manual r900 with mondial & cat 7.0

Impact Crusher R900 - ManualPage 0

Serial number:

CONTENT:

I P f Sid 2I. Preface Side 2II. Intended use Side 4III Safety Side 6 Safety hazard symbols Side 7Operating instructions Side 13p gMaintenance work Side 24IV.Technical data Side 26Overview Side 27Building groups Side 28V Start up Side 34V. Start up Side 34Operation devices Side 35Transport Side 41 System set up Side 43Gap adjustment Side 46

VI O ti Sid 48VI. Operation Side 48Special operating information Side 49Procedure crusher operation Side 51VII. Maintenance Side 53Hydraulic system Side 54 Di l t Sid 56Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59

CONTENTV-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67CONTENT

R900 IMPACT CRUSHER

Recommended oil qualities Side 67VIII. Standard forms Side 68Rockster warranty registration Side 69CAT warranty registration Side 70Warranty claim Side 71Terms and conditions Side 72

Page 1

Terms and conditions Side 72

CONTENT:

I P f Sid 2I. Preface Side 2II. Intended use Side 4III Safety Side 6 Safety hazard symbols Side 7Operating instructions Side 13p gMaintenance work Side 24IV.Technical data Side 26Overview Side 27Building groups Side 28V Start up Side 34V. Start up Side 34Operation devices Side 35Transport Side 41 System set up Side 43Gap adjustment Side 46

VI O ti Sid 48VI. Operation Side 48Special operating information Side 49Procedure crusher operation Side 51VII. Maintenance Side 53Hydraulic system Side 54 Di l t Sid 56Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59V-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67I PREFACE Recommended oil qualities Side 67VIII. Standard forms Side 68Rockster warranty registration Side 69CAT warranty registration Side 70Warranty claim Side 71Terms and conditions Side 72

I. PREFACER900 IMPACT CRUSHER

Page 2


I. PREFACE

PREFACE:

This Operator's Manual applies for the track-mounted crushing plants R900 manufactured by Kormann Rockster Recycler GmbH. The crushers are designed for the processing of virgin stone and recycling material.

The technical specifications, drawings, photos, and other information contained in this manual are non-binding and p , g , p , gmay be changed, revised or updated due to further technical developments at any time without obligation.

The machine owner/operator is responsible to supplement the information contained in this manual with any and all applicable local guidelines and regulations for safety prevention and environmental protection.

This Operator's Manual must be available and accessible at the operation site at all times.

All persons who operate, maintain, repair or transport the crusher plant must first read and understand this Operator's Manual and must conscientiously observe and follow the guidelines and regulations herein.

Manufacturer:Manufacturer:Kormann Rockster Recycler GmbHWirtschaftszeile West 2, 4284 Ennsdorf / AustriaPhone: +43 (0) 7223 81000 Fax: +43 (0) 7223 81000-329e-Mail: [email protected] Homepage: www.rockster.at

Page 3I. PREFACE

INHALTSVERZEICHNIS:CONTENT:

I P f Sid 2INHALTSVERZEICHNIS:

I. Vorwort Seite 2

II. Verwendungszweck Seite 4

I. Preface Side 2II. Intended use Side 4III Safety Side 6 Safety hazard symbols Side 7Operating instructions Side 13

III. Sicherheit Seite 6 Sicherheits/Gefahrensymbole Seite 7Betriebsanleitung Seite 13Wartungsarbeiten Seite 24

p gMaintenance work Side 24IV.Technical data Side 26Overview Side 27Building groups Side 28V Start up Side 34IV. Technische Daten Seite 26Überblick Seite 27Baugruppen Seite 28

V. Inbetriebnahme Seite 34

V. Start up Side 34Operation devices Side 35Transport Side 41 System set up Side 43Gap adjustment Side 46

VI O ti Sid 48Bedienelemente Seite 35Transport Seite 41Aufstellen der Anlage Seite 43Spaltverstellung Seite 46

VI B t i b S it 48

VI. Operation Side 48Special operating information Side 49Procedure crusher operation Side 51VII. Maintenance Side 53Hydraulic system Side 54 Di l t Sid 56VI. Betrieb Seite 48Besondere Betriebshinweise Seite 49Vorgangsweise Brecherbetrieb Seite 51

VII. Wartung Seite 53Hydraulikanlage Seite 54

Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59Hydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58II INTENDED USEV-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64

II. INTENDED USER900 IMPACT CRUSHER


Page 4II. INTENDED USE


INTENDED USE:

The machine is constructed in compliance with prevailing technical standards and safety regulations. Nonetheless, the operation or use of the machine may be connected with hazards which may endanger personal safety or lead to material damage to the machine and/or other objectsmaterial damage to the machine and/or other objects.

Operate the machine only in good order and condition and only in the intended manner of use. Observe all safety regulations and accident-prevention guidelines according to this Operator's Manual and applicable local regulations. Circumstances or technical defects which may pose a threat to operational safety must be immediately remedied or repaired.

The machine is intended solely for the purpose of crushing, screening, or sorting recycling material. Use of the machine for any other purpose is contrary to the manufacturer's intended purpose. The manufacturer/dealer is not liable for damages arising from such contrary use. The customer/operator assumes sole risk and responsibility forliable for damages arising from such contrary use. The customer/operator assumes sole risk and responsibility for costs and damages which may result from such contrary use.

Use of the machine according to the manufacturer's intended purpose explicitly includes the observation of and compliance with all parts of the Operator's Manual and the adherence to inspection and maintenance regulations.

Page 5II. INTENDED USE



I. Vorwort Seite 2


I. Preface Side 2II. Intended use Side 4III Safety Side 6Safety hazard symbols Side 7Operating instructions Side 13






VI B t i b S it 48



Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59Hydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58III SAFETYV-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64

III. SAFETYR900 IMPACT CRUSHER


Page 6III. SAFETY


SAFETY HAZARD SYMBOLS:

Many of the following symbols appear frequently in these operating instructions; they call special attention to hazardous situations which may arise when operating the machine.

Danger of entrapment. Do not reach into open machinery.

Entrapment may cause serious or fatal injuries.

Body parts can be drawn in and crushed or torn.

Be sure that all machinery has come to a complete standstill before opening or removing protective coversBe sure that all machinery has come to a complete standstill before opening or removing protective covers.

Keep in mind the necessary run-down time for rotating/sliding/reciprocating machinery (rotor, jaws, belt pulleys, V-belts, flywheel, vibro plate, pre-screener, centrifugal weights, etc.).

Danger of entrapment. Do not reach into open machinery.

Entrapment in rotating parts may cause serious or fatal injuries.

Body parts can be drawn in and crushed or torn.

Be sure that all machinery has come to a complete standstill before opening or removing protective covers. Ignition key and battery switch have to be pulled off, the machine has to be protected against start-up by external persons.

Page 7III. SAFETY

SAFETY HAZARD SYMBOLS (continued):

Crush hazard. Caution is required at points where hands and/or feet can be crushed.

Never use feet, hands, fingers, or other body parts to support or hold machine parts.

Always use the provided anchors and/or mechanical supports.

Danger of falling/flying material.

Do not enter loading/discharging zones. Doing so may cause serious or fatal injuries.

A hard hat must be worn in the immediate vicinity of the machine.

Personal hearing protection must be worn.

Page 8III. SAFETY


Wide or loose clothing may be drawn into or caught in moving machinery.

Wear EN/ANSI tested, correctly fitting protective clothing.

Personal protective gear includes hard hat, goggles, hearing protection, close-fitting overalls, steel-toed boots, flourescent safety vest and protective gloves. Do not wear jewellery.

The operator's manual must be read and understood before operating the machine.

Read and observe the various warning symbols on the machine.Read and observe the various warning symbols on the machine.

Only specially schooled and trained personnel may operate or work with the machine.

Turn off the motor and remove the key from the ignition before beginning maintenance or adjustment work. Ignition key and battery switch have to be pulled off, the machine has to be protected against start-up by external persons.

The key and battery switch must be kept on your person during maintenance or repair work.

We recommend, to never work alone.

Page 9III. SAFETY


Danger of falling: do not climb onto or stand on the machine when it is moving or in operation.

Only use the intended upward mobility “ladder on the catwalk”.Only use the intended upward mobility ladder on the catwalk .

An appropriate work platform with fall protection must be used when working at heights exceeding 2 m.

Danger of burning or scalding: beware of hot machinery or exhaust parts.

Beware of escaping hydraulic oil.

Pressurized hydraulic oil can penetrate the skin and lead to poisoning.

The system must be depressurized before beginning maintenance or adjustment work.

If hydraulic oil has penetrated the skin it must be surgically removed Seek professional medical care immediatelyIf hydraulic oil has penetrated the skin it must be surgically removed. Seek professional medical care immediately.

