Duratech GRINDMASTER 512 User manual

P. O . B OX 1940, JAMESTOWN, ND 58402-1940
MARCH 2001 0500080
TM
GRINDMASTER 512
Industrial Grinder
Manual 1:
Operating Instructions

Clearing the Way for a Better Tomorrow

TM
DuraTech Industries International Inc. (DuraTech) has made every effort to assure that
this manual completely and accurately describes the operation and maintenance of the
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.
This manual, as well as materials provided by component suppliers to DuraTech 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. GRINDMASTER 512 is a trademark of Duratech Industries International, Inc.
GRINDMASTER 512
Industrial Grinder
Manual 1:
Operating Instructions

Clearing the Way for a Better Tomorrow

i
512 GRINDMASTER OPERATING INSTRUCTIONS
FOREWORD
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.
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 512 GRINDMASTER OPERATING INSTRUCTIONS
TABLE OF CONTENTS
Manual 1: Operating Instructions .................................... 1
Introduction ................................................................................ 2
Purpose ....................................................................................... 2
Section 1: Safety ....................................................................... 3
1.1 Safety-alert symbols ........................................................................................ 4
1.2 Operator - personal equipment ........................................................................ 6
1.3 Machine safety labels ..................................................................................... 7
1.4 Shielding ........................................................................................................... 9
1.5 Industrial Grinder safety review ...................................................................... 9
1.6 Thrown objects and operator safety .............................................................. 10
1.7 Service and maintenance ............................................................................... 10
1.8 Personal protection equipment ...................................................................... 10
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 ...................................................................................................... 13
2.6 Screens .......................................................................................................... 14
2.7 Drive Belts .................................................................................................... 15
2.8 Conveyor ....................................................................................................... 15
2.9 Wheels and Tires ........................................................................................... 16
2.10 Fuel System ................................................................................................... 16
2.11 Engine Cooling System .................................................................................. 16
2.12 Hydraulic cooler ............................................................................................ 16
2.13 Starting System .............................................................................................. 17
2.14 Lights ............................................................................................................. 17
2.15 Overview of the 512 operator controls .......................................................... 17

iii
TABLE OF CONTENTS
512 GRINDMASTER OPERATING INSTRUCTIONS
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 .................................................................. 23
3.6 Grinding Materials ......................................................................................... 24
3.7 Clearing Jams ................................................................................................ 26
3.8 Belt Tracking ................................................................................................. 27
3.9 Conveyor ....................................................................................................... 30
3.10 Preparing the 512 for transport ..................................................................... 31
3.11 Preparing the 512 for operation after transport ............................................. 32
3.12 Preparing the 512 for storage ........................................................................ 32
3.13 Removing the 512 from storage .................................................................... 32
Section 4: Engine Maintenance ............................................... 33
Section 5: General Maintenance ............................................. 33
5.1 Batteries ........................................................................................................ 33
5.2 Lubrication ..................................................................................................... 34
5.3 Hydraulic system ........................................................................................... 38
5.4 Axle, wheels and tires ................................................................................... 39
5.5 Brake component lubrication ......................................................................... 40
5.6 Rotor bearing installation ............................................................................... 41
5.7 Rotor bearing maintenance ............................................................................ 44
5.8 Seal Replacement .......................................................................................... 44
Appendix A: Warranty .............................................................. 45
Appendix B: Specifications ..................................................... 46
GRINDMASTER 512 Documentation Comment Form ............ 47

iv 512 GRINDMASTER OPERATING INSTRUCTIONS
TABLE OF CONTENTS
Clearing the Way for a Better Tomorrow

1GRINDMASTER 512 OPERATING INSTRUCTIONS 1
GRINDMASTER 512
Manual 1:
Operating Instructions
TM

2GRINDMASTER 512 OPERATING INSTRUCTIONS
Introduction
Your model GRINDMASTER 512TM 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.
Purpose
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.
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: GRINDMASTER 512 SERIAL NO. ________________________
How to use the manual
Manual organization
This manual is organized into the following parts:
• Manual 1: Operating instructions explain how to set up, use and maintain the GRINDMASTER 512.
Dealer responsibilities
• Thoroughly review this section, "Dealer Responsibilities," and perform the tasks outlined. Also perform
a daily pre-operation inspection as described in Section 3, "Operation."
• Upon delivery of the unit to the customer, it is the dealer's responsibility to conduct a training session on
the safe operation of the unit for the primary operator(s). Dealer must also conduct a "walk-around"
inspection of all safety instructional decals on the machine itself.

