denote important
information or notes in regards to maintenance and use of
the machine. The text for this information is surrounded
by a box with a light grey background, and twill begin
with either IMPORTANT or NOTE.

5
HD-9 OPERATING INSTRUCTIONS
1.2 Operator - personal equipment
THE OPERATOR
Physical Condition
You must be in good physical condition and mental health and not under the influence of any substance (drugs, alcohol)
which might impair vision, dexterity or judgment.
Do not operate a HD-9 when you are fatigued. Be alert - If you get tired while operating your HD-9, take a break.
Fatigue may result in loss of control. Working with any industrial equipment can be strenuous. If you have any
condition that might be aggravated by strenuous work, check with your doctor before operating
Proper Clothing
Clothing must be sturdy and snug-fitting, but allow complete freedom of movement.
Avoid loosefitting jackets, scarfs, neckties, jewelry, flared or cuffed pants, unconfined
long hair or anything that could become entangled with the machine.
Protect your hands with gloves when handling flail and sections. Heavyduty, nonslip
gloves improve your grip and protect your hands.
Good footing is most important. Wear sturdy boots with nonslip soles. Steel-toed safety
boots are recommended.
To reduce the risk of injury to your eyes never operate a HD-9 unless wearing goggles or
properly fitted safety glasses with adequate top and side protection.
Engine noise may damage your hearing. Always wear sound barriers (ear plugs or ear
mufflers) to protect your hearing. Continual and regular users should have their hearing
checked regularly.

6HD-9 OPERATING INSTRUCTIONS
1.3 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. Keep unauthorized personnel out of the grinding
area!
WARNING: FOR YOUR PROTECTION AND SAFETY OF
OTHERS, FOLLOW THESE SAFETY RULES.
1. Read and understand operators manual before
operating machine.
2. Place all controls in neutral, stop engine, remove
ignition key, lock out power source, and wait for all
motion to stop before servicing, adjusting, repairing,
or unplugging.
3. Read and understand all decals on machine for your
safety.
4. Keep all shields in place while machine is in
operation.
5. Keep hands, feet, hair, and clothing away from
moving parts.
6. Keep others away from machine while in operation.
7. Install safety locks before transporting, or working
beneath components.
8. Do not allow riders at any time.
9. Do not leave machine unattended with engine
running.
10. Keep all hydraulic lines, couplings, and fittings free of
leaks during operation.
11. Keep away from overhead electrical lines.
Electrocution can occur without direct contact.
12. Review safety instructions periodically.
6500118
6500208

7
HD-9 OPERATING INSTRUCTIONS
DANGER: ROTATING PART HAZARD STAY OUT OF
TUB WHEN ENGINE IS RUNNING
1. Keep others away.
2. Place all controls in neutral, stop engine, remove key,
and wait for all moving parts to stop before servicing,
adjusting, repairing, unplugging, or entering the tub
for any reason.
3. Disconnect driveline on PTO driven models.
WARNING: OVERHEAD CONVEYOR HAZARD
To prevent serious injury or death:
Do not walk under conveyor at any time.
Stay clear of conveyor during operation, raising, and
lowering.
Lower conveyor fully before servicing.
Keep others away.
DANGER: ELECTROCUTION HAZARD
To prevent serious injury or death from electrocution.
Stay away from power lines when operating boom loader,
folding and raising conveyor, and transporting on roads.
This machine is not grounded, electrocution may occur
without direct contact.
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.
6500212
6500214
6500216
6500220

8HD-9 OPERATING INSTRUCTIONS
1.4 Shielding
The HD-9 is equipped with shielding. All Shields should be kept in place during operation. Bodily injury may occur if
the unit is operated without shields.
WARNING: Shields are installed for your protection and to keep material off machine parts. Do not
operate this Industrial Tub Grinder without shields in place and in operating condition.
1.5 Industrial Grinder safety review
WARNING: Before attempting to operate your Industrial Grinder, carefully read and follow
instructions given below and contained elsewhere in this manual.
Each and every aspect of the DuraTech Industries Tub Grinder should be reviewed by each operator on a frequent basis.
Safety systems are in place that result in direct operator security.
• Keep all foreign objects including rocks, pieces of metal and other incompressibles out of the tub and
away from the rotor. A thrown foreign object may cause injury or damage to the machine. A foreign
object is any object which the unit is not designed to grind.
• Allow only responsible, properly instructed individuals to operate machines. Carefully supervise
inexperienced operators.
•Never operate the unit without all safety features, including shields, in place and in operating
condition.
• Make no modifications to this equipment unless specifically requested or recommended by DuraTech
Industries.
• Tighten or replace any loose or cracked bolts, chains, hoses or connections.
• Check overhead for electrical power lines or other obstructions and be certain there is adequate clearance.
• Allow no one on the tub grinder at any time during operation.
• Unauthorized personnel should stay out of the grinding area.
• Always perform the pre-operation inspection before operating this machine.
• Ensure rotor is at a complete stop and engine is shut down before any performing any maintenance.
•Never grab rope, cable, twine or similar material hanging out of tub while the tub grinder is
running.