Page 10III. SAFETY


Personal safety hazard: acids chemicals und caustic fluidsPersonal safety hazard: acids, chemicals, und caustic fluids.

Personal safet ha ard magnetic fieldPersonal safety hazard: magnetic field.

Do not allow persons with pacemakers or other electronic medical devices to enter the danger zone.

Personal safety hazard: electrical current.

Danger of serious or fatal injuries.

Never perform work on the electrical system if you are not thoroughly familiar with all technical details and specifications.

Only qualified electricians may perform work on the electrical system.

Page 11III. SAFETY


These symbols call attention to various regulations and prohibitions to prevent damage and avoid hazardous situations, as well as highlight special manufacturer's instructions for correct machine operation.

Page 12III. SAFETY

OPERATING INSTRUCTIONS:

The operating instructions must always be within easy access at the site of operation of the machine.

Universally applicable statutory and other binding regulations/laws concerning accident prevention andUniversally applicable statutory and other binding regulations/laws concerning accident prevention and environmental protection (supplementary to the operating instructions) must be observed/complied with.

These obligations can also concern handling hazardous materials; or providing and wearing protective equipment as well as road transport regulations.

The operating instructions must be supplemented by instructions including supervisory and reporting obligations with regard to special operational circumstances, for example with reference to workflows, work organisation, staff employed etc.

All persons authorised for work on the machine must have read and understood the operating instructions beforeAll persons authorised for work on the machine must have read and understood the operating instructions before commencing work. This applies in particular for individuals who only occasionally work with the machine, for example during maintenance or assembly work on the machine.

Regularly check that the personnel are working with an awareness of the safety and hazard aspects in compliance with the operating instructionswith the operating instructions.

All safety and hazard indications must be easily visible and legible and must be observed. Damaged safety and hazard indications have to be replaced immediately. Removal of the safety and hazard instructions from the system is strictly prohibited.

Personnel must tie back long hair and may not wear loose clothing or jewellery (also rings). There is risk of injury, for example, if the hair or clothing becomes caught or pulled into the machine. Personnel authorised for work on the machine are personally responsible for compliance with the regulations.

Page 13III. SAFETY

OPERATING INSTRUCTIONS (continued):

Personal protective equipment must be worn in compliance with the regulations to the extent necessary.

In the event of changes to the operating state of the machine (insofar as these are safety-relevant) the systemIn the event of changes to the operating state of the machine (insofar as these are safety-relevant), the system must be stopped and brought to a standstill and the fault reported to the person responsible; the latter must immediately rectify the fault or have it rectified, and return the system to its correct operating state.

No changes and assembly or conversion work may be carried out on the machine without authorisation by the manufacturer. This applies in particular for mechanical, electrical and hydraulic safety devices as well as for welding work on load-bearing components.

Replacement and wearing parts must correspond to the technical requirements specified by the manufacturer. This is always guaranteed for original and wearing parts.

Specified schedules and/or those cited in the operating instructions for recurrent tests must be adhered to.

Page 14III. SAFETY

OPERATING PERSONNEL:

Operating personnel must be instructed in correct and safe operation of the system and its accompanying accessories.

Work on/with the machine may only be carried out by reliable, trained and instructed personnel who have experience in working with machines. Observe the statutory minimum age.

Clearly specify areas of responsibility for personnel in regard to operation, assembly, maintenance, commissioning etc.

Ensure that only authorized personnel work on the machine.

Also specify responsibilities for machine transportation drivers in respect to road-transport regulations, and ensureAlso specify responsibilities for machine transportation drivers in respect to road transport regulations, and ensure that drivers do not receive instructions contrary to safety by third parties.

Personnel who are to be trained or instructed or who are currently receiving general training may only work on the machine under continuous supervision by an experienced person.

Work on the electrical system of the machine may only be carried out by qualified electricians or by instructed personnel under the guidance and supervision of a qualified electrician in accordance with the regulations concerning electrical engineering.

Work on the hydraulics of the machine may only be carried out by personnel with specialist knowledge of hydraulic systems.

Page 15III. SAFETY

BEFORE COMMENCING WORK OPERATING PERSONNEL MUST:

...be instructed in the work to be performed by means of a specialist training.

be advised of the dangers…be advised of the dangers.

...check all safety relevant covers and casings on their correct position

...be informed about safety functions, like f.i. the EMERGENCY OFF switch, in order to be able to use th i fthem in any case of emergency.

…be familiar with all moving parts of the system, in order to beware of these.

...have read and understood the operating instructions together with all warning/safety instructions in theoperating instructions as well as all other safety-relevant warning/safety instructions for the product.

...take sufficient time to examine in detail and become familiar with the warning instructions, th i i ifi dtheir significance and consequence.

Page 16III. SAFETY

HYDRAULIC SYSTEMS AND THEIR COMPONENTS:

Only persons with special knowledge and experience may work on the hydraulic units.

Return all control valves to the neutral position (discharge system pressure). Switch off the motor before disconnecting or removing hydraulic pipes, tank covers, hydraulic filters or couplings. Disconnect the power supply.

Replaced hydraulic components must correspond to the same standard and quality. Ensure that the parts are correctly mounted.

Beware of leaking hydraulic pipes. Pressurized hydraulic oil can penetrate through the skin or cause injury to the eyes. Leaks in pressure pipes may not be visible to the naked eye. Never check leaks with your hands or fingers. Use an aid, such as cardboard for example.

Always wear goggles. If hydraulic oil comes into contact with the eyes, seek medical advice immediately.y g gg y y y

Immediately replace defective hydraulic pipes. Fires can result from leakages. Ensure that the replaced hydraulic pipes correspond to the specifications of the original. Ensure that the hydraulic pipes are correctly mounted and laid.

Never exceed safety limits. Never set overpressure valves higher than the default settings.y p g g

Page 17III. SAFETY

ELECTRICAL SYSTEMS AND MOTORS:

In case of electric incidents of safety relevant components, immediately switch off the diesel engine, the battery switch and protect the machine against re-start by external persons.

Never carry out work on the electrics of any components without familiarizing yourself with these.Never carry out work on the electrics of any components without familiarizing yourself with these.

Only qualified electricians may carry out work on the electrical system of the machine.

If work on the live parts is necessary, a second person must be present who can operate the EMERGENCY OFF or main switch with shunt release in the event of an emergency Only use voltage insulated toolsmain switch with shunt release in the event of an emergency. Only use voltage-insulated tools.

Electrical equipment within the system must be checked regularly. Damaged cables or loose connections must be repaired immediately. Use original fuses of the specified length and power.

L d ti ti t i i l d t i d i th b tt l d i ThLead connections or connections containing lead are contained in the battery poles and accessories. These materials are carcinogenic. Observe the manufacturer’s instructions of the battery. Always wash your hands.

Never short-circuit the battery poles. A short-circuit can cause fires and damage the electrical system.

Battery acid can cause injuries. Avoid contact with the skin or eyes. Always wear gloves and goggles.

Exhaust gases contain harmful combustion products. Work with the system in an open environment or divert the h i h iexhaust gases into the open air.

Do not touch the motor and exhaust parts. Give the motor and exhaust system sufficient time to cool down before starting maintenance and repair work.

Never refuel while the motor is running. Do not smoke while refuelling. Ensure that there are no exposed light sources in the vicinity.

Do not spill any fuel or completely fill the tank. Spilt fuel must be removed properly and immediately.

Page 18III. SAFETY

MAGNETIC FIELDS:MAGNETIC FIELDS:

There is a risk of magnetic radiation in systems which are equipped with magnetic separators. This affects:o Persons with heart pacemakerso Electronic deviceso Electronic storage media

Entry into the hazard zone can cause damage to health or irreparable damage to electronic appliances.

Personnel must be informed of these hazards accordingly during instructionPersonnel must be informed of these hazards accordingly during instruction.

Explain this hazard to persons outside the company.

Keep persons with heart pacemakers away from the system.

DUST, VAPOUR AND SMOKE:

Grinding, burning or welding work may only be carried out on the machine if this is expressly authorized (danger of explosion).

Clean the system and its environment of dust and flammable substances and ensure sufficient ventilation before burning welding or grinding (danger of explosion)burning, welding or grinding (danger of explosion).

Safety guards must be fitted on the devices so that dust/materials cannot harm the machine user or persons in the immediate surroundings. Ensure that no dust enters the air when loading, adjusting or removing the material to be crushed.

Recommended procedures for eliminating dust are:o Dust protection and dust extractiono Dust removal with water

Page 19III. SAFETY

NOISE:

The noise protection equipment must be in the protective position during operation.

Wear the specified personal ear protection.