3
GRINDMASTER 512 OPERATING INSTRUCTIONS
Section 1: Safety
Thank you for taking the time to read the operation and maintenance manual for the DuraTech GRINDMASTER 512.
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 512 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 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. DuraTech is dedicated to enhancing the safety of
the GRINDMASTER 512.
• When dealer is satisfied that the primary operators have read the operating instructions, and understand
all information concerning the safe operation of the unit, sign and return the User Training Verification
Form found in the GRINDMASTER 512 documentation packet. Note that this form requires both the
dealer's signature and the signatures of up to four primary operators.
• Complete and return the Delivery Notification Form found in the GRINDMASTER 512 documentation
packet. Receipt of this form is required to activate the warranty. Appendix A provides details of the
warranty.
Operator responsibilities
• The operator is responsible for his own safety.
• The operator is responsible for the safety of all others in the area.
• Review "Dealer Responsibilities," to verify that the machine has been prepared for use.
• Note the important safety information in the Foreword and in Section 1, "Safety."
• Thoroughly review sections 1 through 3 which explain normal operation of the machine, and section 5
which explain maintenance requirements. These sections will function as a textbook during the dealer-
conducted training course that is required before use of the unit.
• When all primary operators have read the operating instructions and understand all information
concerning the safe operation of the unit, the dealer will be required to sign the User Training Verification
Form found the 512 documentation packet. Note that 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.
• Manuals for certain third-party components are provided separately. The operator must also be familiar
with their contents.
• Keep copies of all manuals in a readily-accessible location for future reference.

4GRINDMASTER 512 OPERATING INSTRUCTIONS
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 512 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.
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 GRINDMASTER
512.
1.1 Safety-alert symbols
Decals are illustrated in Manual 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 dealer.

5
GRINDMASTER 512 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.

6GRINDMASTER 512 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 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. 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 loose-fitting 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 machinery. 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 GRINDMASTER 512 unless
wearing goggles or properly fitted safety glasses with adequate top and side protection.
Machine 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.

7
GRINDMASTER 512 OPERATING INSTRUCTIONS
6500118
6500208
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.

8GRINDMASTER 512 OPERATING INSTRUCTIONS
6500220
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.
CAUTION: KEEP WHEEL BOLTS TIGHT
6500220

9
GRINDMASTER 512 OPERATING INSTRUCTIONS
1.4 Shielding
The GRINDMASTER 512 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 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.
• Keep all foreign objects including rocks, pieces of metal and other incompressibles out of the hopper 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 Grindmaster 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.
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.

10 GRINDMASTER 512 OPERATING INSTRUCTIONS
1.6 Thrown objects and operator safety
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. Material may be thrown towards the front
of the GRINDMASTER 512. Keep all observers away from the machine, any personnel permitted on the machine
must be in the cab while the grinder is operating.
1.7 Service and maintenance
WARNING: 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 GRINDMASTER 512 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 GRINDMASTER 512, be sure to use only DuraTech authorized parts.
1.8 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.

11
GRINDMASTER 512 OPERATING INSTRUCTIONS
1.9 Fire safety
Locate adequate fire extinguishing equipment (fire extinguisher, fire hose, etc..) prior to start-up or operation of the
unit. At shutdown, always clean off the unit using high-pressure air or water. Remove all debris from around the
radiator, turbo charger, manifold, air intake, top of engine, and all moving parts.
1.10 Important safety reminders
WARNING: 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.
1.11 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.

12 GRINDMASTER 512 OPERATING INSTRUCTIONS
Section 2: Introduction
2.1 Description of the DuraTech GRINDMASTER 512
The GRINDMASTER 512 is a designed to grind
construction and demolition debris, asphalt, bricks, and
concrete blocks. It will also grind wood waste, green
waste, tree branches and trunks, compostables and mulch.
The unit incorporates a number of basic features including
the operator’s compartment, carrier and chassis, debris
hopper, rotor, water cooled diesel engine, hydraulic
system, discharge conveyor, and the axle and hitch
assemblies.
Material is fed into the hopper of the unit by appropriate
means, such as a wheel loader. As the push box moves the
material rearward, the material is exposed to the rotor. The
rotor then grinds up the material before the material is
discharged by the discharge conveyor.
2.2 Carrier and Chassis
The grinder is mounted to tandem axle trailer chassis with DOT approved brakes and lighting. The chassis is equipped
with a standard tow plate that will mount to any truck tractor 5th-wheel.
The Grindmaster chassis is equipped with manually operated trailer dolly support jacks.
2.3 Rotor
The rotor can be equipped with three types of bits: asphalt
bits, C&D bits, or wood bits, which shear material as it is
forced against the shear bar. Each bit is individually bolted
to a holder affixed to the drum face.
Bits may be individually replaced on an as needed basis,
or group replaced if desired.
The rotor drive train consists of 4 major components:
• 425 HP Diesel Engine
• Pump Drive Gearbox
• Hydrostatic Pump
• Rotor Drive Motor
discharge
conveyor in
the working
position
operator cab
drive belt
compartment
engine
cooling
system
hopper
rotor bit