9
HD-9 OPERATING INSTRUCTIONS
WARNING: Loose clothing, necklaces and similar items are easily caught in moving parts. Avoid
the use of these items if possible. Keep long hair confined. Keep hands, feet and clothing away
from power driven parts.
An operational characteristic of all grinders is that objects may be thrown out of the hopper. Thrown objects may
present a safety hazard to persons in the area. This section is to inform the operator of this characteristic, and what can
be done to reduce the risk of injury to the operator and persons in the area. Keep all observers away from the machine.
Figure 1.1 shows an object being hit as the hammer is on the upswing. A general pattern for where thrown objects may
land is shown in Figure 1.2. Note the difference in the size of the area for side A versus side B. Side B is larger.
Dimensioning the size of this area is not practical. The distance a thrown object may travel is dependent on several
conditions, including, but not limited to, rotor speed and diameter, condition of the hammers, style of hammers, object
mass, object shape, amount of material in the tub, and how the hammer strikes the object.
The amount of material in the tub can dampen or stop the object’s potential flight. Keeping the tub full will reduce the
risks. Filling the tub at least 1/2 full when starting will reduce the risk. Using a geyser plate can help reduce thrown
objects. A risk may arise when the tub is being emptied, such as at the end of the grind. Running the engine at slower
speeds when starting or finishing the grind will also help, especially slowing down when emptying the tub. 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.
figure 1.1
an object being hit as the
hammer is on the upswing
1.6 Thrown objects and operator safety

10 HD-9 OPERATING INSTRUCTIONS
WARNING: To minimize the potential risk of injury or property damage, the operator must:
a) Place side B towards open areas, away from property and people.
b) Load the grinder from side A with a loader equipped with an enclosed
cab.
c) Keep observers out of the area.
d) Wear a hard hat and safety glasses, at a minimum, and require that any
other persons in the area are similarly equipped.
e) If the optional tub cover is installed on the machine, the operator should
keep the Tub Cover over the tub as much as possible while grinding.
While grinding, the Tub Cover should be raised only when adding
material to the tub, and then the Tub Cover should only be raised enough
to allow the new materials to be placed in the tub.
figure 1.2
a general dispersal pattern for
thrown objects (not to scale)

11
HD-9 OPERATING INSTRUCTIONS
1.7 Service and maintenance
CAUTION: The stored up energy in the rotor causes it to rotate after the drive has been disengaged.
Before performing any maintenance on the machine or getting into the hopper, be sure rotor and all
moving parts have come to a complete stop. Shut off engine, remove the key and tag the machine out
for maintenance.
Before working on or near the HD-9 for any reason such as servicing, inspecting or unclogging the machine:
• Follow the normal shutdown procedure found in this manual.
• If the unit is still attached to a towing vehicle, place the towing vehicle’s transmission in park and set the
parking/emergency brake.
• Relieve all pressure in the hydraulic system before disconnecting hydraulic lines or performing work on
the system. Make sure all connections are tight and the hoses and lines are in good condition before
applying pressure to the system.
WARNING: Hydraulic fluid escaping under pressure can be invisible and have enough force to
penetrate the skin. When searching for a suspected leak, use a piece of wood or a cardboard rather
than your hands. If injured, seek medical attention immediately to prevent serious infection or
reaction.
When replacing any part on your HD-9, be sure to use only DuraTech Industries authorized parts.
1.8 Important safety reminders
Always follow basic safety precautions when using this unit to reduce the risk of injury.
NEVER perform maintenance in the hopper, 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. Flying debris can injure inattentive personnel.
NEVER climb on, crawl under, or enter the hopper when the engine is running or the machine is in
operation.
NEVER leave the vicinity of the unit with the engine running or with the tub turning.

12 HD-9 OPERATING INSTRUCTIONS
1.9 Towing
Check all lights, brakes and hitch connections before towing. Check your state laws regarding the use of lights, safety
chains, moving wide loads on public roads, and other possible requirements.
Use caution when traveling on public roads, rough or winding roads, or steep terrain.
WARNING: FAILURE TO COMPLY WITH ANY OF THE PRECEDING SAFETY
INSTRUCTIONS OR THOSE THAT FOLLOW WITHIN THIS MANUAL MAY RESULT IN
SEVERE INJURY OR DEATH.
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.
1.10 FirFir
FirFir
Fire Pre Pr
e Pre Pr
e Pree
ee
evv
vv
ventionention
entionention
ention
Grinding wood, hay, and other products in a tub grinder produces a large amount of potentially combustible material.
The risks of fire can be significantly reduced with proper operating and maintenance procedures. This does include
frequent removal of dust, debris, and other combustible materials.
Most of the products that are ground are dry and the grinding process can produce fine, dusty material. The grinding
process can produce heat and the spinning rotor will circulate air within the grinding chamber. For a fire to start, fuel,
oxygen and heat in sufficient quantity, must be present. During normal operation and with a properly maintained tub
grinder, the material being ground will move through the grinding chamber so quickly that it doesn’t have a chance to
heat up sufficiently to start a fire. Also, the rapid rate that a tub grinder can pile material will quickly smother small hot
spots that might occur during normal grinding operations. Keeping the material moving through the machine and across
the top of the rotor is important to keep frictional heating of the material to a minimum.
NEVER : leave the vicinity of the unit with the engine running
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. Be especially cautious when grinding materials that
can burn easily.
• When filling the tub grinder during start-up begin by filling the rear of the tub and avoid placing materials
on the spinning rotor. When material begins to fall over the rotor, set the governor control on “Manual”
and rotate the tub slowly while continuing to fill the tub. Use the tub cover to control thrown objects as
much as possible. When the tub is 1/2 to 2/3 full, the governor control can be set to “auto” and grinding
operations can resume normally. Do not allow the tub to stop for any significant amount of time with
material over the rotor to minimize frictional heating.
• Do not smoke when working with combustible materials.