OILS, GREASES AND OTHER CHEMICAL SUBSTANCES:

Observe the safety regulations applicable for the product when working with oils, greases and other chemicalObserve the safety regulations applicable for the product when working with oils, greases and other chemical substances.

Caution when working with hot operating and process materials (burning or scalding hazard).

BLASTING:

The use of wireless remote control is strictly prohibited even during preparation work for blasting. Acute danger of y p g p p g gexplosion.

The use of a wireless remote control device is prohibited during blasting owing to the danger of explosion.

The machine must be removed from the hazard zone before blastingThe machine must be removed from the hazard zone before blasting.

Ensure that no explosive material can enter the system.

Page 20III. SAFETY

FIRE FIGHTING:

If the slightest signs of fire occur, proceed as follows, depending on the situation:

o Warn persons who are in the vicinity.o Shut down the machine.o Turn off the power with the main switch.o Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe place.o Begin fire fighting and, if necessary, call the fire brigade.o Remove the machine from the hazardous area, if possible.o Fire fighting.

If the unit has already caught fire, proceed as follows, depending on the situation:

o Turn off the machine.o Warn persons who are in the vicinity.o seek sheltero seek sheltero Ensure that there is no hazard for persons, and lead everyone in the vicinity to a safe place.o Call the fire department, firefighting

Page 21III. SAFETY

OPERATING THE SYSTEM:

Only specialists or trained/instructed personnel may operate the system.

Refrain from carrying out any work steps that may pose a risk to safety.

Before positioning the machine and bringing it into operating position, the work environment must be carefully checked for possible obstructions. The load bearing capacity of the ground and traffic arrangement must also be checked.

The operating instructions must have been read and understood before commissioning. Several labels are on the system; spare some time to become familiar with the warning instructions.

Note that the system has sharp corners and edges as well as rough surfaces in part.

Check and ensure that all system parts are fully functional.Check and ensure that all system parts are fully functional.

o Check for defective and missing parts. Immediately repair or replace these parts.o Ensure that all paneling is always correctly mounted and that all EMERGENCY OFF switches are functioning.o Daily maintenance work must be carried out in accordance with the service plan. For a detailed list, see the

service planservice plan.

Walk round the machine before starting work, and ensure that no person(s) are on or under the system or in its vicinity or in danger areas. All persons who are in the immediate environment are to be informed if the system is to be started. Only start the machine if no persons are on or under the system or in its vicinity. All doors must be closed and locked.

Keep all handles, steps, railings, platforms, stages and ladders free of dirt, in particular ice, snow, oils and greases.

Never climb onto, over and/or under running conveyor belts. Always use the ascending aids and catwalks designed and provided for thisprovided for this.

The belt and chain tension must never be checked while the system is running.

Page 22III. SAFETY

OPERATING THE SYSTEM (continued):

Do not work or linger in the vicinity/environment of system parts; these can rise or lower.

Never stay in the loading or unloading zone as long as the system is being loaded or unloaded.

Always wear a protective helmet, for example as protection against stones falling/flying from the machine.

Always observe all safety regulations. Operate all buttons and levers gently. Avoid jerky movements or sudden changes in direction.

Only press EMERGENCY OFF switches in emergencies or during safety exercises.

Check the machine for external signs of damages and defects at least once per shift. Immediately report changes that may have occurred to the person responsible. If required, immediately switch off the machine.

The system must be shut down if malfunctions occur. Faults must be rectified immediately.

On and off switching processes as well as monitoring displays must be observed in accordance with the operating g p g p y p ginstructions.

Parts of the power transmission system, such as the pulley of the drive shaft, flywheels, switches, V-belt pulley, V-belts etc, must be provided with safety guards so that nobody is endangered by rotating parts.

Never remove material blockages if the machine is running.

Before ending work, it must be ensured that the feeding hopper, crusher feed and conveyor belts are free of material. Never leave material on the machine. Otherwise the system will be overloaded on restarting.

Page 23III. SAFETY

MAINTENANCE WORK:

Only specialists or trained/instructed personnel may operate the system.

Maintenance and repair work should always be carried out by at least two persons. We recommend to never work alonealone.

Take personal safety precautions. Always wear a helmet, goggles, ear protection and other requisite protective equipment.

Do not wear wide and baggy clothing and jewellery. This can become caught and/or pulled into the machine. Tie back long hair.

Move the system to an even and firm surface. Turn off the motor and remove the starter key.Move the system to an even and firm surface. Turn off the motor and remove the starter key. Depressurise the hydraulics. Secure hydraulic components.Disconnect the power supply before commencing maintenance work.

Never carry out adjustment or repair work while the motor is running.

Pay attention to the overrun of rotating parts.

Only remove panelling which actually blocks access. Remove oil or grease that has escaped.

Never leave the system unattended if the panelling is removed and the housing is open. Keep bystanders away from the system.

Raised system parts must always be properly secured. Never work below system parts that have not been secured.

If you are working at a height over than 2 m, you must wear an EN/ANSI tested safety harness.Use the catwalks, work platforms or other such safety (EN/ANSI) tested ascending aids and work platforms.provided for this. Do not use ascending aids or work platforms that have not been secured and/or approved.

Page 24III. SAFETY

MAINTENANCE WORK (continued):

Only operate the motors in a well ventilated environment – toxic hazard resulting from exhaust gases.

Caution when looking for leakages in the hydraulic systems Pressurized hydraulic oil can penetrate through the skinCaution when looking for leakages in the hydraulic systems. Pressurized hydraulic oil can penetrate through the skinor cause injury to the eyes. Leaks in pressure pipes may not be visible to the naked eye. Never check leaks with your hands or fingers; use an aid, such as cardboard for example.

Always wear goggles. If hydraulic oil comes into contact with the eyes, seek medical advice immediately.

Damaged, illegible or missing warning signs must be replaced or cleaned.

Special attention must be paid to the moving parts during maintenance work; these must be checked. Any damaged, worn or incomplete parts can fall out. This can lead to injury or death.worn or incomplete parts can fall out. This can lead to injury or death.

Before finishing the maintenance work, all bolts, connections and joins must be tightened. All panelling must be mounted. Replace or repair damaged covers or panelling.

Only fill or refill pressure systems with the specified fluids Start the motor and check for leakagesOnly fill or refill pressure systems with the specified fluids. Start the motor and check for leakages. Activate all control levers and ensure that the system functions correctly.

After completing the tests, check the system for missing spring cotter pins, washers, lock nuts etc..

Check all fluid levels before starting work.

Page 25III. SAFETY



I. Vorwort Seite 2








VI B t i b S it 48



Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59Hydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58IV TECHNICAL DATAV-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64

IV. TECHNICAL DATAR900 IMPACT CRUSHER


Page 26IV. TECHNICAL DATA


OVERVIEWOVERVIEW:

1. Crawler gear2. Drive motor3. Drive system4. Feeding hopper5. Vibration feeder6. Pre-screening with

reversible chute7. Crusher cover8. Impact crusher 9. Main discharge belt10. Side discharge belt11. Magnetic belt

12. V-belt protector13. Panelling14. Diesel tank15. Hydraulic tank16. Catwalk

17. Hydraulic switchbox18. Electric switchbox19. Remote control


BUILDING GROUPS:

CRAWLER GEAR:The crusher system is mounted on a caterpillar crawler. The caterpillar crawlers are driven via a 2-stage gear which enables the system to move at two different speeds. The maximum hill climbing ability is 34°. The chain tread consists f 49 3 ib l t ith 400 idthof 49 x 3-rib plates with 400 mm width.

DRIVE MOTOR:Motor (Caterpillar 7.0/187 kW): see Caterpillar Manual The motor is housed in noise-insulated housing. All filter and fluid displays are easily accessible.g p y y

COMBI-COOLERThe blower wheel is mounted directly on the engine. The water cooler has an additional equalizing tank with a pressure control valve.

OIL-COOLERThe blower wheel is driven hydraulically and limited to 125 bar.

DRIVE SYSTEM:Both the hydrostat for the crusher as well as the hydraulic pump for the operating hydraulics are driven via aBoth the hydrostat for the crusher as well as the hydraulic pump for the operating hydraulics are driven via a distributor gear unit which is flange-mounted on the drive motor.

FEEDING HOPPER:The feeding hopper is made from highly rear resistant Hardox 400 steel. The capacity of the feeding hopper is 4 m³.

VIBRATION FEEDER:The vibration feeder guarantees even material feeding into the hopper. It is lined with highly wear resistant Hardox 400 steel plates. The preliminary screening is integrated in the vibration feeder. The vibration feeder is driven via the vibration drive, which is driven hydraulically. The vibration feeder can be activated or deactivated using the hand lever orvibration drive, which is driven hydraulically. The vibration feeder can be activated or deactivated using the hand lever or by remote control. The speed of the vibration feeder is controlled infinitely via a hydraulic valve.


PRE-SCREENING WITH REVERSIBLE CHUTE:

The screening area of the preliminary screening is 1200 mm x 900 mm.The standard gap width of the zigzag grid is 32 mm. The pre-screened material can be directed onto the side belt via a reversible chute, or is directly routed onto the main conveyor at the crusher. y yThe reversible chute is equipped with two side doors, to remove any blockages.

CRUSHER COVER:Picture IV.1: Reversible chute

The crusher cover covers the crusher feed from above. The crusher cover serves for maintenance purposes only and may be opened only if the rotor is switched off and protected against rotation. It can be opened and closed hydraulically (by wireless remote control or manually) and serves as protection against falling/flying stones when closed with a chain screen and rubber skirt. An irrigation strip is integrated in the crusher cover.

Picture IV.2: Reversible chutecontrol lever

IMPACT CRUSHER R900:

The impact crusher R900 has a 4-radial rotor and is equipped with 2 swing beams which can be adjusted hydraulically independently of each other. The gap widths of the upper impact swing can be hydraulically adjusted from 0 to 170 mm,p y g p pp p g y y j ,he gap width of the lower impact swing from 0 to 100 mm. The rotor speed can be infinitely adjusted from 0 - 850 rpm and can be read on the display (page 37, picture V.3,item 10). In case of large raw material the adjusted rotor speed may not exceed 700 rpm (risk of hammer damage).A mechanical safety device prevents the rotor from twisting during maintenance work. The impact sphere diameter is 1020 mm The hammer arms are available in the qualities standard medium hard and ceramic

Max. rotor speed:750 rpm

Higher rotor speed1020 mm. The hammer arms are available in the qualities standard, medium, hard and ceramic.

The crusher housing can be unfolded hydraulically for maintenance purposes. Inspection doors are located on the side, which can be opened for maintenance purposes and inspecting the impact arms.

only after consultation with the producer

ROTOR SPEED:

The granulation of the final product as well as the wear behavior can be individually affected with the help of the rotor speed. The rotor speed can be set with the rotor speed adjustment button (see page 36, picture V.2: switchboard No 2).


MAIN DISCHARGE BELT:MAIN DISCHARGE BELT:

The main discharge conveyor is a solid steel construction with the dimensions:

Length (centre line distance) 7900 mmWidth (belt width) 1000 mmHeight (discharge height) 3200 mm

The conveyor belt of the main discharge conveyor is located under the crusher where it is protected from impacts by SANPRO plates. The absorbing impact plates are fixed on rubber buffers (rubber mountings), which are additionallySANPRO plates. The absorbing impact plates are fixed on rubber buffers (rubber mountings), which are additionally absorbing the impact effects.The conveyor belt is manufactured in RIP-STOP quality.The drive is hydraulic. The operating pressure is limited with 220 bar.The entire construction can be folded up hydraulically for transport purposes.

Attention: Before folding release side belt (open tensioning spindle of driving drum).Retighten belt before operation and check that belt runs centrally, if necessary reset !(see chapter VII Maintenance)

Attention: when changing the belt, make sure to use an original RIP-STOP-belt from the manufacturer. If using another belt with different qualities than the original, a smooth operation can not be guaranteed. Damages resulting from this will not be issues of warranty or guarantee.


SIDE DISCHARGE BELT:

The side discharge conveyor is a solid steel construction with the dimensions:

Length (centre line distance) 4100 mmWidth (belt width) 500 mmWidth (belt width) 500 mmHeight (discharge height) 2300 mm

The drive is hydraulic. The operating pressure is limited with 210 bar.The entire construction can be folded up hydraulically for transport purposes.

Attention: Before folding, open safety screws, release side belt (open tensioning spindle of driving drum) and fix it with the transport safety screws.

Before operation, tighten safety screws, retighten belt and check that belt runs centrally and, if necessary,Before operation, tighten safety screws, retighten belt and check that belt runs centrally and, if necessary,Reset!

Picture IV.2: Safety screwPicture IV 3: Safety screw

Page 31

Picture IV.3: Safety screw

IV. TECHNICAL DATA

MAGNETIC BELT:

The magnetic conveyor belt is mounted over the main conveyor belt. It separates all loose iron fragments from the crushed material and discharges the metallic impurities beside the main conveyor belt.The gap between the magnetic surface and material to be conveyed must be at least 200 mm.The magnetic conveyor belt should have around 25 mm of slack Overtensioning can damage the bearingsThe magnetic conveyor belt should have around 25 mm of slack. Overtensioning can damage the bearings.The drive is hydraulic. The operating pressure is limited with 80 bar.

V-BELT PROTECTOR:

The V-belt protector is a metal housing. The system must be shut down before checking or tensioning the V-belt. The V-belt protector and the side door must always be closed and secured after working on the V-belt.

PANELLING:PANELLING:

The panelling on the crusher serves to provide operational safety and noise protection. It may only be opened and/or removed for maintenance and repair work. Crusher operation with dismounted panelling must be avoided at all times.

DIESEL TANK:

The diesel tank is equipped with an electrical refuelling pump and is provided with a ventilation opening. This opening is covered with a filter cover. A diesel drain cock is located on the bottom of the diesel tank.

The capacity is 330 liters.


HYDRAULIC TANK:

The hydraulic tank is fitted with an inspection glass,a level sensor and a temperature sensor. The level sensor switches off the vibration chute immediately if the level falls below the adjusted limit, the temperature sensor does the same, if the oil temperature is too high. Time-delayed (ca. 30 sec.) also the operating hydraulics switches off. The capacity is 420 liters Upon filling the hydraulic tank 10 cm must be left from the upper edge (hydraulic tank) to the liquid level420 liters. Upon filling the hydraulic tank, 10 cm must be left from the upper edge (hydraulic tank) to the liquid level.On the underside of the tank a drain cock is located.

CATWALKS:

Catwalks serve for maintenance, revision and monitoring of the system. The catwalks are firmly attached to the system and do not have to be removed for transport.

HYDRAULIC SWITCHBOARD:

The most important manual valves for controlling the system are located in the hydraulic cabinet.

ELECTRICAL SWITCHBOARD:

All the operating elements relevant to the user are located in the electrical cabinet.

REMOTE CONTROLS:

The wireless remote control can be used to move the machine, open/close the crusher cover, activate the hydraulic and activate/deactivate the vibration feeder. The system can also be operated with the cable remote control but only to move the machine. On both remote controls there are EMERGENCY-OFF switch.




I. Vorwort Seite 2








VI B t i b S it 48



Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59Hydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58

V-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67V START UP Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64


V. START UPR900 IMPACT CRUSHER

Page 34


V. START UP

OPERATION DEVICES:

OPERATOR CONTROLS:

The operator controls required for operation are individually described in the following:

HYDRAULIC SWITCHBOARD:

1. Vibration feeder and side discharge belt

2. Main discharge belt

3. Side discharge belt - folding cylinder

4 Main discharge belt folding cylinders4. Main discharge belt - folding cylinders

5. Swing beams - adjustment cylinders (main valve)

6. Open/close crusher

51 2 3 4 65

Picture V.1: Hydraulic switchboard

Page 35V. START UP

ELECTRICAL SWITCHBOARD:

1. Hydrostat left/right rotation (only valid, if Duplex System)

2. Set rotor speed

3. Activate hydraulics

4. Deactivate hydraulics

5. Warning lamp

5

62

3

4

171

6. Diagnostic lamp (drive engine)

7. Switchboard lock

8. Starting aid7 8 9 10

1113

9. Adjustment of engine speed

10. Switch for emergency mode (transport)16

11. Screen box ON/OFF (option)

12. Water pump ON/OFF (option)

13. Vibration chute ON/OFF (manual/remote control)Picture V.2: switch board

12 14 1518

14. Engine – preheat lamp

15. Starter key

16. Tank display

17. Monitoring system (motor and crusher unit)

18. Headlight ON/OFF

Page 36V. START UP

MOTOR MONITORING SYSTEM:

1 This button enables to return to a previous or higher level in the display.

2 With this button error messages can be confirmed.

1 ESC-Button

2 Confirmation–Button

3 4 S ll B tt

89

123+4 Used for navigation between the various menu items in the display.

5+6 Allow to select a value or to change the indication-parameter in thedisplay (see point 9 ).

7 This button effects the confirmation of a selected adjustment as well as

3+4 Scroll – Button

5+6 + / - Buttons

7 Enter – Button

10

12

131112a7 This button effects the confirmation of a selected adjustment as well as

the changing of indication of display to a selected mode.

8 Indicates the current engine speed.

9 After selecting this indication item by using the scroll buttons (3+4) this

7 Enter Button

8 Indication of engine speed

14 5item is going to be marked in grey colour. By pressing the + or – button(5+ 6) the requested indication parameter (hours of operation, coolant temperature, etc) now can be chosen. By pressing the enter button (7)this selected parameter then remains active in the display and indicatesthe condition of this parameter during operation of engine.

9 Indication of second parameter of engine

10 Indication of crusher speed

Picture V 3: Motor monitoring system

1

3

4 5

6 7 2

10 After activating the crusher and running up the crusher with the crusher-speed-adjusting-buttons, the current crusher speed appears in this indication.

11 If the block “menu” is marked in grey and the enter-button (7) will then be pressed, you will get into a further submenu (inputs, outputs, alarm protocol andlanguage). Within this menu field you can navigate with the scroll buttons (3+4). After selecting a menu field this one can be called by pressing the enter

( ) f f / f

11 Operating-information-display

Picture V.3: Motor monitoring system

button (7). After e.g. selecting the menu field language the requested language can be adjusted by pressing the +/- buttons. This one has to be confirmed then with the enter-button (7). In the menu field “alarms” the last 100 error messages can be called by pressing the scroll-buttons (3+4). With the ESC-button (1) you can return from this level in the display to the main menu (=standard indication).

12 The current problem (indicated as plaintext) appears in the display until the error is corrected or due to a change of the operating status of the engine the error is cleared. In case of critical operation conditions (e.g. excess temperature of the cooling water) the diesel engine will stop

12 Indication of arising problems of diesel motor

12a Indication as per code number of engine manual

automatically. An automatic cut-off due to lack of cooling water is not provided (a regular control of the coolant level is necessary).

12a Errors, which are not indicated as plaintext here appear with the appropriate code number. The meaning of this code can be read in the engine manual.

13 These notices / errors are also indicated as plaintext. If there are no notices, the display is empty.

13 Indication of arisingproblems of crusher control

Page 37V. START UP

ERROR MESSAGES OF ENGINE CONTROL SYSTEM

The pressure in the hydraulic circuit of crusher drive has exceeded the adjusted limit value or the crusher speed went below the crusher limit value. The feeder stops immediately as long as this overload of crusher is active. When there is no more overload (hydraulic pressure again at a lower level) the feeder starts again automatically.

Crusher overload

Indication, that the level of hydraulic oil in the oil tank has reached a level below the limit value. The feeder stops immediately. After a short period of time (30 seconds) also the complete hydraulics stops. To start again the hydraulics, the oil level must reach a higher level (oil must be filled up in the tank or the function of level senor has to be checked).

Hydr. oil level too low

Indicates, that the temperature of the hydraulic oil has exceeded the adjusted limit value. The feeder stops immediately. After a short period of time (30 seconds) also the complete hydraulics stops. A new activation is only possible, if the oil has cooled down and reached a lower temperature range (under the adjusted limit value).

Is indicated, when the load at the main conveyor (pressure in the hydraulic circuit) is too high. The feeder will stop

Oil temp. too high

automatically. For a further activation the hydraulic –on –button has to be pressed on the electrical switchboard or on the remote control (see page 36, picture V.2: electrical switchboard, item 3 or page 39, picture V.4 switch 11).

This message is indicated, if the safety switch of side conveyor has been activated. The complete hydraulic stops

Overload of main conveyor

g , y y p y pimmediately. For new start of hydraulics, this safety switch has to be readjusted.

Is indicated, when the limit switch at the crusher cover or the switch board is not adjusted in the right position (distance between surface of switch and surface at crusher cover: 2 – 3 mm). If this happens during operating the crusher, the f f ( ) ff f

Switch side conveyor

feeder will stop immediately and after some short time delay (5 seconds) also the crusher switches off. If the error disappears (problem caused by bad contact or shaking of the plant) during this time, then the feeder will restart again automatically.

Indicates, that the electric motor of water pump of sprinkling unit has switched of because of lack of water in the suction

Limit switch

p p p gline (only if an optionally sprinkling pump was installed).

The last 100 error messages can be seen in the error diagnostics (see page 37, point 11, operating-information-display).

Level of water

Page 38V. START UP

WIRELESS REMOTE CONTROL:

Left caterpillar crawler moves forwards

Right caterpillar crawler moves forwards

1. Forwards left

2. Forwards right1 2

Left caterpillar crawler moves backwards

Right caterpillar crawler moves backwards

3. Backwards left

4 Backwards right

3 4

5 6


Both caterpillar crawlers move forwards simultaneously in fast motion

B th t ill l b k d i lt l i f t ti

4. Backwards right

5. Forwards fast

6 B k d f t

7 8

Both caterpillar crawlers move backwards simultaneously in fast motion

Open crusher cover

6. Backwards fast

7. Crusher cover open 9 10

Close crusher cover

Press buttons 9 and 10 simultaneously for two seconds until LED blinks green. The ON/OFF switch (no. 11) must be pulled.

8. Crusher cover close

9 – 10. Start

Activate operation hydraulics

Activate and deactivate vibration feeder Picture V.4: Wireless remote control

9. Hydraulic ON

10. Vibro on/off

11

Pull for activating remote control.Press to switch machine and remote control off.

The remote control has to be activated before the start-up of the machine!

11. EMERGENCY-OFF

Page 39V. START UP

CABLE REMOTE CONTROL:2

Left caterpillar crawler moves forwards

Right caterpillar crawler moves forwards

1

3 4

2

51. Forwards left

2 Forwards right Right caterpillar crawler moves forwards

For straight-ahead movement press both buttons (1,2) at the same time

Left caterpillar crawler moves backwards

Picture V.5: Cable remote control2. Forwards right

3. Backwards left


For straight backwards movement press both buttons (3,4) at the same time

4. Backwards right

Pull to activate the remote control. Press in order to stop the machine in an emergency.

Picture V.6: Connecting point

5. Emergency OFFSwitch

CRUSH HAZARD: Particular caution must be exercised in respect to operating chains when using the cable remote controlchains when using the cable remote control.

Connecting the cable remote control to the crusher at the industry connecting point, see picture V.6/7.

ATTENTION: Machine function is only guaranteed, if the circuit is closed via cable remote control or the industry connecting point.

Picture V.7: Connecting cable remote control

Page 40

cable remote control

V. START UP

TRANSPORT:

UNLOADING THE SYSTEM:

Check machine on loose parts or material accumulations.Activate remote control (see page 39) or plug in cable remote control (see page 40). Start the motor (see Caterpillar Manual)Start the motor (see Caterpillar Manual).Press the hydraulic button on electrical switchboard (see page 36, point 3).Set ascent angle of the low-loader ramps to not more than 15° (or ratio 1:4).Carefully drive away from low-loader at low engine speed (below 1000 rpm).

LOADING THE SYSTEM:LOADING THE SYSTEM:

Check machine on loose parts or material accumulations.Fold and secure side conveyor and catwalk ladders.Carefully drive onto the low-loader at low engine speed (below 1000 rpm) – Observe angel of ascentFasten s stem ith appropriate chains at the anchoring pointsFasten system with appropriate chains at the anchoring points.After the loading reverse battery switch and pull off ignition key.

ATTENTION: be serve transport dimensions.Set ascent angle of the low-loader ramps to not more than 15° (or ratio 1:4).U d t l l d (f t l h i l )Use adequate low-loader ramps (for steel chain crawlers).Make sure to have a stable ground during the loading and unloading process.Remove snow, ice and material from ramps and caterpillar crawlers.Use outriggers of the trailerMachine tilts when it passes the ramp angle.

Page 41V. START UP

TRANSPORT SAFETY:

Observe the statutory transport dimensions currently applicable.

Secure the system against slipping at the eight anchoring points envisaged for this.

Picture V.8: laterallashing points Picture V.9: backwards lashing points

Picture V 10: frontlashing points

Page 42

Picture V.10: frontlashing points

V. START UP

SYSTEM SET UP:SYSTEM SET UP:

Ensure an even ground space, if necessary compact.

Bring the crusher into position. Move the system as close as possible to the material to be crushed.

A suitable ramp must be tipped for loading with a wheeled loader (although this is not recommended)A clear view onto the hopper and crusher feed must be provided for excavator loading.The material to be crushed must be located in the rear part of the hopper for excavator loading.

ATTENTION: If an impact crusher is in use, there is an acute hazard from falling/flying stones (rock fall).

Bring the main conveyor belt and side conveyor belt into the working position (see picture V.11; position 1+2).

Att ti O f t d ti ht i !Attention: Open safety screws and tightening screws!

Check that belt runs centrally and, if necessary,reset (see chapter VII. maintenance).

Check belt tension.

Picture V 11: Hydraulic switchboard

1 2

Picture V.11: Hydraulic switchboard

NOTE: The material cone under the main and side conveyor belt must not rise above the driving drums. RISK OF DAMAGE TO THE DRIVE UNIT AND THE CONVEYOR BELTS.

Page 43V. START UP

MATERIAL PREPARATION:

The crushing material must be pre-crushed, depending on the machine type.The process material (recycling material) must not exceed a max. length of 500 mm.If hard rock is used as feeding material, this value may only be max. 300 mm.

Objects that cannot be crushed must not enter the crusher.

Remove impurities such as iron, wood and similar from the material to be crushed.

Metal objects larger than the gap width set must not enter the crusher.

CAUTION: Risk of damage to the conveyor belts – cut iron pieces that are too long, max. length 500 mm, max. diameter 15 mm.max. length 500 mm, max. diameter 15 mm.

REMOVING BLOCKAGES:

S it h ff th hi ll ff i iti k d b tt it hSwitch off the machine, pull off ignition key and battery switch.(Protect machine against re-start by external persons).

The machine must always be switched off. The rotor must be brought to a standstill before removing any blockages and must be secured against turning. g g g

Never step into the crusher

Remove the blockage with extreme caution.

Page 44V. START UP

1. A clear view onto the hopper and crusher feed must be provided for excavator loading.If an impact crusher is in use, there is a risk of flying/falling stones behind the crusher feed.

Point 1

Point 2 Point 3

2. Material preparation: As far as possible, remove all impurities from the process material. To large parts should be crushed to task size.

3. The material cone under the main and side conveyor belt must not rise above the driving drums – Risk of damage to the drive unit and the conveyor belts.

Page 45V. START UP

GAP ADJUSTMENT:

The particle size of the end product can be determined by setting the crushing gap width. This should be done only with secured rotor!

If an impact crusher is in use, the crushing gap width must be set as follows:

Remove mounting plates from the setting cylinders/plates (Picture V.13).Start the diesel motor Picture V.12: Setting cylinderStart the diesel motor.Activate the hydraulics.Activate the main valve of the swing beam (see page 35, picture V.1, point 5).

Bring the setting cylinder into position (pocket adjusting clips, see picture V.15), move the setting cylinder into the required position using the manual valve

g y

move the setting cylinder into the required position using the manual valve (picture V.14) and adjust the baffle plates in this manner until the setting plates are loose and can be pulled out from the guide.

Move setting plates. Forwards = Increase gapBackwards = Decrease gapBackwards = Decrease gap

Adjusting plates are available in thicknesses of 10 mm and 20 mm (Picture V.13)

NOTE: Possible gap settings (with new blow bars)U b ffl l t 0 170

Picture V.13: Setting plates

Upper baffle plate: 0 – 170 mmLower baffle plate: 0 – 100 mm

Attention: Pay attention to springs because of risk of injury!

Attention: Danger of falling – the gap adjustment must be done only from the catwalk!

Picture V.14: Setting plates

Page 46V. START UP

SETTING THE CRUSHER (continued):

Open inspection flaps.

CRUSH HAZARD: PAY ATTENTION TO OVERRUNNING PARTS!

[1,5-3] = y

Check the gap between the hammer and the baffle plate.Setting from upper to lower baffle plate should be selected at a ratio of1,5 :1 to 3 :1, depending on material, feeding size and crushing ratio.

The setting for the gap sizes also depends on the material and impurities (see side 43 material preparation).

NOTE: The smaller the crushing gap the greater the wear in relation to the throughput performanceNOTE: The smaller the crushing gap, the greater the wear in relation to the throughput performance.

ATTENTION: Always check the crushing gap set and ensure that the rotor can run freely –RISK OF DAMAGE TO THE ROTOR!

Release setting cylinderRemove adjustment boltPull in piston rod of setting cylinderBring the manual valve (page 35, picture V.1, point 5) into the neutral position.Attach mounting plateAttach mounting plate.

Page 47V. START UP



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VI B t i b S it 48




V-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67VI OPERATION Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64


VI. OPERATIONR900 IMPACT CRUSHER

Page 48


VI. OPERATION

SPECIAL OPERATING INFORMATION:

VIBRATION FEEDER:

Switch on the vibration feeder:The vibration feeder is manually activated in the “Manual” position ( 36 i t V 2 N 13 ib ti f d )(see page 36, picture V.2. Nr. 13, vibration feeder) The ball valve (see picture VI.1) in the control panel is closed (closed=vertical)The vibration feeder can be switched on and off via the ball valve (see picture VI.1)

The rate governor (see picture VI.1) on the control station is used to control the required Picture VI.1: rate governor , white arrow

conveyor speed for the material on the vibration feeder.If the vibration chute does not work, the green “Hydraulic-ON” - switch must again be pressed.

Switch on the vibration feeder via remote control:

gball valve, red arrow

The vibration feeder can be activated via the remote control (see page 39) provided that the “Radio" position is switched on (see page 36, picture V.2, Nr. 13) and provided that the ball valve in the control panel is closed. The vibration feeder can be activated and deactivated via wireless remote control.

The ball valve must be closed in order to use the remote function of the vibration chuteThe ball valve must be closed in order to use the remote function of the vibration chute.

THE CRUSHER CAN BECOME BLOCKED IF THE VIBRATION FEEDER TRANSPORT SPEED IS TOO HIGH. THIS CAN REDUCE PERFORMANCE, INCREASE WEAR AND LEAD TO INFERIOR QUALITY OF THE CRUSHED MATERIAL.

CRUSHER COVER:The crusher cover can be opened and closed again by hand or by remote control, if required.This procedure is necessary if process material has become blocked in the infeed area of the impact crusher (observe process size) Opening the crusher cover increases the infeed and the material is able to enter the(observe process size). Opening the crusher cover increases the infeed and the material is able to enter the crusher space. The crusher cover serves for maintenance purposes only and may be opened only if the rotor is switched off and protected against rotation.

DURING OPERATION OF THE MACHINE NEVER OPEN THE CRUSHER COVER. MATERIAL IS HURLED OUT BACKWARDS FROM THE CRUSHER!

Page 49

OUT BACKWARDS FROM THE CRUSHER!

VI. OPERATION

SPECIAL OPERATING INFORMATION:

ROTOR:

Always check the rotor for free running before starting operation. The quality of the final product, e.g. limestone, can be controlled by fine adjustment of the rotor speed: a higher rotational speed increases the degree of fines, a lower rotationalspeed reduces the degree of fines.

REVERSIBLE CHUTE:

The reversible chute guides the pre-screened material into the main discharge belt or the side discharge belt, depending on i trequirements.

Only operate the reversible chute if the material flow for pre-screening is interrupted and the hopper has become empty, otherwise the reverse mechanism may become jammed.

MAIN DISCHARGE BELT:

The main discharge belt is protected from overloads by a pressure switch. This pressure balance deactivates the vibration feeder in the event of an overload. For a further activation the “Hydraulic-ON” button has to be pressed on the electrical switchboard or on the remote control. The most frequent causes of overloading for the main discharge belt are:

a) Blockages of concrete iron between belt and crusher dischargea) Blockages of concrete iron between belt and crusher dischargeb) Accumulation of material due to slow belt speed

It is important to check the conveyor belt for iron pieces and other impurities that may have become caught several times during crushing. This minimizes downtimes of the belt (gaps). The main discharge belt can also be operated in the reverse direction for a short period if requiredThe main discharge belt can also be operated in the reverse direction for a short period, if required.

MAGNETIC BELT:

With a ball valve the magnetic belt can be used independently from the manual valve be turned off and on. (see 35 i t V 1 iti 2) Th ti b lt b d f h t i d b ti th lpage 35, picture V.1, position 2). The magnetic belt can be reversed for a short period by operating the manual

valve in the opposite direction (spring offset). Short forwards and backwards movements can help release material blockages. The exchange of the hydraulic quick couplings on the magnetic belt engine enables the change of the direction of the magnetic belt.

Page 50VI. OPERATION

PROCEDURE FOR CRUSHER OPERATION:

IMPORTANT: FIRST CAREFULLY READ THROUGH THE SECTION "SPECIAL OPERATING INFORMATION". (see pages 49-50)

See Caterpillar Manual.Step 1:

5

62

3

4

171

2

3

4

1

pThe starter key is located in the switchboard (see picture VI.2 item 14).In case of difficulties during the starting procedure, the button “Starting Aid“(item 7) must be pressed during starting.

Press the hydraulic button in the switchboard (see picture VI.2 item 3).

Step 1:Start motor

Step 2:

7 8 9 101113

7 813

Press the hydraulic button in the switchboard (see picture VI.2 item 3).The operating hydraulics are activated in the idle mode.

Turn the hydrostat switch (see picture VI.2 item 1) into the “Impact crusher" position.

Start hydraulic

Step 3:Start hydrostat

Picture VI.2: switch board

12 14 1516

18 14

Increase the rotor speed with the rotary knob (see picture VI.2. item 2) to appr. 100-150 rpm. The current rotor speed can be controlled at the display.

Step 4:Start up rotor

Step 5:

Picture VI.2: switch board

Switch on the conveyor belts at the hydraulic switchboard (see picture VI.3)by pressing the hydraulic valves.

Increase the motor speed with the switch (see picture VI.2 item 8). The crusher speed increases proportionally to the motor speed.

Step 5:Start conveyor belts

Step 6:Increase motor speed p p p y p

1 2MOTOR SPEED DURING CRUSHING OPERATION MAX. 2000 RPM!

Picture VI.3: Hydraulic switchboard


PROCEDURE FOR CRUSHER OPERATION (continued):

Set the required rotor speed, depending on the required crushing material, with the rotary knob (see picture VI.2. item 2).

Step 7:

Adjust rotor speed

Close the ball valve on the crusher frame (closed=lever is vertical to the direction of flow, see picture VI.4).

Turn the switch “Vibro chute” (see page 51, picture VI.2, item 13)

Step 8:

Start magnetto “radio” or “manual” operation. Adjust the speed with the rate governor at the operator console (see page 49, picture VI.1).

When choosing “radio” operation, the ball valve (see page 49, picture VI.1) has to be closed.(closed=lever vertically to the direction flow).

Step 9:

Start vibr. FeederPi t VI 4 b ll l

The crusher is ready for operation. You can now start feeding the material.Step 10:

Feeding

Picture VI.4: ball valve

The sequence described ensures that no material blockage forms in the system to interrupt the workflow.Proceed in the reverse order when stopping the system.




I. Vorwort Seite 2








VI B t i b S it 48




V-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67VII MAINTENANCE Keilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64


VII. MAINTENANCER900 IMPACT CRUSHER

Page 53


VII. MAINTAINANCE

HYDRAULIC SYSTEM:

Replacing the return flow filter and overflow oil filter:First filter change 100 hours after first commissioning, further filter changes every 1000 hours or according to clogging indicator.

Turn off diesel motor.Cl filt h i ( t )Clean filter housing (outer).Remove filter cover.Pull out filter element (with disassembly handles).Insert new filter element. Picture VII.1: Main cocks

Picture VII.4: Return filter

Replacing the filter of the hydrostat:First filter change 100 hours after first commissioning, further filter changes every 1000 hours (see picture VII.2).

Changing the hydraulic oil:Changing the hydraulic oil:Change of hydraulic oil all 1000 hours or annually.Bring hydraulic oil to operating temperature. Turn off motor.Close main cocks (see picture VII.1).Open drain cock (see picture VII.3).D i ilDrain oil.Close drain cock.Open main cocks.Clean filling cap – open. (see picture VII.2.1)Pour in new oil until upper edge of inspection glass.

Picture VII.3: Drain cock

Picture VII.2: Hydrostat filter

pp g p gVent pump: open (2-3 turns) ventilation screw (see picture VII.5).As soon as oil leaks from the ventilation screw, close it again.Start system.Activate load (ventilation)Activate load (ventilation).Check oil level. (see picture VII.2.1)Shut down system. Fill up further with oil below level.

Picture VII.5: Ventilation screw

Picture VII.2.1: filling gap and oil level indicator

Page 54

oil-level indicator

VII. MAINTAINANCE

Manometer 1 (picture VII.3: green arrow) :

60 bar, shows the charge pressure of the hydrostatic pumpDuring operation the manometer has to show between 28-34 bar.

Manometer 2 (picture VII 3: red arrow) :Manometer 2 (picture VII.3: red arrow) :

600 bar, shows the operating pressure of the hydrostatic pumpDuring operation the pressure in this manometer ranges from 90 to 420 bar.

Hydraulic oil cooler:In principle, the hydraulic oil cooler does not require maintenance. If required, blow out with compressed air from inside to outside. Pay attention to a clean cooler mesh!attention to a clean cooler mesh!

Attention: Danger of overheating if cooler is contaminated!

Picture VII.6: Manometers

Attention: Danger of overheating if cooler is contaminated!

Charge air-, Watercooler:

Water level = the distance from filler to water has to be 8 cm (Page 61, Picture VII.21)For further maintenance instructions see Caterpillar manual.Coolant temperature resistance has to be -35°C After refilling coolant check temperature resistance

Attention: Danger of overheating when Cooler is polluted

Page 55VII. MAINTAINANCE

DIESEL MOTOR:

See Caterpillar Manual.

VIBRATION FEEDER:

Checking the oil:Correct oil level = Lower edge oil-level plug (see picture VII.7).Open oil-level plug – if no oil emerges, refill with oil.

Oil hOil change:Open oil-level plug.Open oil drain plug.Drain oil.Close drain plug.

Picture VII.7: Oil level plugs

p gFill with new oil – up to lower edge of oil-level plug or. 3.5 l.Close oil-level plug.

Check fastening bolts of vibration gear for firm mounting once a week.

TRANSFER GEAR BOX:TRANSFER GEAR BOX:Open oil drain plug and bleeder screw.Drain oil.Close drain plug and bleeder screw.Fill with new oil (ca. 1 liter) - between mark (min and max) at the dip stick (see picture VII.8).

Picture VII. 8: Dip stick transfer gear box


CATERPILLAR CRAWLER:

The crawler gear chain and 3-rib base plates are maintenance-free.Weekly inspection for potentially loose bolts.The track rollers are maintenance-free.A weekly visual inspection must be carried out for possible leakages in the areaA weekly visual inspection must be carried out for possible leakages in the areaof the duocone seals. The drive wheel unit is maintenance-free. It consists of the drive wheel with the sliding elements, the cross member with mounted spring assembly and integrated grease tension cylinder.

Picture VII.9: Chain tensionA weekly inspection must be carried out for possible leakages in the sliding elementsof the drive wheel. The grease tension cylinder has the function of bringing the crawler gear chain into the operating position.Feeding is achieved by means of grease filling (via hand lever press).The chain is correctly tensioned if there is slack of approx. 25 mm on both sides of theThe chain is correctly tensioned if there is slack of approx. 25 mm on both sides of the chain support. It must be noted that only the drive wheel feeding or chain tensioning is initiated with the grease tension cylinder; the spring travel of the spring assembly is not shortened.The grease tension cylinder must be relieved by carefully unscrewing the filling valve.The pressurised grease then escapes via a groove in the filling valve in order to loosen the chain.The main ring gear is maintenance freeThe main ring gear is maintenance-free. A regular visual inspection must be carried out, as incorrect chain tensioning can lead to premature wear.

Accumulating material can become trapped between the track and carrying rollers as well as the lead and drive wheels. This material then obstructs the crawler gear parts from working together effectively, which can lead to increased wear and chain breakage. For this reason, it must be ensured that all crawler gear components are regularly cleaned and that foreign bodies and accumulated material are removed.

Crawler gear unit

Correct oil level with correct oil plug arrangement (see side VII.10).Filling volume: 6 litre

Picture VII.10: Crawler gear unit


CONVEYOR BELTS:

Check the conveyor belts for cracks, cuts etc as part of the daily visual inspection.Damage can be caused by foreign bodies (e.g. iron pieces) which become caught in the belt frame or between the track rollers.Crushing material may also have accumulated in the frame edges which can have a considerable adverse effect onCrushing material may also have accumulated in the frame edges, which can have a considerable adverse effect on the belt running.Freezing temperatures in particular can lead to faults in and damage to the conveyor unit.All carrying rollers, track rollers, lower chord rollers and side guide rollers must run freely.The tail pulleys of the main conveyor must be checked for free running.Accumulated materials can cause the conveyor belt to stop and consequently lead to blockage in the crusher. This also applies for the driving drums of the main and side conveyor belts.Check the belt scrapers for correct mounting.Replace worn belt scrapers.Ensure correct belt tensioning.Ensure correct belt tensioning.

MAGNETIC BELT:

The belt must be checked regularly to ascertain whether it is running straight and if necessary correctedThe belt must be checked regularly to ascertain whether it is running straight and, if necessary corrected.The bearings must be lubricated accordingly.Dedusting belts must be checked for damage and, if necessary, replaced.


V-BELTS:Check V-belts for correct tensioning (see picture VII 10)Check V belts for correct tensioning (see picture VII.10).D = 0,016 . x D....[mm] x .... [m] F = FORCE = 50-65 NTo tension the V-belts, open the door for the motor housing.The V-belts are tensioned by moving the hydraulic motor backwards using slide rails. Ensure correct belt tensioning.

IMPACT CRUSHER:Open eyebolts (siehe Bild VII.12).Start diesel motorA ti t h d li

Picture VII.11:V-belt tension

Picture VII.14: Rotor-protectionActivate hydraulicsOpen crusher, secure with bolt (see picture VII.15)Stop diesel motor, remove starter keyRemove battery switchSecure the rotor against twisting (see picture VII.14).O h i b h id ( i VII 13)

p

Open hammer arm protection on both sides (see picture VII.13)Pull hammer arms sideways out from the guideClean the guide noses, rotate or replace the hammer armsPush hammer arms into the guide nosesTighten the hammer arm protection on both sides Picture VII 12: Crusher eyeboltsg pVisual inspection of the wearing plates and rotor protection for abrasion andfirm mountingClose crusher coverTighten eyeboltsOpen inspection flaps

Picture VII.15: Position fixingof open crusher cover

Picture VII.12: Crusher eyebolts

Open inspection flapsCheck gap between hammer arms and baffle plate, if necessary adjust (see commissioning set impact crusher)

IF A GAP INSPECTION IS NOT CARRIED OUT, THE HAMMER ARMS CAN COLLIDE WITH THE BAFFLE PLATE DAMAGE TO THE CRUSHER!ARMS CAN COLLIDE WITH THE BAFFLE PLATE - DAMAGE TO THE CRUSHER!Close inspection flaps. Crusher is ready for operation.After 2-3 hours of crushing process check eyebolts for firm mounting.

To reverse or exchange the hammers pull them out in the direction of the catwalk.

Picture VII.13: Hammer protection


Preparation before WeldingStep 1: (A till C)

•(A) Take care that all electrical connection-points to the diesel-engine and control-unit are disconnected

•(B) Turn off the circuit breaker Nr.19 and 24 till 29

•(C) Disconnect both connector of the PLC (position 23)

A

A

A

B B

C

Page 6060

Preparation before Welding continuation

Step 2: (D till E)•(D) Take off the main-fuse (pos. 31 and 34)

•(E) Turn off the main-battery-switch (pos 32)•(E) Turn off the main-battery-switch (pos. 32)

D

D

E

D

Page 6161

Preparation before Welding continuation

Step 3: (F)

•(F) Pull out the connector for the remote-control

FF

Page 6262

OIL LEVEL MONITOR:

Diesel motor Hydraulic tank

Computer ohne einen Bildschirm verwenden

Picture VII.16: Dip stick diesel motor

Vibration gear Crawler gear

Bild VII.17: Oil level hydraulic tank

Picture VII.18: Oil level vibration gear Picture VII.19: Oil level crawler gear


OIL LEVEL MONITOR: Coolant Level Check

Transfer gear-box

Picture VII.20: Oil level Transfer gear-box Bild VII.21: Coolant-compensating tank

Page 64VII. MAINTENANCE

1000h orannually 200 h 100 h 50 h daily SERVICE AND REPAIR PLAN:

Impact crusher:Impact crusher:x Check hammer arms wear statusx Check crusher gap

x Check hammer arms for firm mountingx Check baffle plates for firm mounting

Check impact swings wearx Check impact swings wearx Check rotor protection plate for firm mountingx Check crusher housing reinforced plating wear statusx Check crusher housing reinforced plating for firm mounting

x Check crusher housing bolts for firm mountingLubricate shaft bearing (5 pump lifts with grease press per lubrication interval)x Lubricate shaft bearing (5 pump lifts with grease press per lubrication interval)Vibration feeder and gear, pre-screening:

x Check bolts and connections for firm mountingx Check wear

x x Oil change (first after 100h, then annually or after 1000h)Chutes and hoppers:Chutes and hoppers:

x Check material clearancex Check wear

Main discharge belt:x Check conveyor belt for damagex Check conveyor routex Check conveyor route

x Lubricate bearings of the tail pulley and the driving drum (1-2 pump lifts with grease press)x Check setting and belt tensionx Check safety guard

Side discharge belt:x Check conveyor belt for damagex Check conveyor belt for damagex Check conveyor route

x Lubricate bearings of the tail pulley and the driving drum (1-2 pump lifts with grease press)x Check setting and belt tensionx Check safety guard

Magnetic separator:Magnetic separator:x Check belt for damagex Check conveyor routex Lubricate bearings of the tail pulley and the driving drum (1/2 or every 2nd day 1 pump lift with grease press)x Check setting and belt tensionx Check safety guard


x Check safety guard

1000h orannually 200 h 100 h 50h daily SERVICE AND REPAIR PLAN (continued):

Caterpillar crawler gear:x Visual inspection, according to instructions in Maintenance/Crawler track Chapterx Check chain tension (25mm sag)

x Gear oil – change, first after 500h, then annually or after 1000hStructures and platforms:

x Check structures and platforms for firm mountingDrive unit:Maintenance and repair work, see Caterpillar 7.0 Manual!

x Check V-belt tensionx Check firm mounting of components

C / fx Clean/Replace the air filter insertx Replace the air filter safety cartridge

Combi-Cooler:x Clean cooling elementx Check water level

Ch k th l t/ tif ( CAT M l)Check the coolant/antifreeze (see CAT-Manual) Oil-cooler:

x Clean cooling element Hydrostat:

x x Replace filter first after 100 h, then every 1000 hours or annually (concerining filter display)L b i t h d t t b i (3 lift ith l b i ti i t l)x Lubricate hydrostat bearings (3 pump lifts with grease press per lubrication interval)Hydraulics:

x x Change of return flow filter first after 100 h, then every 1000 hours or annuallyx x Change of overflow oil filter first after 100 h, then every 1000 hours or annuallyx Funnel-air-filter

x Check system for leakagesx Check system for leakagesPump transfer gear:

x Check oil-levelx x Oil change first after 100 h, then annually or after 1000h

V-belt drive:x Check V-belt and V-belt tensionx Check V-belt and V-belt tension

x Check V-belt pulley for firm mounting (one-time after 100h)Complete electrical system:

x Check cable and connecting plugs for firm mounting 8one-time after 100h)x Check components for firm mounting

x Check emergency OFF switch for correct functioning


x Check emergency OFF switch for correct functioning

RECOMMENDED OIL QUALITIES:

Gear oil Hydraulic oil Grease Motor oil Antifreeze

RECOMMENDED OIL QUALITIES:

Blasia 220Degol BG 220Energol GR-XP 220Alphamax 220Engranajes HP 220

Energol HLP 46Tellus HLP 46Renolin B15 VG 46OSO 46

Aralup HLP 2BP Energrease LS-EP2Beacon EP2Centoplex 2

Vanellus-Multigrad 15 W 40 Vanellus C3Rimula Super 15 W 40Titan Universal HD 15 W 40Blitum T 15 W 40

Use only antifreeze who issuitable for all kind of metal(aluminium, steel) and complyingwith the standard ASTM D4985 or ASTM D6210Engranajes HP 220

Falcon CLP 220Epona Z 220Spartan EP 220Renep Compound 106Gearmaster CLP 220Kluberoil GEM 1 220

Centoplex 2Mobilux EP2Shell Alvania EP Fett 2Tribol 3030

Blitum T 15 W 40ECL Cat-anti-freeze

protectionRowe – Hightec AntifreezeArteco Havoline AFC

or ASTM D6210.

Kluberoil GEM 1-220Mobilgear XMP 220Ripress EP 220Gear HST 220Optigear BM 220Rembrandt EP 2S T 220

Arteco – Havoline AFCArteco – Havoline XLC

Super Tauro 220Omala 220Meropa 220Carter EP 2201100-220

Errors and printing errors excepted !!




I. Vorwort Seite 2








VI B t i b S it 48



Diesel motor Side 56Vibration feeder Side 56Caterpillar crawler Side 57Crawler gear Side 57Conveyor belts Side 58V belts Side 59

VIII. STANDARD FORMSHydraulikanlage Seite 54Diesel Motor Seite 56Vibrationsrinne Seite 55Laufwerk Seite 56Laufwerksgetriebe Seite 56Fördergurte Seite 58

V-belts Side 59Impact crusher Side 59Welding preparations Side 60Oil level monitor Side 63Service plan Side 65 Recommended oil qualities Side 67VIII. STANDARD FORMS

R900 IMPACT CRUSHERKeilriemen Seite 59Prallbrecher Seite 59Ölstandskontrolle Seite 60Wartungsplan Seite 62Schmiermittelübersicht Seite 64


Page 68VIII. STANDARD FORMS


VII. WARTUNG

manual r900 with mondial & cat 7.0

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